Komatsu PC270LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005905 PDF

Description

Komatsu PC270LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005905  – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC270LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005905  – PDF DOWNLOAD

Language : English
Pages : 838
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC270LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005905  – PDF DOWNLOAD

• SERIAL NUMBERS PC270LC-7L – A86001 and UP

CONTENTS 2
SAFETY 15
Safety Notice 15
IMPORTANT SAFETY NOTICE 15
General Precautions 15
Preparations For Work 15
Precautions During Work 15
GENERAL 18
HOW TO READ THE SHOP MANUAL 19
Volumes 19
Distribution And Updating 19
Filing Method 19
Revised Edition Mark 19
Revisions 19
Symbols 19
HOISTING INSTRUCTIONS 20
Hoisting 20
Wire Ropes 20
PUSH-PULL TYPE COUPLER 21
COATING MATERIALS 23
STANDARD TIGHTENING TORQUE 25
Standard Tightening Torque Of Bolts And Nuts 25
Tightening Torque Of Split Flange Bolts 26
Tightening Torque For Flared Nuts 26
Table Of Tightening Torques For O-ring Boss Piping Joints 26
Table Of Tightening Torques For O-ring Boss Plugs 27
Tightening Torque For 102 And 114 Engine Series 27
Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type) 28
ELECTRIC WIRE CODE 29
Classification By Thickness 29
Classification By Color And Code 29
CONVERSION TABLES 30
Method Of Using The Conversion Table 30
SPECIFICATION DIMENSION DRAWINGS 38
Dimensions 38
Working Ranges 39
SPECIFICATIONS 40
WEIGHT TABLE 42
FUEL, COOLANT AND LUBRICANTS 44
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil 45
ENGINE RELATED PARTS 49
RADIATOR OIL COOLER AFTERCOOLER 50
POWER TRAIN 51
FINAL DRIVE 52
SWING MACHINERY 54
SWING CIRCLE 57
TRACK FRAME RECOIL SPRING 58
IDLER 60
CARRIER ROLLER 62
TRACK ROLLER 0
TRACK SHOE 64
TRIPLE GROUSER SHOE 67
HYDRAULIC EQUIPMENT LAYOUT DRAWING 68
HYDRAULIC TANK 70
HYDRAULIC PUMP 71
HPV95+95 71
LS valve 76
PC Valve 76
LS(PC)-EPC Valve 89
CONTROL VALVE 92
SELF PRESSURE REDUCING VALVE 110
Main Relief Valve 113
VARIABLE PRESSURE COMPENSATION VALVE 114
CLSS 116
SWING MOTOR 118
Relief Valve Portion 123
REVERSE PREVENTION VALVE 124
CENTER SWIVEL JOINT 127
TRAVEL MOTOR 129
Motor Operation 132
Parking Brake Operation 134
Brake Valve Operation 135
TRAVEL JUNCTION VALVE 141
TRAVEL PPC SHUTTLE VALVE 143
VALVE CONTROL 146
WORK EQUIPMENT SWING PPC VALVE 147
TRAVEL PPC VALVE 152
SERVICE PPC VALVE 162
SOLENOID VALVE 166
PPC ACCUMULATOR 169
RETURN OIL FILTER 170
BOOM HYDRAULIC DRIFT PREVENTION VALVE 171
LIFT CHECK VALVE 175
ATTACHMENT CIRCUIT SELECTOR VALVE 176
HYDRAULIC CYLINDERS 178
Boom Cylinder 178
Arm Cylinder 178
Bucket Cylinder 178
WORK EQUIPMENT 180
100 Hours 181
500 Hours 181
Dimension Of Arm 182
Dimension Of Bucket 184
AIR CONDITIONER 186
Piping 186
ENGINE CONTROL 187
Fuel Control Dial 189
Governor Motor 190
Engine Throttle And Pump Controller 192
Input And Output Signals 193
ELECTRONIC CONTROL SYSTEM 195
Total System Diagram 196
MULTI MONITOR SYSTEM 219
Monitor Panel 220
Monitor Control, Display Portion Monitor Portion 222
Maintenance Function 232
7-SEGMENT MONITOR SYSTEM 238
Monitor panel 239
SENSORS 245
Engine Oil Level Sensor 245
Engine Oil Pressure Sensor (For Low Pressure) 246
Coolant Temperature Sensor 246
Hydraulic Oil Temperature Sensor 246
Fuel Level Sensor 247
Air Cleaner Clogging Sensor 247
STANDARD VALUE TABLES 251
Engine 251
Chassis 252
SERVICE TOOLS 265
ENGINE 267
Engine Speed 267
Exhaust Gas Color 269
Valve Clearance 271
Compression Pressure 273
Blow-by Pressure 274
Fuel Injection Timing 275
Engine Oil Pressure 277
Engine Speed Sensor 278
Defective Cylinder 279
BELT TENSION – AIR COMPRESSOR 280
ENGINE CONTROL SYSTEM FAILURE 281
SWING CIRCLE BEARINGS 282
TRACK SHOE TENSION 283
SPROCKET 283
OIL PRESSURE 284
Work Equipment, Swing And Travel 284
Control Circuit 288
Pump PC Control Circuit 289
Pump LS Control Circuit 292
Solenoid Valve Output Pressure 297
PPC Valve Output Pressure 300
WORK EQUIPMENT AND SWING PPC VALVE 301
WORK EQUIPMENT – HYDRAULIC DRIFT 302
RELEASING PRESSURE IN HYDRAULIC CIRCUIT 304
OIL LEAKAGE 305
AIR BLEEDING OF VARIOUS PARTS 308
DIODE INSPECTION PROCEDURES 310
MULTI-MONITOR PANEL 312
Monitor Panel Functions – Conventional And Special 313
Conventional Function: Operator’s Menu 313
Special Function: Service Menu 313
Operator’s Menu And Display (Outline) 314
Table For Service And Failure Code Numbers 319
Service Menu 321
7-SEGMENTS MONITOR PANEL – SPECIAL FUNCTIONS 336
Ordinary functions and special functions of monitor panel 337
Display of operator menu 338
Operation and display of service menu 339
ELECTRICAL SYSTEM TROUBLESHOOTING 352
PM TUNE UP SERVICE 354
POINTS TO REMEMBER WHEN TROUBLESHOOTING 363
SEQUENCE OF EVENTS IN TROUBLESHOOTING 365
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 366
CHECKS BEFORE TROUBLESHOOTING 374
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING 375
Classification Of Troubleshooting 375
Steps For Troubleshooting 375
Failure-looking Phenomenon And Troubleshooting No 376
ELECTRICAL CIRCUIT DIAGRAM SYSTEM 379
Connector Table 379
S/N A86001-A86216 379
S/N A86217-UP 384
Connector Location Diagram 390
S/N A86001-A86216 390
S/N A86217-UP 396
ELECTRICAL CIRCUIT DIAGRAMS 401
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 402
T-BRANCH BOX AND T-BRANCH TABLE 424
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE 428
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 435
Points To Remember If Abnormality Returns To Normal By Itself 435
User Code Memory Retention Function 435
Information In Troubleshooting Table 436
E101 – ABNORMAL DATA IN ERROR HISTORY 438
E112 – SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION 440
E113 – SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION 442
E114 – SHORT OR OPEN IN WINDOW WASHER SYSTEM 444
S/N A86001-A86216 444
S/N A86217-UP 446
E115 – ABNORMAL WINDSHIELD WIPER MOTION 448
E116 – ABNORMALITY IN PARKING WIPER ARM 450
E201 – SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID 452
S/N A86001-A86216 452
S/N A86217-UP 454
E203 – SHORT IN SWING holding brake SOLENOID 456
S/N A86001-A86216 456
S/N A86217-UP 458
E204 – SHORT IN MERGE/DIVIDE SOLENOID 460
S/N A86001-A86216 460
S/N A86217-UP 462
E205 – SHORT IN 2 STAGE RELIEF SOLENOID 464
S/N A86001-A86216 464
S/N A86217-UP 466
E206 – SHORT IN TRAVEL SPEED SHIFT SOLENOID 468
S/N A86001-A86216 468
S/N A86217-UP 470
E211 – OPEN IN TRAVEL INTERLOCKING SOLENOID 472
S/N A86001-A86216 472
S/N A86217-UP 474
E213 – OPEN IN SWING holding BRAKE SOLENOID 476
S/N A86001-A86216 476
S/N A86217-UP 478
E214 – OPEN OF MERGE/DIVIDE SOLENOID 480
S/N A86001-A86216 480
S/N A86217-UP 482
E215 – OPEN IN 2 STAGE RELIEF SOLENOID 484
S/N A86001-A86216 484
S/N A86217-UP 486
E216 – OPEN IN TRAVEL SPEED SOLENOID 488
S/N A86001-A86216 488
S/N A86217-UP 490
E217 – ABNORMAL INPUT FOR MODEL CODE 492
E218 – OPEN IN S-NET SIGNAL 494
E222 – SHORT IN LS-EPC SOLENOID 496
E223 – OPEN IN LS-EPC SOLENOID SYSTEM 498
E224 – ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL 500
E225 – ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL 502
E226 – ABNORMAL PRESSURE SENSOR POWER SUPPLY 504
E227 – ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER 506
E228 – SHORT IN ATTACHMENT RETURN SWITCHING RELAY 508
E232 – SHORT IN PC-EPC SOLENOID 510
E233 – OPEN IN PC-EPC SOLENOID SYSTEM 512
E238 – OPEN IN ATTACHMENT RETURN SWITCH RELAY 514
E245 – SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM 516
E246 – OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM 518
E256 – INCORRECT NONVOLATILE MEMORY DATA 520
E306 – ABNORMAL GOVERNOR POTENTIOMETER SIGNALS 522
E308 – ABNORMAL FUEL DIAL SIGNALS 524
E315 – SHORT IN BATTERY RELAY SYSTEM 526
E316 – STEP OUT IN GOVERNOR MOTOR 528
E317 – OPEN IN GOVERNOR MOTOR PHASE “A” AND “B” 530
E318 – SHORT IN GOVERNOR MOTOR PHASE “A” AND “B” 532
E501 – MODEL SELECTION FUNCTION NOT PROVIDED 534
E502 – MODEL SELECTING SIGNAL FAULT 535
A000N1 – ENGINE SPEED OUT OF RANGE AT HIGH IDLE 536
A000N2 ENGINE SPEED OUT OF RANGE AT LOW IDLE 537
AA10NX – AIR CLEANER CLOGGING 538
AB00KE – LOW CHARGING VOLTAGE 540
S/N A86001-A86216 541
S/N A86217-UP 542
B@BAZG – ABNORMALLY LOWERED ENGINE OIL PRESSURE 544
B@BAZK – ABNORMALLY LOWERED ENGINE OIL LEVEL 546
B@BCNS – ENGINE COOLING WATER OVERHEATING 548
B@BCZK ABNORMALLY LOWERED RADIATOR WATER LEVEL 550
B@HANS – HYDRAULIC OIL OVERHEATING 552
ELECTRICAL SYSTEM (E-MODE) 554
Information Contained In Troubleshooting Table 554
Before Carrying Out Troubleshooting Of E Mode 556
E-1 – ENGINE DOES NOT START (ENGINE DOES NOT ROTATE) 557
Serial No A86001 – A86216 560
Serial No A86217 – UP 561
E-2 – ENGINE STOPS WHILE IN OPERATION 562
E-3 – ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING 563
Serial No A86001 – A86216 564
Serial No A86217 – UP 565
E-4 – ENGINE DOES NOT STOP 566
Serial No A86001 – A86216 567
Serial No A86001 – UP 568
E-5 – AUTO-DECELERATOR DOES NOT WORK 569
E-6 – AUTO ENGINE WARM-UP DEVICE DOES NOT WORK 570
E-7 – PREHEATER DOES NOT WORK 572
E-8 – ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE 574
E-9 – ONE-TOUCH POWER MAX SWITCH DOES NOT WORK 576
E-10 – NO DISPLAY IN MONITOR PANEL AT ALL 578
E-11 – PART OF DISPLAY ON MONITOR PANEL IS MISSING 580
E-12 – MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 580
E-13 – FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING 581
E-14 – ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 582
E-15 – HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 583
E-16 – FUEL GAUGE DOES NOT DISPLAY CORRECTLY 584
E-17 – SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 586
E-18 – WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS 588
E-19 – WINDSHIELD WIPER DOES NOT WORK 590
E-20 – ALARMING BUZZER CANNOT BE CANCELLED 592
E-21 – “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 594
E-22 – “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 595
E-23 – “ARM DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 596
E-24 – “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 597
E-25 – “BUCKET DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 598
E-26 – “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 599
E-27 – “SWING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 600
E-28 – “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 602
E-29 – “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 604
E-30 – “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 606
E-31 – AIR CONDITIONER DOES NOT WORK 608
Serial No A86001 – A86216 608
Serial No A86217 and UP 610
E-31-E11 611
E-31-E12 611
E-31-E15 612
E-31-E16 612
E-31-E18 613
E-31-E43 613
E-31-E44 614
E-31-E45 615
E-31 Troubleshooting by failure phenomenon 617
E-32 TRAVEL ALARM DOES NOT SOUND 621
HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE) 622
System Chart 622
Information Contained In Troubleshooting Table 624
H-1 – ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 625
H-2 – ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS 626
H-3 – NO WORK EQUIPMENT, TRAVEL OR SWING MOVE 627
H-4 – ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 627
H-5 – AUTO-DECELERATOR DOES NOT WORK 628
H-6 – FINE CONTROL MODE DOES NOT FUNCTION 628
H-7 – BOOM MOVES SLOWLY OR LACKS POWER 629
H-8 – ARM MOVES SLOWLY OR LACKS POWER 630
H-9 – BUCKET MOVES SLOWLY OR LACKS POWER 631
H-10 – WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION 631
H-11 – WORK EQUIPMENT HAS TO MUCH HYDRAULIC DRIFT 632
H-12 – WORK EQUIPMENT HAS BIG TIME LAG 633
H-13 – OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT 633
H-14 – ONE-TOUCH POWER MAX SWITCH DOES NOT OPERATE 634
H-15 – IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY 634
H-16 – IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY 634
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 635
H-18 – MACHINE SWERVES IN TRAVEL 636
H-19 – MACHINE TRAVELS SLOWLY 637
H-20 – MACHINE CANNOT BE EASILY STEERED OR LACKS POWER 638
H-21 – TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST 639
H-22 – TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) 640
H-23 – MACHINE DOES NOT SWING 641
H-24 – SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 642
H-25 – EXCESSIVE OVERRUN WHEN STOPPING SWING 643
H-26 – THERE IS A SHOCK WHEN STOPPING SWING 644
H-27 – THERE IS ABNORMAL NOISE CAUSED WHEN STOPPING SWING 644
H-28 – SWING NATURAL DRIFT IS TOO BIG 645
METHOD OF USING MANUAL 651
PRECAUTIONS DURING OPERATION 652
Precautions When Carrying Out Removal Work 652
Precautions When Carrying Out Installation Work 653
Precautions When Completing The Operations 654
Other Precautions 654
SPECIAL TOOL LIST 655
SKETCHES OF SPECIAL TOOLS 659
STARTING MOTOR 660
Removal 660
Installation 660
FUEL INJECTION PUMP 661
Removal 661
Installation 664
ENGINE FRONT SEAL 666
Removal 666
Installation 666
ENGINE REAR SEAL 668
Removal 668
Installation 669
CYLINDER HEAD 670
Removal 670
Installation 674
CONNECTOR REPAIR PROCEDURES 677
Contact Terminal Removal (HD30 Type) 677
Striping Insulation 678
Crimping Contact Terminal (HD30 Type) 679
Insertion Of Contact Terminal (HD30 Type) 680
Contact Terminal Removal (DT Type) 681
Striping Insulation 682
Crimping Contact Terminal (DT Type) 683
Insertion Of Contact Terminal (DT Type) 684
RADIATOR 685
Removal 685
Installation 686
HYDRAULIC OIL COOLER 687
Removal 687
Installation 688
ENGINE AND HYDRAULIC PUMPS 689
Removal 689
Installation 694
FINAL DRIVE 696
Removal 696
Installation 697
Disassembly 698
Assembly 703
SWING MOTOR AND SWING MACHINERY 710
Removal 710
Installation 711
Disassembly 712
S/N A86001-A86216 712
S/N A86217-UP 716
Assembly 720
S/N A86001-A86216 720
S/N A86217-UP 726
CARRIER ROLLER 732
Assembly 732
TRACK ROLLER 734
Assembly 734
IDLER 735
Disassembly 735
Assembly 736
RECOIL SPRING 739
Disassembly 739
Assembly 740
SPROCKET 742
Removal 742
Installation 742
TRACK SHOE 743
Expansion Of Track Shoe 743
Assembly 744
SWING CIRCLE 745
Removal 745
Installation 745
REVOLVING FRAME 746
Removal 746
Installation 748
CENTER SWIVEL JOINT 749
Removal 749
Installation 750
Disassembly 751
Assembly 752
HYDRAULIC TANK 753
Removal 753
Installation 755
CONTROL VALVE 756
Removal 756
Installation 759
Disassembly 760
Assembly 762
HYDRAULIC PUMP 763
Removal 763
Installation 765
HYDRAULIC PUMP INPUT SHAFT – OIL SEAL 766
Removal 766
Installation 766
WORK EQUIPMENT PPC VALVE 767
Assembly 767
TRAVEL PPC VALVE 768
Assembly 768
HYDRAULIC CYLINDER 769
Disassembly 769
Assembly 772
WORK EQUIPMENT 776
Removal 776
Installation 778
AIR CONDITIONER 779
Removal 779
S/N A86001-A86216 779
S/N A8617-UP 783
Installation 785
S/N A86001-A86216 785
S/N A86217-UP 786
COUNTERWEIGHT 787
Removal 787
Installation 787
CAB 788
Removal 788
S/N A86001-A86216 788
S/N A86217-UP 791
Installation 794
S/N A86001-A86216 794
S/N A86217-UP 794
OPERATOR’S CAB GLASS 795
Removal 796
Installation 797
FRONT WINDOW 806
Removal 806
Installation 809
MONITOR 814
Removal 814
Installation 814
GOVERNOR PUMP CONTROLLER 815
Removal 815
S/N A86001-A86216 815
S/N A86217-UP 816
Installation 816
S/N A86001-A86216 816
S/N A86217-UP 816

DESCRIPTION:

Komatsu PC270LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005905  – PDF DOWNLOAD

• SERIAL NUMBERS PC270LC-7L – A86001 and UP

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 sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
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. In addition, this section gives the judgement standards
when inspecting disassembled parts.
STANDARD VALE 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.
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
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 each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND DRAWINGS
This section has the foldout drawings for the machine.

G.B  21/12/24