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Komatsu PC270LC-8 Hydraulic Excavator Shop Manual CEBM007202 PDF

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Komatsu PC270LC-8 Hydraulic Excavator Shop Manual CEBM007202 – PDF DOWNLOAD

SERIAL NUMBERS PC270LC-8 A87001 and UP

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Description

Komatsu PC270LC-8 Hydraulic Excavator Shop Manual CEBM007202 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC270LC-8 Hydraulic Excavator Shop Manual CEBM007202 – PDF DOWNLOAD 

Language : English
Pages : 1147
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC270LC-8 Hydraulic Excavator Shop Manual CEBM007202 – PDF DOWNLOAD 

SERIAL NUMBERS PC270LC-8 A87001 and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

TABLE OF CONTENTS:

Komatsu PC270LC-8 Hydraulic Excavator Shop Manual CEBM007202 – PDF DOWNLOAD

SERIAL NUMBERS PC270LC-8 A87001 and UP

CEBM007202 – PC270LC-8 sn A87001 and up 1
CONTENTS 2
REVISED PAGES 3
SAFETY 13
SAFETY NOTICE 13
IMPORTANT SAFETY NOTICE 13
GENERAL PRECAUTIONS 13
PREPARATIONS FOR WORK 13
PRECAUTIONS DURING WORK 13
GENERAL 16
HOW TO READ THE SHOP MANUAL 17
VOLUMES 17
DISTRIBUTION AND UPDATING 17
FILING METHOD 17
REVISED EDITION MARK 17
REVISIONS 17
SYMBOLS 17
HOISTING INSTRUCTIONS 18
HOISTING 18
WIRE ROPES 18
PUSH PULL COUPLER 19
TYPE 1 19
DISCONNECTION 19
CONNECTION 19
TYPE 2 20
DISCONNECTION 20
CONNECTION 20
TYPE 3 21
DISCONNECTION 21
CONNECTION 21
COATING MATERIALS 22
EXPLANATION OF MAINTENANCE STANDARD TERMS 24
STANDARD TIGHTENING TORQUE 26
Bolts and Nuts 26
Hose Nuts 27
Split Flange Bolts 27
Flared Nuts 27
O-ring Boss Piping Joints 28
O-ring Boss Plugs 28
Hoses (Taper Seal Type and Face Seal Type) 28
ELECTRIC WIRE CODE 29
Classification by Thickness 29
Classification by Color and Code 29
How To Read Electric Wire Code 30
CONVERSION TABLES 33
Method of Using the Conversion Table 33
01 GENERAL 39
SPECIFICATION AND TECHNICAL DATA 40
Specification Dimension Drawings 40
Working Range Diagram 41
Specifications 42
Weight table 44
TABLE OF FUEL, COOLANT AND LUBRICANTS 46
Lubrication Chart 48
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD 49
ENGINE AND COOLING 51
Engine related parts 51
Radiator, oil cooler, aftercooler and fuel cooler 52
POWER TRAIN 53
Power train 53
Final drive 54
Swing machinery 58
Swing circle 60
UNDERCARRIAGE AND FRAME 62
Track frame and recoil spring 62
Standard shoe 63
Idler 64
Carrier roller 66
Track roller 67
Track shoe 70
Triple grouser shoe 72
HYDRAULIC SYSTEM 74
Hydraulic equipment layout drawing 74
Hydraulic tank and filter 76
Hydraulic pump 78
Type: HPV95+95 78
Pilot oil filter 100
For breaker 100
Control valve 102
Sectional view (1/5) 104
Sectional view (2/5) 106
Sectional view (3/5) 108
Sectional view (4/5) 110
Sectional view (5/5) 112
CLSS 114
Functions and operation by valve 118
Unload valve 120
Introduction of LS pressure 122
LS bypass plug 123
Pressure compensation valve 124
Pressure compensation valve inner shuttle valve 127
Boom regeneration circuit 129
Arm regeneration circuit 131
Merge-divider valve 133
LS select valve 135
Self pressure reducing valve 136
Travel junction valve 139
Travel PPC shuttle valve 141
Boom drift preventive valve 143
Arm drift preventive valve (if equipped) 146
When abnormally high pressure is generated 149
Quick return valve 150
Lift check valve 152
Main relief valve 153
2-stage safety-suction valve 154
Swing Motor 156
Center swivel joint 166
Travel motor 168
PPC valve 181
Work equipment and swing PPC valve 181
Travel PPC valve 186
Service PPC valve (with EPC valve) 196
Service PPC valve 202
Control valve 204
Solenoid valve 206
PPC Accumulator 208
Return oil filter 209
For breaker 209
Attachment circuit selector valve 210
Hydraulic cylinder 212
Boom cylinder 212
Arm cylinder 212
Bucket cylinder 212
WORK EQUIPMENT 214
Dimensions of components 214
CAB AND ITS ATTACHMENTS 220
Air conditioner piping 220
ELECTRICAL SYSTEM 221
Engine control 221
Engine controller 224
Coolant temperature sensor 227
Oil pressure switch 227
Rotation sensor 228
Boost pressure and temperature sensor 228
WIF (water-in-fuel detection) sensor 229
Engine oil level sensor 229
Electrical control system 230
Machine control system diagram 230
MONITOR SYSTEM 254
Machine monitor 255
Monitor control, display portion 258
Switches 264
SENSORS 281
Fuel level sensor 281
Air cleaner clogging sensor 282
Coolant level sensor 282
KOMTRAX TERMINAL SYSTEM 283
KOMTRAX communication modem 284
20 STANDARD VALUE TABLES 285
STANDARD SERVICE VALUE TABLE 286
Engine related parts 286
Chassis related parts 287
30 TESTING AND ADJUSTING 301
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 303
Sketch of special tool 307
ENGINE SPEED 308
INTAKE AIR PRESSURE (BOOST PRESSURE) 310
EXHAUST GAS COLOR 311
VALVE CLEARANCE 313
COMPRESSION PRESSURE 315
Determining A Defective Cylinder 318
Procedures 318
Determining Cylinder Group 318
Isolating The Defective Cylinder 318
BLOW-BY PRESSURE 319
ENGINE OIL PRESSURE 320
HANDLING FUEL SYSTEM PARTS 321
Releasing Residual Pressure From Fuel System 321
Fuel Pressure 322
Fuel Return Rate And Leakage 325
Bleeding Air From Fuel Circuit 330
Fuel Circuit – Checking For Leakage 331
AIR CONDITIONER COMPRESSOR BELT 332
FAN BELT 333
SWING CIRCLE BEARING 334
TRACK CHAIN TENSION 335
WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS OIL PRESSURE 336
CONTROL CIRCUIT BASIC PRESSURE 340
OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 342
Measuring 342
Adjusting 344
OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 345
Measuring 345
Adjusting 349
SOLENOID VALVE OUTPUT PRESSURE 350
Measuring 350
PPC Lock Solenoid Valve Operation Table 352
2-Stage Relief Solenoid Valve Operation Table 352
Swing Holding Brake Solenoid Valve Operation Table 352
Travel Speed Shifting Solenoid Valve Operation Table 352
Travel Junction Solenoid Valve Operation Table 353
ATT Return Selector Solenoid Valve Operation Table 353
PPC VALVE OUTPUT PRESSURE 354
WORK EQUIPMENT AND SWING PPC VALVES 357
HYDRAULIC DRIFT OF WORK EQUIPMENT 358
RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 359
OIL LEAKAGE 360
BLEEDING AIR FROM EACH PART 363
CAB TIPPING STOPPER 366
MIRRORS 367
SPECIAL FUNCTIONS OF MACHINE MONITOR 371
Long Distance Transport Mode 434
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER 436
PREPARATION WORK FOR ELECTRICAL SYSTEM 437
PROCEDURE FOR TESTING DIODES 442
PM CLINIC SERVICE 444
40 TROUBLESHOOTING 453
GENERAL INFORMATION 457
Points To Remember 457
Sequence Of Events In Troubleshooting 459
Handling Electric Equipment and Hydraulic Components 460
New Connectors for Tier 3 Engines 468
Check Before Troubleshooting 472
Classification And Troubleshooting Steps 473
Troubleshooting Classification 473
Troubleshooting steps 473
Information In Troubleshooting Table 474
Related Circuit Diagram 475
Possible Problems and Troubleshooting No 476
How To Read Electric Wire Code 479
Connection Table For Connector Pin Numbers 482
T-branch boxes and T-branch adapters Table 518
FAILURE CODE (DISPLAY OF CODE) 521
Failure Codes Table 521
Before Troubleshooting With Failure Code Displayed 526
Fuse Box Connection Table 526
Locations Of Fusible Links 527
Location Of Fuse Box And Fuse Nos 527
Trouble That Occurs When Power Supply Of Pump Controller Is Defective 528
989L00 Engine Controller Lock Caution 1 530
989M00 Engine Controller Lock Caution 2 530
989N00 Engine Controller Lock Caution 3 531
AA10NX Air Cleaner Clogging 531
AB00KE Charge Voltage Low 532
B@BAZG Eng Oil Press Low 534
B@BAZK Eng Oil Level Low 534
B@BCNS Eng Water Overheat 535
B@BCZK Eng Water Level Low 535
B@HANS Hyd Oil Overheat 536
CA111 EMC Critical Internal Failure 536
CA115 Eng Ne and Bkup Speed Sens Error 537
CA122 Chg Air Press Sensor High Error 538
CA123 Chg Air Press Sensor Low Error 540
CA131 Throttle Sensor High Error 542
CA132 Throttle Sensor Low Error 544
CA144 Coolant Temp Sens High Error 546
CA145 Coolant Temp Sens Low Error 548
CA153 Chg Air Temp Sensor High Error 550
CA154 Chg Air Temp Sensor Low Error 552
CA155 Chg Air Temp High Speed Derate 554
CA187 Sens Supply 2 Volt Low Error 556
CA221 Ambient Press Sens High Error 558
CA222 Ambient Press Sens Low Error 560
CA227 Sens Supply 2 Volt High Error 562
CA234 Eng Overspeed 563
CA238 Ne Speed Sens Supply Volt Error 564
CA271 IMV/PCV1 Short Error 565
CA272 IMV/PCV1 Open Error 566
CA322 Inj #1 Open/Short Error 568
CA323 Inj #5 Open/Short Error 570
CA324 Inj #3 Open/Short Error 572
CA325 Inj #6 Open/Short Error 574
CA331 Inj #2 Open/Short Error 576
CA332 Inj #4 Open/Short Error 578
CA342 Calibration Code Incompatibility 580
CA351 Injectors Drive Circuit Error 582
CA352 Sens Supply 1 Volt Low Error 584
CA386 Sens Supply 1 Volt High Error 586
CA428 Water in Fuel Sensor High Error 588
CA429 Water in Fuel Sensor Low Error 590
CA435 Eng Oil Press Sw Error 592
CA441 Battery Voltage Low Error 593
CA442 Battery Voltage High Error 596
CA449 Rail Press Very High Error 598
CA451 Rail Press Sensor High Error 600
CA452 Rail Press Sensor Low Error 602
CA488 Chg Air Temp High Torque Derate 604
CA553 Rail Press High Error 604
CA559 Rail Press Low Error 605
CA689 Eng Ne Speed Sensor Error 606
CA731 Eng Bkup Speed Sens Phase Error 608
CA757 All Continuous Data Lost Error 610
CA778 Eng Bkup Speed Sensor Error 612
CA1633 KOMNET Datalink Timeout Error 614
CA2185 Throt Sens Sup Volt High Error 615
CA2186 Throt Sens Sup Volt Low Error 616
CA2249 Rail Press Very Low Error 617
CA2311 IMV Solenoid Error 618
CA2555 Grid Htr Relay Volt High Error 620
CA2556 Grid Htr Relay Volt Low Error 622
D19JKZ Personal Code Relay Abnormality 624
D862KA GPS Antenna Discon 626
DA22KK Pump Solenoid Power Low Error 628
DA25KP 5 V Sensor 1 Power Abnormality 630
DA29KQ Model Selection Abnormality 636
DA2RMC CAN Discon (Pump Con Detected) 638
DAF8KB Short Circuit In Camera Power Supply 646
DAFGMC GPS Module Error 648
DAFRMC CAN Discon (Monitor Detected) 649
DGH2KB Hydr Oil Sensor Short 656
DHPAMA F Pump Press Sensor Abnormality 658
DHPBMA R Pump Press Sensor Abnormality 660
DHS3MA Arm Curl PPC Press Sensor Abnormality 662
DHS4MA Bucket Curl PPC Press Sensor Abnormality 664
DHS8MA Boom Raise PPC Press Sensor Abnormality 666
DHSAMA Swing RH PPC Press Sensor Abnormality 668
DHSBMA Swing LH PPC Press Sensor Abnormality 670
DHSDMA Bucket Dump PPC Press Sensor Abnormality 672
DHX1MA Overload Sensor Abnormality (Analog) 674
DW43KA Travel Speed Sol Discon 678
DW43KB Travel Speed Sol Short 680
DW45KA Swing Brake Sol Discon 682
DW45KB Swing Brake Sol Short 684
DW91KA Travel Junction Sol Discon 686
DW91KB Travel Junction Sol Short 688
DWA2KA Service Sol Discon 690
DWA2KB Service Sol Short 691
DWK0KA 2-Stage Relief Sol Discon 692
DWK0KB 2-Stage Relief Sol Short 694
DXA8KA PC-EPC (F) Sol Discon 696
DXA8KB PC-EPC (F) Sol Short 698
DXA9KA PC-EPC (R) Sol Discon 700
DXA9KB PC-EPC (R) Sol Short 702
DXE0KA LS-EPC Sol Discon 704
DXE0KB LS-EPC Sol Short 706
DXE4KA Service Current EPC Discon 708
DXE4KB Service Current EPC Short 710
DXE5KA Merge-divider Main Sol Discon 712
DXE5KB Merge-divider Main Sol Short 714
DXE6KA Merge-divider LS Sol Discon 716
DXE6KB Merge-divider LS Sol Short 718
DY20KA Wiper Working Abnormality 720
DY20MA Wiper Parking Abnormality 722
DY2CKA Washer Drive Discon 724
DY2CKB Washer Drive Short 726
DY2DKB Wiper Drive (For) Short 728
DY2EKB Wiper Drive (Rev) Short 730
ELECTRICAL SYSTEM (E-MODE) 732
Troubleshooting Table 732
E-1 No Machine Monitor Display When Starting Switch Is Turned On 734
E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine) 736
E-3 Engine Does Not Start 739
E-4 Preheater Does Not Operate 744
E-5 Automatic Warm-up System Does Not Operate (In Cold Season) 748
E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked 750
E-7 Precaution Lights Up While Engine Is Running 752
E-8 Emergency Stop Item Lights Up While Engine Is Running 757
E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally 758
E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally 760
E-11 Fuel Level Gauge Does Not Indicate Normally 764
E-12 Machine Monitor Content Displays Are Different From Applicable Machine 767
E-13 Machine Monitor Does Not Display Some Items 767
E-14 Function Switch Does Not Work 767
E-15 Auto-decelerator Does Not Operate Normally 768
E-16 Working Mode Does Not Change 769
E-17 Travel Speed Does Not Change 770
E-18 Alarm Buzzer Cannot be Stopped 771
E-19 Windshield Wiper and Window Washer Do Not Operate 772
E-20 Power Maximizing Function Does Not Operate Normally 774
E-21 Swing Holding Brake Does Not Operate Normally 776
E-22 Travel Alarm Does Not Sound or Does Not Stop 778
E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record) 780
E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position 792
E-25 Machine Monitor Cannot Be Set In Service Mode 792
E-26 Monitoring Function Does Not Display Lever Control Signal Normally 793
E-27 KOMTRAX System Does Not Operate Normally 802
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 804
System Diagram of Hydraulic and Mechanical System 804
Information In Troubleshooting Table 806
H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow 807
H-2 Engine Speed Drops Sharply or Engine Stalls 809
H-3 Work Equipment, Swing, and Travel Systems Do Not Work 810
H-4 Abnormal Noise Is Heard Around Hydraulic Pump 810
H-5 Auto-decelerator Does Not Work 811
H-6 Fine Control Mode Does Not Function or Responds Slow 811
H-7 Boom Moves Slowly or Lacks Power 812
H-8 Arm Moves Slowly or Lacks Power 813
H-9 Bucket Moves Slowly or Lacks Power 814
H-10 Work Equipment Does Not Move In Its Single Operation 814
H-11 Work Equipment Hydraulic Drift Is Too Fast 815
H-12 Work Equipment Has Big Time Lag 817
H-13 Other Work Equipment Moves When Relieving Single Circuit 817
H-14 Power Maximizing Function Does Not Work 818
H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly 818
H-16 In Swing and Boom Raise Operation, Boom Moves Slowly 819
H-17 In Swing and Travel Operation, Travel Speed Drops Sharply 819
H-18 Machine Swerves In Travel 820
H-19 Machine Travels Slowly 821
H-20 Machine Steers With Difficulty or Lacks Power 822
H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast 823
H-22 Track Shoe Does Not Turn (On One Side Only) 824
H-23 Machine Does Not Swing 825
H-24 Swing Acceleration Is Poor or Swing Speed Is Slow 827
H-25 Excessive Overrun When Stopping Swing 829
H-26 The Machine Jerks When Stopping Swing 830
H-27 Loud Sound Occurs When Upper Structure Stops Swinging 830
H-28 Swing Hydraulic Drift Is Too Big 831
H-29 Attachment Circuit Is Not Changed 832
H-30 Oil Flow In Attachment Circuit Cannot Be Controlled 832
50 DISASSEMBLY AND ASSEMBLY 833
HOW TO READ THIS SECTION 837
Removal And Installation Of Assemblies 837
Removal 837
Installation 837
Disassembly And Assembly Of Assemblies 838
Disassembly 838
Assembly 839
SPECIAL TOOLS LIST 840
SKETCHES OF SPECIAL TOOLS 845
CONNECTOR REPAIR PROCEDURES 849
Stripping Insulation 849
Wire Inspection 849
Contact Terminal Removal (HD30 Type) 850
Crimping Contact Terminal (HD30 Type) 851
Insertion Of Contact Terminal (HD30 Type) 852
Contact Terminal Removal (DT Type) 853
Crimping Contact Terminal (DT Type) 854
Insertion Of Contact Terminal (DT Type) 855
ENGINE AND COOLING SYSTEM 856
Fuel Supply Pump 856
Removal 856
Installation 860
Fuel Injector Assembly 862
Removal 862
Installation 867
Engine Front Seal 873
Removal 873
Installation 875
Engine Rear Seal 877
Removal 877
Installation 878
Cylinder Head Assembly 881
Removal 881
Installation 889
Radiator Assembly 899
Removal 899
Installation 901
Hydraulic Oil Cooler Assembly 903
Removal 903
Installation 905
Aftercooler Assembly 906
Removal 906
Installation 908
Fuel Cooler Assembly 909
Removal 909
Installation 909
Engine And Hydraulic Pump Assembly 910
Removal 910
Installation 919
POWER TRAIN 923
Final Drive Assembly 923
Removal 923
Installation 924
Final Drive 925
Disassembly 925
Assembly 929
Swing Motor and Swing Machinery Assembly 936
Removal 936
Installation 938
Swing Motor and Swing Machinery Assembly 939
Disassembly 939
Assembly 944
Swing Circle Assembly 950
Removal 950
Installation 950
UNDERCARRIAGE AND FRAME 951
Carrier Roller 951
Assembly 951
Track Roller 952
Assembly 952
Idler, Recoil Spring 953
Removal 953
Installation 953
Idler 954
Disassembly 954
Assembly 955
Recoil Spring 958
Disassembly 958
Assembly 959
Sprocket 961
Removal 961
Installation 961
Track Shoe 962
Expanding Track Shoe 962
Installation 963
Revolving Frame 964
Removal 964
Installation 966
Counterweight 967
Removal 967
Installation 969
HYDRAULIC SYSTEM 970
Center Swivel Joint 970
Removal 970
Installation 972
Disassembly 973
Assembly 974
Hydraulic Tank Assembly 975
Removal 975
Installation 978
Control Valve 979
Removal 979
Installation 984
Precautions for Replacing Pressure Compensation Valve Seal 986
Precautions for Assembling Control Valve 988
Hydraulic Pump 991
Removal 991
Installation 995
Oil Seal In Hydraulic Pump Input Shaft 996
Removal 996
Installation 996
Work Equipment PPC Valve 997
Disassembly 997
Assembly 997
Travel PPC Valve 999
Disassembly 999
Assembly 1000
Hydraulic Cylinder 1002
Disassembly 1003
Assembly 1005
WORK EQUIPMENT 1009
Work Equipment 1009
Removal 1009
Installation 1011
CAB AND ITS ATTACHMENTS 1012
Operator’s Cab 1012
Removal 1012
Installation 1015
Operator Cab Glass (Fixed Glass) 1016
Removal 1017
Installation 1018
Front Window 1027
Removal 1027
Installation 1030
Floor Frame 1035
Removal 1035
Installation 1039
ELECTRICAL SYSTEM 1040
Air Conditioner Unit 1040
Removal 1040
Installation 1044
KOMTRAX Communication Modem 1045
Removal 1045
Installation 1045
Monitor 1046
Removal 1046
Installation 1047
Pump Controller 1048
Removal 1048
Installation 1049
Engine Controller 1051
Removal 1051
Installation 1052
60 AIR CONDITIONER 1053
STRUCTURE AND FUNCTION 1056
Air Conditioner Component 1056
Configuration and Function of Refrigerating cycle 1058
Outline of Refrigerating Cycle 1059
Air Conditioner Unit 1062
Functions of Major Components in the Air Conditioner Unit 1064
Control Plate 1066
Compressor 1069
Condenser and Receiver Drier 1070
TESTING AND ADJUSTING 1071
Caution About Refrigerant 1071
Troubleshooting Procedure 1072
Block Diagram 1073
Circuit Diagram and Arrangement of Connector Pins 1074
Detail of Air Conditioner Unit 1076
Part and Connector Locations 1078
Testing Air Leakage (Ducts) 1082
Testing with Self-diagnosis Function 1084
Testing Temperature Control 1087
Testing Vent (Mode) Changeover 1090
Testing Recirc/Fresh Changeover 1094
Testing Inner Sensor 1096
Testing Evaporator Temperature Sensor 1097
Testing Sunlight Sensor 1099
Testing (Dual) Pressure Switch for Refrigerant 1100
Testing Relays 1102
TROUBLESHOOTING 1104
Troubleshooting Chart 1 1104
Troubleshooting Chart 2 1105
Troubleshooting for Electrical System (E mode) 1108
E-1 Power Supply System (Air Conditioner does not Operate) 1109
E-2 Compressor System (Air is Not Cooled) 1113
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 1116
E-4 Temperature Cannot be Controlled 1120
E-5 Vent (Mode) Cannot be Changed Over 1123
E-6 Recirc/Fresh Air Cannot be Changed Over 1126
Troubleshooting With Gauge Pressure 1129
Connection of Service Tool 1132
Precautions for connecting air conditioner piping 1134
Handling of Compressor Oil 1135
Control of Compressor Oil 1135
Adding of Compressor Oil 1135
Compressor Replacement 1136
Applying Compressor Oil for O-ring 1136
Desiccant Replacement Procedure 1137
90 DIAGRAMS AND SCHEMATICS 1139
HYDRAULIC SYSTEM 1141
Hydraulic Circuit Diagram 1141
ELECTRICAL SYSTEM 1142
Electrical Circuit Diagram (1/5) 1142
Electrical Circuit Diagram (2/5) 1143
Electrical Circuit Diagram (3/5) 1144
Electrical Circuit Diagram (4/5) 1145
Electrical Circuit Diagram (5/5) 1146
Electrical Connector Arrangement Diagram 1147

S.V 15/12/24

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