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Komatsu PC270LC-8 Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC270LC-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : PC270LC-8 A87001 and UP
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Description
Komatsu PC270LC-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC270LC-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC270LC-8
Serial Number: A87001 and up
Book Code: CEBM007202
Language: English
Pages: 1147
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC270LC-8 Hydraulic Excavator Shop Manual
1 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 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.
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.
AIR CONDITIONING:
Structure, function, testing, adjusting, and troubleshooting of air conditioning system.
DIAGRAMS AND DRAWINGS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC270LC-8 Hydraulic Excavator Shop Manual
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
KOMATSU PC270LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
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