Komatsu Hydraulic Excavator PC270LC-LE, PC270LC-L, PC270LL-L Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC270LC-6LE, PC270LC-7L, PC270LL-7L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC270LC-6LE, PC270LC-7L, PC270LL-7L workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBD003001 - Hydraulic Excavator PC270LC-6LE Shop Manual.pdf
CEBM005905 - Hydraulic Excavator PC270LC-7L Shop Manual.pdf
CEBM014600 - Logging Excavator GALEO PC270LL-7L Shop Manual.pdf
CEAM008702 - Hydraulic Excavator PC270LC-7L Operation & Maintenance Manual.pdf
CEAM014700 - Hydraulic Excavator GALEO PC270LC-7L Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,654 pages
File Format: PDF
Language: English
CEAM008702 - Hydraulic Excavator PC270LC-7L Operation & Maintenance Manual...2
INTRODUCTION...4
FOREWORD...5
SAFETY INFORMATION...6
Signal Words...6
Other Signal Words...6
INTRODUCTION...7
DIRECTIONS OF MACHINE...7
PRODUCT INFORMATION...8
Machine Serial Number Plate And Its Location...8
Engine Serial Number Plate And Its Location...8
Service Meter Location...9
Your Machine Serial Numbers And Distributor...9
TABLE OF CONTENTS...10
SAFETY...20
SAFETY LABELS...21
Position For Attaching Safety Labels...21
Safety Labels...22
SAFETY INFORMATION...28
Safety Rules...28
If Abnormalities Are Found...28
Working Wear And Personal Protective Items...28
Fire Extinguisher And First Aid Kit...28
Safety Equipment...28
Keep Machine Clean...29
Keep Operator's Compartment Clean...29
Leaving Operator's Seat With Lock...29
Handrails And Steps...30
Mounting And Dismounting...30
No Persons On Attachments...30
Burn Prevention...31
Hot Coolant...31
Hot Oil...31
Fire Prevention And Explosion Prevention...31
Fire Caused By Fuel Or Oil...31
Fire Caused By Accumulation Of Flammable Material...32
Fire Coming From Electric Wiring...32
Fire Coming From Hydraulic Line...32
Explosion Caused By Lighting Equipment...32
Action If Fire Occurs...32
Windshield Washer Fluid...32
Falling Objects, Flying Objects And Intruding Objects Prevention...32
Attachment Installation...33
Attachment Combinations...33
Cab Widow Glass...33
Unauthorized Modifications...33
Safety At Jobsite...33
Working On Loose Ground...34
Distance To High Voltage Cables...34
Ensure Good Visibility...35
Ventilation For Enclosed Area...35
Signalman's Signal And Signs...35
Emergency Exit From Operator's Cab...35
Asbestos Dust Hazard Prevention...35
SAFE MACHINE OPERATION...36
Starting Engine...36
Checks Before Starting Engine...36
Safety Rules For Starting Engine...36
Starting Engine In Cold Weather...36
OPERATION...37
Checks After Starting Engine, Before Operation...37
Safety Rules For Changing Machine Directions...37
Safety Rules For Traveling...38
Traveling On Slopes...38
Operations On Slopes...39
Prohibited Operations...40
Operations On Snow...41
Parking Machine...42
Transportation...43
Loading And Unloading...43
Shipping The Machine...44
Battery...45
Battery Hazard Prevention...45
Starting Engine With Booster Cables...46
Towing...47
Safety Rules For Towing...47
Lifting Objects With Bucket...48
Lifting Work Using Bucket With Hook...48
Safety Rules For Lifting Objects...48
SAFETY MAINTENANCE INFORMATION...49
Warning Tag...49
Keep Work Place Clean And Tidy...49
Appoint Leader When Working With Others...49
Stop Engine Before Carrying Out Maintenance...50
Two Workers For Maintenance When Engine Is Running...51
Proper Tools...51
Accumulator...52
Personnel...53
Attachments...53
Noise...53
When Using Hammer...53
Welding...54
Removing Battery Terminals...54
Adjusting Track Tension...54
Do Not Disassemble Recoil Springs...54
Safety Rules For High-pressure Oil...54
Safety Handling High-pressure Hoses...55
Waste Materials...55
Air Conditioner Maintenance...55
Compressed Air...55
Periodic Replacement Of Safety Critical Parts...55
OPERATION...56
GENERAL VIEW...57
General View Of Machine...57
General View Controls And Gauges...58
EXPLANATION OF COMPONENTS...59
Machine Monitor...59
Basic Operation Of Machine Monitor...60
If There Is Abnormality When Starting Engine...60
If Any Abnormality Occurs During Operation...61
Basic Check Items...62
Radiator Coolant Level Monitor...62
Engine Oil Level Monitor...63
Maintenance Interval Monitor...63
Caution Items...64
Charge Monitor...64
Fuel Level Monitor...65
Air Cleaner Clogging Monitor...65
Engine Coolant Temperature Monitor...65
Hydraulic Oil Temperature Monitor...65
Emergency Stop Items...66
Engine Coolant Temperature Monitor...66
Hydraulic Oil Temperature Monitor...67
Engine Oil Pressure Monitor...67
Meter Display Portion...68
Pilot Display...68
Gauges and Meters...70
Monitor Switches...72
Working Mode Selector Switch (Basic Switch)...73
Auto-deceleration Switch...74
Travel Speed Selector Switch...75
Wiper Switch...76
Window Washer Switch...76
Maintenance Switch...77
Select Switch...79
Back Switch...80
Up Switch, Down Switch...80
Input Confirmation Switch...80
Liquid Crystal Monitor Adjustment Switch...81
Switches...83
Starting Switch...83
Fuel Control Dial...84
Cigarette Lighter...84
Swing Lock Switch...84
Lamp Switch...85
Alarm Buzzer Stop Switch...85
Horn Switch...85
Knob Switch...85
Room Lamp Switch...86
Emergency Pump Drive Switch...86
Swing Brake Cancel Switch...86
Rotating Lamp Switch...86
Control Levers, Pedals...87
Safety Lock Lever...87
Travel Levers...88
Work Equipment Control Lever...89
Ceiling Window...90
Front Window...90
Emergency Exit From Operator's Cab...95
Door Lock...96
Cap, Cover With Lock...97
Method Of Opening And Closing Cap With Lock...97
Method Of Opening And Closing Cover With Lock...97
Hot And Cool Box...98
Magazine Box With Cup Holder...98
Ashtray...98
Air Conditioner...99
General Location Of Control Panel...99
Operation...104
Precautions When Using Air Conditioner...110
Check, Maintain Machine Equipped With Air Conditioner...110
Other Functions...111
Car Radio...112
Explanation Of Components...112
Method Of Operation...115
Power Pick-up Port...117
Fuse...117
Fuse Capacities And Circuit Names...118
Fusible Link...118
Controller...119
Toolbox...119
Grease Gun Holder...119
Handling The Accumulator...120
Releasing Pressure In Control Circuit...121
MACHINE OPERATIONS AND CONTROLS...122
Before Starting Engine...122
Walk-Around Checks...122
Checks Before Starting...123
Adjustments Before Operation...130
Seat Belt...132
Before Starting Engine...133
Starting Engine...136
Normal Starting...136
Starting Engine In Cold Weather...138
After Starting Engine...140
Breaking-in The New Machine...140
Warm-up Operation...141
In Cold Areas (Automatic Warm-up Operation)...145
Stopping The Engine...150
Check After Shutting Off Engine...150
Machine Operation...151
Preparations For Moving The Machine...151
Moving Machine Forward...152
Moving Machine Backward...153
Stopping Machine...154
Steering The Machine...155
Steering The Machine When Stopped...155
Changing Direction Of The Machine...156
Counter-rotation Turn (Spin Turn)...156
Swinging...157
Work Equipment Controls And Operations...158
Operating Working Mode...159
Working Mode...159
One-touch Power Max. Switch...159
Prohibited Operations...160
Swing Force...160
Travel Force...160
Hydraulic Cylinder Stroke Ends...160
Bucket Dropping Force...161
Machine Dropping Force...161
Digging Hard Rocky Ground...161
Sudden Lever Shifting High Speed Travel...161
General Operation Information...162
Traveling...162
High Speed Travel...162
Permissible Water Depth...162
Traveling On Slopes...163
Traveling Downhill...164
Engine Stopped On Slope...164
Precautions On Slopes...164
Escape From Mud...165
Stuck One Side Of Track...165
Stuck Both Sides Of Tracks...165
Recommended Applications...166
Backhoe Work...166
Shovel Work...166
Ditching Work...166
Loading Work...167
Replacement And Inversion Of Bucket...168
Replacement...168
Inversion...170
Parking Machine...172
Check After Shut Off Engine...173
Machine Inspection After Daily Work...173
Locking...174
TRANSPORTATION...174
Transportation Procedure...174
Loading And Unloading With Trailer...175
Loading...176
Securing Machine...178
Unloading...180
Lifting Machine...182
COLD WEATHER OPERATION...184
Fuel And Lubricants...184
Cooling System Coolant...184
Battery...185
Monitor...186
After Operations...187
After Cold Weather Season...187
LONG TERM STORAGE...188
Before Storage...188
During Storage...188
After Storage...188
Starting Machine...188
TROUBLESHOOTING...189
After Running Out Of Fuel...189
Phenomena That Are Not Failures...189
Towing The Machine...190
Lightweight Towing Hook...191
Precautions On Particular Jobsites...191
Discharged Battery...192
Removal And Installation Of Battery...193
Battery Charges...193
Starting Engine With Booster Cables...194
Other Trouble...196
Electrical System...196
Chassis...197
Engine...197
Electronic Control System...199
MAINTENANCE...202
MAINTENANCE INFORMATION...203
Service Meter Reading...203
Komatsu Genuine Replacement Parts...203
Komatsu Genuine Lubricants...203
Windshield Washer Fluid...203
Fresh And Clean Lubricants...203
Check Drained Oil And Used Filter...203
Fuel Strainer...203
Welding Instructions...203
Do Not Drop Things Inside Machine...203
Dusty Jobsite...204
Avoid Mixing Lubricants...204
Locking The Inspection Covers...204
Hydraulic System - Air Bleeding...204
Hydraulic Hose Installation...204
Checks After Inspection And Maintenance Works...204
Selecting Fuel And Lubricants To Match Ambient Temperature...205
LUBRICANTS, COOLANT AND FILTERS...205
Handling Oil, Fuel, Coolant, And Performing Oil Clinic...205
Oil...205
Fuel...205
Cooling System Coolant...206
Grease...206
Carrying Out Kowa (Komatsu Oil Wear Analysis)...206
Oil And Fuel Storage...207
Filters...207
Lubrication Chart Decal Explanation...208
Electric System Maintenance...210
Handling Hydraulic System...210
WEAR PARTS LIST...211
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...212
Proper Selection Of Fuel, Coolant And Lubricants...212
TIGHTENING TORQUE SPECIFICATIONS...214
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...215
Safety Critical Parts...215
MAINTENANCE SCHEDULE...216
Maintenance Schedule Chart...216
Maintenance Interval For Hydraulic Breaker...218
Replacing Hydraulic Element...218
Changing Oil In Hydraulic Tank...218
Replacing Additional Filter Element For Breaker...218
MAINTENANCE PROCEDURE...219
Initial 250 Hours Maintenance...219
Initial 1000 Hours Maintenance (Only After The First 1000 Hours)...219
When Required...220
Check, Clean And Replace Air Cleaner Element...220
Clean Inside Of Cooling System...224
Check And Tighten Track Shoe Bolts...227
Check And Adjust Track Tension...228
Check Electrical Intake Air Heater...229
Replace Bucket Teeth (Vertical Pin Type)...230
Replace Bucket Teeth (Horizontal Pin Type)...233
Adjust Bucket Clearance...234
Check Window Washer Fluid Level, Add Fluid...235
Check And Adjust Air Conditioner...236
Cleaning Cab Floor...237
Bleeding Air From Hydraulic System...240
Releasing Internal Pressure In Hydraulic Circuit...242
Check Nitrogen Gas Charge Pressure In Accumulator (Control Circuit)...243
Check Before Starting...244
Every 100 Hours Maintenance...245
Lubricating...245
Every 250 Hours Maintenance...246
Check Oil Level In Machinery Case, Add Oil...246
Check Oil Level In Final Drive Case, Add Oil...246
Check Level Of Battery Electrolyte...247
Check, Adjust Tension Of Air Conditioner Compressor Belt...249
Every 500 Hours Maintenance...250
Lubricating...250
Lubricate Swing Circle (2 Points)...252
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge...253
Replace Fuel Filter Cartridge...254
Check Swing Pinion Grease Level, Add Grease...255
Clean & Inspect Radiator Fins, Oil Cooler Fins & Condenser Fins...256
Clean Internal & External Air Filters Of Air Conditioner System...257
Replace Breather Element In Hydraulic Tank...258
Every 1000 Hours Maintenance...259
Replace Hydraulic Filter Element...259
Change Oil In Swing Machinery Case...261
Check Oil Level In Damper Case, Add Oil...262
Check All Tightening Parts Of Turbocharger...262
Check Play Of Turbocharger Rotor...262
Replace Corrosion Resistor Cartridge...263
Check Fan Belt Tension And Replace Fan Belt...263
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)...263
Every 2000 Hours Maintenance...264
Change Oil In Final Drive Case...264
Clean Hydraulic Tank Strainer...265
Clean, Check Turbocharger...265
Check Alternator, Starting Motor...265
Check Engine Valve Clearance, Adjust...265
Check Vibration Damper...265
Every 4000 Hours Maintenance...266
Check Water Pump...266
Every 5000 Hours Maintenance...267
Change Oil In Hydraulic Tank...267
SPECIFICATIONS...268
SPECIFICATIONS...269
OPTIONS, ATTACHMENTS...272
GENERAL PRECAUTIONS...273
Precautions Related To Safety...273
Precautions When Selecting...273
Read The Instruction Manual Thoroughly...273
Precautions When Removing Or Installing...273
Precautions When Using...273
Precautions When Installing Attachments...275
HANDLING BUCKET WITH HOOK...276
Checking For Damage To Bucket With Hook...276
Prohibited Operations...276
Precautions During Operations...276
MACHINES READY FOR ATTACHMENTS...277
Explanation Of Components...277
Stop Valve...277
Selector Valve...278
Attachment Control Pedal...278
Lock Pin...278
Additional Filter For Breaker...279
Accumulator...279
Hydraulic Circuit...280
Switching The Hydraulic Circuit...280
Adjusting Oil Flow...280
Switching Between Breaker And General Attachment...280
Hydraulic Circuit Connection...281
Oil Flow...282
Replace Additional Breaker Filter Element...283
Attachment Installation And Removal Procedure...284
Removal Procedure...284
Installation Procedure...285
Operation...286
When Using Breaker...286
When Using Crusher Or Other General Attachment...287
Long-term Storage...288
Specifications...288
ATTACHMENT GUIDE...289
Selection Of Track Shoes...289
Method Of Selecting Shoes...289
Selection Of Bucket Teeth...290
Selecting Teeth...290
Standards For Selecting Vertical And Horizontal Pin Type Teeth...291
Handling Trapezoidal Bucket...292
How To Excavate...292
Ditch Gradient Of 45...292
Ditch Gradient Of 40 And 38...293
Handling Extension Arm...293
Handling Clamshell Bucket...294
How To Perform Excavation...294
Precautions When Using...294
Lubricating...294
RECOMMENDED ATTACHMENT OPERATIONS...295
Hydraulic Breaker...295
Main Applications...295
Prohibited Operations...297
Greasing Position For Hydraulic Breaker...299
CEAM014700 - Hydraulic Excavator GALEO PC270LC-7L Operation & Maintenance Manual...300
COVER...300
INTRODUCTION...306
FOREWORD...307
SAFETY INFORMATION...308
SIGNAL WORDS...308
OTHER SIGNAL WORDS...308
INTRODUCTION...309
INTENDED USE...309
DIRECTIONS OF MACHINE...309
BREAKING IN THE MACHINE...309
PRODUCT INFORMATION...310
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...310
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...310
SERVICE METER LOCATION...311
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...311
TABLE OF CONTENTS...312
SAFETY...322
SAFETY LABELS...323
POSITION FOR ATTACHING SAFETY LABELS...323
UNIQUE SAFETY DECALS FOR LOG LOADER AND ROAD BUILDER EXCAVATORS...329
SAFETY INFORMATION...335
SAFETY RULES...335
IF ABNORMALITIES ARE FOUND...335
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...335
FIRE EXTINGUISHER AND FIRST AID KIT...335
SAFETY EQUIPMENT...335
KEEP MACHINE CLEAN...336
KEEP OPERATOR'S COMPARTMENT CLEAN...336
LEAVING OPERATOR'S SEAT WITH LOCK...336
HANDRAILS AND STEPS...337
MOUNTING AND DISMOUNTING...337
NO PERSONS ON ATTACHMENTS...337
BURN PREVENTION...338
HOT COOLANT...338
HOT OIL...338
FIRE PREVENTION AND EXPLOSION PREVENTION...338
FIRE CAUSED BY FUEL OR OIL...338
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...339
FIRE COMING FROM ELECTRIC WIRING...339
FIRE COMING FROM HYDRAULIC LINE...339
EXPLOSION CAUSED BY LIGHTING EQUIPMENT...339
ACTION IF FIRE OCCURS...339
WINDSHIELD WASHER FLUID...339
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...339
PROTECTION AGAINST FALLING OR FLYING OBJECTS...340
ATTACHMENT INSTALLATION...341
ATTACHMENT COMBINATIONS...341
CAB WIDOW GLASS...341
UNAUTHORIZED MODIFICATIONS...341
SAFETY AT JOBSITE...341
WORKING ON LOOSE GROUND...342
DISTANCE TO HIGH VOLTAGE CABLES...342
ENSURE GOOD VISIBILITY...343
VENTILATION FOR ENCLOSED AREA...343
SIGNALMAN'S SIGNAL AND SIGNS...343
EMERGENCY EXIT FROM OPERATOR'S CAB...343
ASBESTOS DUST HAZARD PREVENTION...344
SAFE MACHINE OPERATION...345
STARTING ENGINE...345
CHECKS BEFORE STARTING ENGINE...345
SAFETY RULES FOR STARTING ENGINE...345
STARTING ENGINE IN COLD WEATHER...345
OPERATION...346
CHECKS AFTER STARTING ENGINE, BEFORE OPERATION...346
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...346
SAFETY RULES FOR TRAVELING...347
TRAVELING ON SLOPES...347
OPERATIONS ON SLOPES...348
PROHIBITED OPERATIONS...348
OPERATIONS ON SNOW...349
PARKING MACHINE...350
TRANSPORTATION...351
SHIPPING THE MACHINE...351
BATTERY...352
BATTERY HAZARD PREVENTION...352
STARTING ENGINE WITH BOOSTER CABLES...353
TOWING...354
SAFETY RULES FOR TOWING...354
LIFTING OBJECTS WITH BUCKET...355
SAFETY RULES FOR LIFTING OBJECTS...355
SAFETY MAINTENANCE INFORMATION...356
WARNING TAG...356
KEEP WORK PLACE CLEAN AND TIDY...356
APPOINT LEADER WHEN WORKING WITH OTHERS...356
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...357
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...358
PROPER TOOLS...358
ACCUMULATOR...358
PERSONNEL...359
ATTACHMENTS...359
NOISE...359
WELDING...360
REMOVING BATTERY TERMINALS...360
DO NOT DISASSEMBLE RECOIL SPRINGS...361
SAFETY RULES FOR HIGH-PRESSURE OIL...361
SAFETY HANDLING HIGH-PRESSURE HOSES...361
WASTE MATERIALS...362
AIR CONDITIONER MAINTENANCE...362
COMPRESSED AIR...362
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...362
OPERATION...364
GENERAL VIEW...365
GENERAL VIEW OF LOG LOADER MACHINE...365
GENERAL VIEW OF ROAD BUILDER MACHINE...366
GENERAL VIEW CONTROLS AND GAUGES...367
EXPLANATION OF COMPONENTS...368
MACHINE MONITOR...368
BASIC OPERATION OF MACHINE MONITOR...369
IF THERE IS ABNORMALITY WHEN STARTING ENGINE...369
IF ANY ABNORMALITY OCCURS DURING OPERATION...370
BASIC CHECK ITEMS...371
RADIATOR WATER LEVEL MONITOR...371
ENGINE OIL LEVEL MONITOR...372
MAINTENANCE INTERVAL MONITOR...372
CAUTION ITEMS...373
CHARGE MONITOR...373
FUEL LEVEL MONITOR...374
AIR CLEANER CLOGGING MONITOR...374
ENGINE WATER TEMPERATURE MONITOR...374
EMERGENCY STOP ITEMS...375
ENGINE WATER TEMPERATURE MONITOR...375
HYDRAULIC OIL TEMPERATURE MONITOR...376
ENGINE OIL PRESSURE MONITOR...376
METER DISPLAY PORTION...377
PILOT DISPLAY...377
METERS...379
MONITOR SWITCHES...381
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)...382
AUTO-DECELERATION SWITCH...383
TRAVEL SPEED SELECTOR SWITCH...384
WIPER SWITCH...385
WINDOW WASHER SWITCH...385
MAINTENANCE SWITCH...386
SELECT SWITCH...388
BACK SWITCH...389
UP SWITCH, DOWN SWITCH...389
INPUT CONFIRMATION SWITCH...389
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH...390
SWITCHES...393
STARTING SWITCH...394
FUEL CONTROL DIAL...395
CIGARETTE LIGHTER...395
SWING LOCK SWITCH...395
LAMP SWITCH...396
ALARM BUZZER STOP SWITCH...396
HORN SWITCH...396
LOG LOADER GRAPPLE ROTATION CW SWITCH...396
LOG LOADER GRAPPLE CLOSE SWITCH...396
POWER MAX SWITCH...397
LOG LOADER GRAPPLE ROTATION CCW SWITCH...397
LOG LOADER GRAPPLE OPEN SWITCH...397
ROOM LAMP SWITCH...397
EMERGENCY PUMP DRIVE SWITCH...398
SWING BRAKE CANCEL SWITCH...398
CONTROL LEVERS, PEDALS...399
SAFETY LOCK LEVER...399
TRAVEL LEVERS...400
WORK EQUIPMENT CONTROL LEVER...401
CEILING WINDOW...402
FRONT WINDOW...402
EMERGENCY EXIT FROM OPERATOR'S CAB - FROM INSIDE...407
EMERGENCY EXIT FROM OPERATOR'S CAB - FROM OUTSIDE...407
DOOR LOCK...409
CAP, COVER WITH LOCK...409
METHOD OF OPENING AND CLOSING CAP WITH LOCK...409
METHOD OF OPENING AND CLOSING COVER WITH LOCK...410
HOT AND COOL BOX...410
MAGAZINE BOX WITH CUP HOLDER...410
ASHTRAY...410
AIR CONDITIONER...411
GENERAL LOCATION OF CONTROL PANEL...411
METHOD OF OPERATION...415
PRECAUTIONS WHEN USING AIR CONDITIONER...422
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...422
OTHER FUNCTIONS...423
CAR RADIO...424
EXPLANATION OF COMPONENTS...424
METHOD OF OPERATION...427
POWER PICK-UP PORT...429
FUSE...429
FUSE CAPACITIES AND CIRCUIT NAMES...430
FUSIBLE LINK...430
CONTROLLER...431
TOOLBOX...431
GREASE GUN HOLDER...431
HANDLING THE ACCUMULATOR...432
RELEASING PRESSURE IN CONTROL CIRCUIT...432
MACHINE OPERATIONS AND CONTROLS...433
BEFORE STARTING ENGINE...433
WALK-AROUND CHECKS...433
CHECKS BEFORE STARTING...434
ADJUSTMENTS BEFORE OPERATION...441
ADJUSTMENT OF MIRRORS...442
SEAT BELT...443
BEFORE STARTING ENGINE...444
STARTING ENGINE...447
NORMAL STARTING...447
STARTING ENGINE IN COLD WEATHER...448
AFTER STARTING ENGINE...451
BREAKING-IN THE NEW MACHINE...451
WARM-UP OPERATION...452
AUTOMATIC WARM-UP OPERATION...456
STOPPING THE ENGINE...460
CHECK AFTER SHUTING OFF ENGINE...460
MACHINE OPERATION...461
PREPARATIONS FOR MOVING THE MACHINE...461
MOVING MACHINE FORWARD...462
MOVING MACHINE BACKWARD...463
STOPPING MACHINE...464
STEERING THE MACHINE...465
STEERING THE MACHINE WHEN STOPPED...465
CHANGING DIRECTION OF THE MACHINE...466
COUNTER-ROTATION TURN (SPIN TURN)...466
SWINGING...467
WORK EQUIPMENT CONTROLS AND OPERATIONS...468
OPERATING WORKING MODE...469
WORKING MODE...469
ONE-TOUCH POWER MAX. SWITCH...469
PROHIBITED OPERATIONS...470
OPERATIONS USING SWING FORCE...470
OPERATIONS USING TRAVEL FORCE...470
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS...470
OPERATIONS USING BUCKET DROPPING FORCE...471
OPERATIONS USING MACHINE DROPPING FORCE...471
DIGGING HARD ROCKY GROUND...471
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...471
GENERAL OPERATION INFORMATION...472
TRAVELING...472
HIGH SPEED TRAVEL...472
PERMISSIBLE WATER DEPTH...472
TRAVELING ON SLOPES...473
TRAVELING DOWNHILL...474
ENGINE STOPPED ON SLOPE...474
PRECAUTIONS ON SLOPES...474
ESCAPE FROM MUD...475
STUCK ONE SIDE OF TRACK...475
STUCK BOTH SIDES OF TRACKS...475
ROAD BUILDER RECOMMENDED APPLICATIONS...476
BACKHOE WORK...476
SHOVEL WORK...476
DITCHING WORK...476
LOADING WORK...477
REPLACEMENT AND INVERSION OF BUCKET...478
REPLACEMENT...478
INVERSION...480
PARKING MACHINE...481
CHECK AFTER FINISHING WORK...483
LOCKING...484
TRANSPORTATION...485
TRANSPORTATION PROCEDURE...485
LOADING AND UNLOADING WITH TRAILER...486
LOADING...486
SECURING THE MACHINE...489
MACHINES WITH CAB RISER...491
UNLOADING...493
LIFTING THE MACHINE...496
COLD WEATHER OPERATION...497
FUEL AND LUBRICANTS...497
COOLING SYSTEM COOLANT...497
BATTERY...498
AFTER OPERATIONS...499
AFTER COLD WEATHER SEASON...499
LONG TERM STORAGE...500
BEFORE STORAGE...500
DURING STORAGE...500
AFTER STORAGE...500
STARTING MACHINE...501
TROUBLESHOOTING...501
AFTER RUNNING OUT OF FUEL...501
PHENOMENA THAT ARE NOT FAILURES...501
TOWING THE MACHINE...502
LIGHTWEIGHT TOWING HOOK...502
PRECAUTIONS ON PARTICULAR JOBSITES...503
DISCHARGED BATTERY...503
REMOVAL AND INSTALLATION OF BATTERY...504
BATTERY CHARGES...504
STARTING ENGINE WITH BOOSTER CABLES...505
OTHER TROUBLE...507
ELECTRICAL SYSTEM...507
CHASSIS...508
ENGINE...508
ELECTRONIC CONTROL SYSTEM...510
MAINTENANCE...512
MAINTENANCE INFORMATION...513
SERVICE METER READING...513
KOMATSU GENUINE REPLACEMENT PARTS...513
KOMATSU GENUINE LUBRICANTS...513
WINDSHIELD WASHER FLUID...513
FRESH AND CLEAN LUBRICANTS...513
CHECK DRAINED OIL AND USED FILTER...513
FUEL STRAINER...513
WELDING INSTRUCTIONS...513
DO NOT DROP THINGS INSIDE MACHINE...513
DUSTY JOBSITE...514
AVOID MIXING LUBRICANTS...514
LOCKING THE INSPECTION COVERS...514
HYDRAULIC SYSTEM - AIR BLEEDING...514
HYDRAULIC HOSE INSTALLATION...514
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...514
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE...515
LUBRICANTS, COOLANT AND FILTERS...515
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...515
OIL...515
FUEL...515
COOLING SYSTEM COOLANT...516
GREASE...516
CARRYING OUT KOWA...516
OIL AND FUEL STORAGE...517
FILTERS...517
ELECTRIC SYSTEM MAINTENANCE...518
HANDLING HYDRAULIC SYSTEM...518
WEAR PARTS LIST...519
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...520
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...520
TIGHTENING TORQUE SPECIFICATIONS...522
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...523
SAFETY CRITICAL PARTS...523
MAINTENANCE SCHEDULE...524
MAINTENANCE SCHEDULE CHART...524
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...527
REPLACING HYDRAULIC ELEMENT...527
CHANGING OIL IN HYDRAULIC TANK...527
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER...527
MAINTENANCE PROCEDURE...528
INITIAL 10 HOURS MAINTENANCE...528
LUBRICATION ROAD BUILDER MACHINE...528
INITIAL 250 HOURS MAINTENANCE...530
WHEN REQUIRED...531
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...531
CLEAN INSIDE OF COOLING SYSTEM...534
CHECK AND TIGHTEN TRACK SHOE BOLTS...536
CHECK AND ADJUST TRACK TENSION...537
CHECK ELECTRICAL INTAKE AIR HEATER...538
ADJUST BUCKET CLEARANCE...539
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...540
CHECK AND ADJUST AIR CONDITIONER...541
CLEANING CAB FLOOR...543
BLEEDING AIR FROM HYDRAULIC SYSTEM...545
RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...547
CHECK BEFORE STARTING...548
EVERY 100 HOURS MAINTENANCE...549
LUBRICATING...549
EVERY 250 HOURS MAINTENANCE...550
LUBRICATION...550
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...550
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...551
CHECK LEVEL OF BATTERY ELECTROLYTE...552
LUBRICATE SWING CIRCLE (3 POINTS)...554
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...554
EVERY 500 HOURS MAINTENANCE...555
LUBRICATION...555
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...556
REPLACE FUEL FILTER CARTRIDGE...557
CHECK SWING PINION GREASE LEVEL, ADD GREASE...558
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...559
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...560
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...561
EVERY 1000 HOURS MAINTENANCE...562
REPLACE HYDRAULIC FILTER ELEMENT...562
CHANGE OIL IN SWING MACHINERY CASE...563
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...564
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...564
CHECK PLAY OF TURBOCHARGER ROTOR...564
CHECK FAN BELT TENSION AND REPLACE FAN BELT...564
EVERY 2000 HOURS MAINTENANCE...565
CHANGE OIL IN FINAL DRIVE CASE...565
CLEAN HYDRAULIC TANK STRAINER...566
CLEAN, CHECK TURBOCHARGER...566
CHECK ALTERNATOR, STARTING MOTOR...566
CHECK ENGINE VALVE CLEARANCE, ADJUST...566
CHECK VIBRATION DAMPER...566
EVERY 4000 HOURS MAINTENENCE...567
CHECK WATER PUMP...567
EVERY 5000 HOURS MAINTENANCE...568
CHANGE OIL IN HYDRAULIC TANK...568
SPECIFICATIONS...570
SPECIFICATIONS...571
DIMENSIONS...571
WORKING RANGE...573
WORKING RANGE - ROAD BUILDER...573
LIFTING CAPACITY- ROAD BUILDER...575
OPTIONS, ATTACHMENTS...578
CEBD003001 - Hydraulic Excavator PC270LC-6LE Shop Manual...582
COVER...582
CONTENTS...583
00 FOREWORD...590
SAFETY...593
GENERAL...595
HOW TO READ THE SHOP MANUAL...596
HOISTING INSTRUCTIONS...597
COATING MATERIALS...598
STANDARD TIGHTENING TORQUE...599
ELECTRIC WIRE CODE...601
CONVERSION TABLES...602
01 GENERAL...608
GENERAL ASSEMBLY DRAWING ...609
SPECIFICATIONS...610
WEIGHT TABLE...613
FUEL, COOLANT AND LUBRICANTS...615
ENGINE OIL SPECIFICATIONS...616
NORMAL OPERATION...616
ARCTIC OPERATION...616
DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFICATION...617
FINAL DRIVE OIL SPECIFICATIONS...617
DIESEL FUEL SPECIFICATIONS...617
COOLANT SPECIFICATIONS...618
GENERAL...618
WATER...618
ANTIFREEZE...618
10 STRUCTURE AND FUNCTION...620
ENGINE RELATED PARTS...623
RADIATOR AND OIL COOLER...624
POWER TRAIN...625
FINAL DRIVE...626
SWING CIRCLE...628
SWING MACHINERY...630
TRACK FRAME AND RECOIL SPRING...631
TRACK SHOE...632
HYDRAULIC PIPING DRAWING...634
HYDRAULIC CIRCUIT DIAGRAM...636
HYDRAULIC TANK...638
HYDRAULIC PUMP...639
BASIC PUMP...639
LS (LOADING SENSING) AND PC (POWER CONTROL) VALVE...645
IN-LINE OIL FILTER...657
CONTROL VALVE...658
OUTLINE...658
NINE-SPOOL VALVE (STANDARD PLUS THREE SERVICE VALVES)...659
MAIN STRUCTURE...660
SIX-SPOOL VALVE (STANDARD)...663
SAFETY-SUCTION VALVE FOR SERVICE VALVE...664
SELF-REDUCING PRESSURE VALVE...664
FUNCTION...667
OPERATION...667
CLSS...670
OUTLINE OF CLSS...670
OPERATION OF EACH FUNCTION AND VALVE...673
OPERATION OF CLSS SYSTEM AS A WHOLE...699
SWING MOTOR...715
BASIC MOTOR...715
SWING LOCK VALVE...717
RELIEF VALVE PORTION...718
REVERSE PREVENTION VALVE (SWING DAMPENING)...719
CENTER SWIVEL JOINT...721
TRAVEL MOTOR...722
VALVE CONTROL...730
WORK EQUIPMENT AND SWING PPC VALVE...731
OPERATION...733
TRAVEL PPC VALVE...735
OPERATION...737
SERVICE PPC VALVE...739
OPERATION...739
SAFETY LOCK VALVE...741
STRAIGHT-TRAVEL SYSTEM...742
FUNCTION...742
EPC VALVE...743
OPERATION...744
BOOM LOCK VALVE...745
OPERATION...746
ADDITIONAL FILTER FOR BREAKER...748
WORK EQUIPMENT...749
AIR CONDITIONER...750
BASIC INFORMATION ON AIR CONDITIONERS...751
UNITS RELATED TO REFRIGERATION...751
PRINCIPLE OF COOLING...755
REFRIGERANTS...760
SAFETY PRECAUTIONS...760
REFRIGERATOR OIL (LUBE OIL)...760
AIR CONDITIONING CONDENSER...762
FUNCTION...762
GENERAL DESCRIPTION...762
AIR CONDITIONER COMPRESSOR...765
RECEIVER WITH SIGHT GLASS...766
AIR CONDITIONER UNIT...768
OUTLINE...768
ELECTRICAL WIRING DIAGRAM...770
ELECTRICAL CIRCUIT DIAGRAM...772
ENGINE CONTROL SYSTEM...776
FUNCTION...776
OPERATION OF SYSTEM...777
COMPONENTS OF SYSTEM...778
ELECTRONIC CONTROL SYSTEM...782
TOTAL SYSTEM DIAGRAM...783
PUMP AND ENGINE MUTUAL CONTROL FUNCTION...784
PUMP AND VALVE CONTROL FUNCTION...789
POWER MAXIMIZING AND SWIFT SLOW-DOWN FUNCTION...792
AUTO-DECELERATION FUNCTION...793
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION...795
SWING CONTROL FUNCTION...797
TRAVEL CONTROL FUNCTIONACTIVE MODE FUNCTION...799
ACTIVE MODE FUNCTION...801
COMPONENTS OF SYSTEM...803
MACHINE MONITOR SYSTEM...806
FUNCTION...806
MONITOR PANEL...807
MONITOR DISPLAY...808
OIL MAINTENANCE FUNCTION...810
SWITCHES...812
SENSORS...813
COOLANT LEVEL SENSOR...813
ENGINE OIL LEVEL SENSOR...814
HYDRAULIC OIL SENSOR...814
ENGINE OIL PRESSURE SENSOR...814
COOLANT TEMPERATURE SENSOR...815
FUEL LEVEL SENSOR...815
AIR CLEANER CLOGGING SENSOR...815
20 TESTING, ADJUSTING AND TROUBLESHOOTING...816
TESTING AND ADJUSTING...821
STANDARD VALUES TABLE...822
FOR ENGINE - PC270LC-6LE...822
FOR CHASSIS...823
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...842
MEASURING ENGINE SPEED...843
MEASURING EXHAUST GAS COLOR...844
ADJUSTING VALVE CLEARANCE...845
MEASURING COMPRESSION PRESSURE...846
MEASURING BLOW-BY PRESSURE...847
TESTING AND ADJUSTING FUEL INJECTION TIMING...848
MEASURING ENGINE OIL PRESSURE...849
TESTING AND ADJUSTING FAN BELT TENSION...850
TESTING AND ADJUSTING A/C COMPRESSOR BELT TENSION...851
ADJUSTING THE ENGINE SPEED SENSOR...852
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...853
MEASURING EQUIPMENT CYCLE TIMES...854
TESTING AND ADJUSTING PILOT OIL PRESSURE ...855
TESTING AND ADJUSTING MAIN HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT...857
TESTING SERVO PISTON INPUT PRESSURE...861
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE...863
TESTING AND ADJUSTING PC VALVE...865
TESTING SOLENOID VALVE OUTPUT PRESSURES (LS-EPC, PC-EPC AND ON/OFF SOLENOID VALUES)...867
MEASURING PPC VALVE OUTPUT PRESSURE...871
PRESSURE SWITCH PIPING DIAGRAM...872
ADJUSTING WORK EQUIPMENT * SWING PPC VALVE...873
TESTING TRAVEL DEVIATION...874
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...875
MEASURING OIL LEAKAGE...877
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...879
TESTING CLEARANCE OF SWING CIRCLE BEARING...880
TESTING AND ADJUSTING TRACK SHOE TENSION...881
BLEEDING AIR...883
TROUBLESHOOTING...885
POINTS TO REMEMER WHEN TROUBLESHOOTING...886
SEQUENCE OF EVENTS IN TROUBLESHOOTING...887
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...888
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT...888
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS...893
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...894
CHECKS BEFORE TROUBLESHOOTING...896
CONNECTOR TYPES AND MOUNTING LOCATIONS...897
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...901
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...911
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...912
METHOD OF USING JUDGEMENT TABLE...921
METHOD OF USING TROUBLESHOOTING CHARTS...923
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...925
SERVICE CODE TABLE...930
TROUBLESHOOTING OF COMMUNICATION ABNOMALITY SYSTEM (N MODE)...931
N-1 [E218] COMMUNICATIONS ABNORMALITY...931
TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)(E MODE)...934
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER SYSTEM...934
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...935
JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...939
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM...941
E-1 ABNOMALITY IN ENGINE THROTTLE - PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...943
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...944
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...945
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED...946
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...947
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...948
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED...949
E-8 ENGINE DOES NOT START...951
E-9 ENGINE SPEED IS IRREGULAR...955
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED TO LOW)...959
E-11 ENGINE DOES NOT STOP...961
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOE NOT STOP)...963
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...965
METHOD OF USING TROUBLESHOOTING CHARTS...965
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...969
S-2 ENGINE DOES NOT START...971
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...974
S-4 ENGINE STOPS DURING OPERATIONS ...975
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...976
S-6 ENGINE LACKS OUTPUT (NO POWER)...977
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...978
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...979
S-9 OIL BECOMES CONTAMINATED QUICKLY...980
S-10 FUEL CONSUMPTION IS EXCESSIVE...981
S-11 OIL IS IN COOLANT, OR COLLANT SPURTS BACK, OR COOLANT LEVLE GOES DOWN...982
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...983
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL)...984
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...985
S-15 ABNORMAL NOISE IS MADE...986
S-16 VIBRATION IS EXCESSIVE...987
TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM)(C MODE)...988
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...988
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...989
JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...997
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE...999
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...1001
C-2 [E232] SHORT CIRCUIT IN PUMP EPC SOLENOID SYSTEM IS DISPLAYED...1003
C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED...1005
C-4 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...1007
C-5 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...1009
C-6 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED...1011
C-7 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED...1012
C-8 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYEDPC270LC-6LE...1013
C-9 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...1014
C-10 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...1015
C-11 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED...1016
C-12 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...1017
C-13 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...1018
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...1019
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...1021
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...1022
C-17 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...1023
C-18 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...1024
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED...1025
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...1026
TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (INPUT SIGNAL SYSTEM (F MODE)...1028
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...1028
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...1029
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...1030
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...1031
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...1032
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...1033
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...1034
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP ...1035
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP...1036
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...1037
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP...1038
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...1039
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM...1039
PUMP MERGE/DIVIDER LOGIC...1043
SOLENOID ACTUATION TABLE...1044
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW...1045
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...1047
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...1047
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...1048
H-5 AUTO-DECELERATION DOES NOT WORK (PPC SHUTTLE VALVE IS EQUIPPED ONLY IN TRAVEL PPC VALVE)...1048
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...1049
H-7 BOOM IS SLOW OR LACKS POWER...1051
H-8 ARM IS SLOW OR LACKS POWER...1053
H-9 BUCKET IS SLOW OR LACKS POWER...1055
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...1056
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...1056
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...1057
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...1057
H-14 LACK OF POWER WHEN PRESSURE RISES...1058
H-15 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED ...1059
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGE LOAD IS SLOW...1059
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...1060
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...1060
H-19 TRAVEL DEVIATION...1060
H-20 TRAVEL SPEED IS SLOW...1061
H-21 STEERING DOES NOT TURN EASILY OR LACKS POWER...1063
H-22 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED...1065
H-23 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...1065
H-24 DOES NOT SWING...1066
H-25 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW...1067
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING...1069
H-27 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...1069
H-28 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...1070
H-29 EXCESSIVE HYDRAULIC DRIFT OF SWING...1070
H-30 SWING SPEED IS FASTER THAN SPECIFIED SPEED IN L/O AND F/O MODES...1071
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M CODE)...1073
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...1073
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM...1075
M-1 [E101] ABNORMALITY IN ERRO DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED...1077
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED...1078
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED...1079
M-4 [E108] ENGINE COOLANT TEMPERATURE 105 C (221F) DETECTED IS DISPLAYED...1079
M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS...1081
M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT...1083
M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE MODEL...1083
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH...1085
M-9 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP...1088
M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH...1089
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE L...1091
M-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMAL...1093
M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR SECOND. CAUTION ITEM FLASHES BUT BUZZER D...1097
M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS...1097
M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)...1098
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE...1099
M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF THE GAUGE LAMPS LIGHT UP DURING OPERATION)...1100
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL...1101
M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...1101
M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP...1102
M-21 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH...1103
M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING...1104
M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED...1104
M-24 DEFECTIVE FUEL LEVER SENSOR SYSTEM...1105
M-25 DEFECTIVE COOLANT TEMPERATUER SENSOR SYSTEM...1106
M-26 DEFECTIVE ENGINE OIL SENSOR SYSTEM...1107
M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM...1108
M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM...1109
M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED...1111
M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED...1117
30 DISASSEMBLY AND ASSEMBLY...1120
METHOD OF USING MANUAL...1125
WHEN REMOVING OR INSTALLING UNIT ASSEMBLIES...1125
GENERAL PRECAUTIONS...1125
LISTING OF SPECIAL TOOLS...1125
PRECAUTIONS WHEN CARRYING OUT OPERATION...1126
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...1126
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...1127
PRECAUTIONS WHEN COMPLETING OPERATIONS...1127
SPECIAL TOOLS LIST...1128
SPECIAL TOOL SKETCH...1132
STARTER MOTOR...1134
REMOVAL...1134
INSTALLATION...1134
ALTERNATOR...1135
REMOVAL...1135
INSTALLATION...1135
AIR CONDITIONER COMPRESSOR...1136
REMOVAL...1136
INSTALLATION...1136
AIR CONDITIONER CONDENSER...1137
REMOVAL...1137
INSTALLATION...1137
RECEIVER DRIER...1138
REMOVAL...1138
INSTALLATION...1138
FUEL INJECTION PUMP...1139
REMOVAL...1139
INSTALLATION...1140
WATER PUMP...1141
REMOVAL...1141
INSTALLATION...1142
NOZZLE HOLDER...1143
REMOVAL...1143
INSTALLATION...1143
TURBOCHARGER...1144
REMOVAL...1144
INSTALLATION...1144
THERMOSTAT...1145
REMOVAL...1145
INSTALLATION...1145
GOVERNOR MOTOR...1146
REMOVAL...1146
INSTALLATION...1146
CYLINDER HEAD ASSEMBLY...1147
REMOVAL...1147
INSTALLATION...1149
RADIATOR - HYDRAULIC OIL COOLER...1151
REMOVAL...1151
INSTALLATION...1152
ENGINE, MAIN PUMP...1153
REMOVAL...1153
INSTALLATION...1156
DAMPER...1157
REMOVAL...1157
INSTALLATION...1157
FUEL TANK...1158
REMOVAL...1158
INSTALLATION...1158
CENTER SWIVEL JOINT...1159
REMOVAL...1159
INSTALLATION...1160
DISASSEMBLY...1161
ASSEMBLY...1161
FINAL DRIVE...1163
REMOVAL...1163
INSTALLATION...1163
DISASSEMBLY...1164
ASSEMBLY...1167
SPROCKET...1171
REMOVAL...1171
INSTALLATION...1171
SWING MOTOR AND MACHINERY...1173
REMOVAL...1173
INSTALLATION...1174
SWING MACHINERY...1175
DISASSEMBLY...1175
ASSEMBLY...1178
REVOLVING FRAME...1183
REMOVAL...1183
INSTALLATION...1184
SWING CIRCLE...1185
REMOVAL...1185
INSTALLATION...1185
IDLER-RECOIL SPRING...1186
REMOVAL...1186
INSTALLATION...1186
IDLER RECOIL SPRING...1187
DISASSEMBLY...1187
ASSEMBLY...1188
IDLER...1189
DISASSEMBLY...1189
ASSEMBLY...1190
TRACK ROLLER...1193
REMOVAL...1193
INSTALLATION...1194
DISASSEMBLY...1195
ASSEMBLY...1196
CARRIER ROLLER...1199
REMOVAL...1199
INSTALLATION...1199
DISASSEMBLY...1200
ASSEMBLY...1201
TRACK SHOE...1203
REMOVAL...1203
INSTALLATION...1203
HYDRAULIC TANK...1205
REMOVAL...1205
INSTALLATION...1206
MAIN PUMP...1207
REMOVAL...1207
INSTALLATION...1209
MAIN PUMP INPUT SHAFT OIL SEAL...1210
REMOVAL...1210
INSTALLATION...1210
CONTROL VALVE...1211
REMOVAL...1211
INSTALLATION...1213
DISASSEMBLY...1214
ASSEMBLY...1219
PUMP MERGER-DIVIDER VALVE...1222
DISASSEMBLY...1222
ASSEMBLY...1222
MAIN RELIEF VALVE...1223
DISASSEMBLY...1223
ASSEMBLY...1223
PC VALVE...1224
REMOVAL...1224
INSTALLATION...1224
LS VALVE...1225
REMOVAL...1225
INSTALLATION...1225
PC-EPC, LS-EPC VALVES...1226
REMOVAL...1226
INSTALLATION...1226
SOLENOID VALVE...1227
REMOVAL...1227
INSTALLATION...1227
WORK EQUIPMENT - SWING PPC VALVE...1229
REMOVAL...1229
INSTALLATION...1229
DISASSEMBLY ...1230
ASSEMBLY...1231
TRAVEL PPC VALVE...1233
REMOVAL...1233
INSTALLATION...1234
DISASSEMBLY...1235
ASSEMBLY...1236
BOOM LOCK VALVE...1237
REMOVAL...1237
INSTALLATION...1237
BOOM CYLINDER...1239
REMOVAL...1239
INSTALLATION...1240
ARM CYLINDER...1241
REMOVAL...1241
INSTALLATION...1242
BUCKET CYLINDER...1243
REMOVAL...1243
INSTALLATION...1244
HYDRAULIC CYLINDER...1245
DISASSEMBLY...1245
ASSEMBLY...1247
WORK EQUIPMENT...1251
REMOVAL...1251
INSTALLATION...1252
BUCKET...1253
REMOVAL...1253
INSTALLATION...1254
ARM...1255
REMOVAL...1255
INSTALLATION...1256
BUCKET - ARM...1257
REMOVAL...1257
INSTALLATION...1258
BOOM...1259
REMOVAL...1259
INSTALLLATION...1260
OPERATOR'S CAB...1261
REMOVAL...1261
INSTALLATION...1262
COUNTERWEIGHT...1263
REMOVAL...1263
INSTALLATION...1263
ENGINE THROTTLE - PUMP CONTROLLER...1264
REMOVAL...1264
INSTALLATION...1264
CONTROL STAND CASE...1265
REMOVAL...1265
INSTALLATION...1266
MONITOR...1267
REMOVAL...1267
INSTALLATION...1267
40 MAINTENANCE STANDARD...1268
SWING MACHINERY...1271
SWING CIRCLE...1274
FINAL DRIVE...1275
TRACK FRAME AND RECOIL SPRING...1277
CARRIER ROLLER...1278
IDLER...1279
TRACK ROLLER...1282
TRACK SHOE...1283
HYDRAULIC PUMP...1285
CONTROL VALVE...1286
VARIABLE PRESSURE COMPENSATION VALVE...1292
SAFETY-SUCTION VALVE FOR SERVICE VALVE...1293
SELF-REDUCING PRESSURE VALVE...1294
SWING MOTOR...1295
TRAVEL MOTOR...1296
WORK EQUIPMENT AND SWING PPC VALVES...1297
TRAVEL PPC VALVE...1298
SERVICE PPC VALVE...1299
EPC SOLENOID VALVE...1300
CENTER SWIVEL JOINT...1301
BOOM LOCK VALVE...1302
HYDRAULIC CYLINDER...1303
WORK EQUIPMENT...1305
DIMENSION OF WORK EQUIPMENT...1307
ARM PORTION...1307
BUCKET PORTION...1309
CEBM005905 - Hydraulic Excavator PC270LC-7L Shop Manual...1313
CONTENTS...1314
SAFETY...1327
Safety Notice...1327
IMPORTANT SAFETY NOTICE...1327
General Precautions...1327
Preparations For Work...1327
Precautions During Work...1327
GENERAL...1330
HOW TO READ THE SHOP MANUAL...1331
Volumes...1331
Distribution And Updating...1331
Filing Method...1331
Revised Edition Mark...1331
Revisions...1331
Symbols...1331
HOISTING INSTRUCTIONS...1332
Hoisting...1332
Wire Ropes...1332
PUSH-PULL TYPE COUPLER...1333
COATING MATERIALS...1335
STANDARD TIGHTENING TORQUE...1337
Standard Tightening Torque Of Bolts And Nuts...1337
Tightening Torque Of Split Flange Bolts...1338
Tightening Torque For Flared Nuts...1338
Table Of Tightening Torques For O-ring Boss Piping Joints...1338
Table Of Tightening Torques For O-ring Boss Plugs...1339
Tightening Torque For 102 And 114 Engine Series...1339
Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type)...1340
ELECTRIC WIRE CODE...1341
Classification By Thickness...1341
Classification By Color And Code...1341
CONVERSION TABLES...1342
Method Of Using The Conversion Table...1342
SPECIFICATION DIMENSION DRAWINGS...1350
Dimensions...1350
Working Ranges...1351
SPECIFICATIONS...1352
WEIGHT TABLE...1354
FUEL, COOLANT AND LUBRICANTS...1356
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil...1357
ENGINE RELATED PARTS...1361
RADIATOR . OIL COOLER . AFTERCOOLER...1362
POWER TRAIN...1363
FINAL DRIVE...1364
SWING MACHINERY...1366
SWING CIRCLE...1369
TRACK FRAME . RECOIL SPRING...1370
IDLER...1372
CARRIER ROLLER...1374
CEBM014600 - Logging Excavator GALEO PC270LL-7L Shop Manual...2151
COVER...2151
CONTENTS...2152
FOREWORD...2152
SAFETY...2155
SAFETY NOTICE...2155
IMPORTANT SAFETY NOTICE...2155
GENERAL PRECAUTIONS...2155
PREPARATIONS FOR WORK...2155
PRECAUTIONS DURING WORK...2155
GENERAL...2157
HOW TO READ THE SHOP MANUAL...2158
VOLUMES...2158
DISTRIBUTION AND UPDATING...2158
FILING METHOD...2158
REVISED EDITION MARK...2158
REVISIONS...2158
SYMBOLS...2158
HOISTING INSTRUCTIONS...2159
HOISTING...2159
WIRE ROPES...2159
COATING MATERIALS...2160
STANDARD TIGHTENING TORQUE...2162
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...2162
TIGHTENING TORQUE OF HOSE NUTS...2163
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...2163
TIGHTENING TORQUE FOR FLARED NUTS...2163
ELECTRIC WIRE CODE...2164
CLASSIFICATION BY THICKNESS...2164
CLASSIFICATION BY COLOR AND CODE...2164
CONVERSION TABLES...2165
METHOD OF USING THE CONVERSION TABLE...2165
01 GENERAL...2171
SPECIFICATION DIMENSION DRAWINGS...2172
PC270LL-7L...2172
DIMENSIONS...2172
WORKING RANGES...2174
WEIGHT TABLE...2177
FUEL, COOLANT AND LUBRICANTS...2179
PC270LL-7L...2179
10 STRUCTURE AND FUNCTION...2181
ENGINE RELATED PARTS...2183
RADIATOR . OIL COOLER . AFTERCOOLER...2184
POWER TRAIN...2185
FINAL DRIVE...2187
SWING CIRCLE...2191
TRACK FRAME . RECOIL SPRING...2193
IDLER...2195
TRACK ROLLER...2197
TRACK SHOE...2198
TRIPLE GROUSER SHOE...2200
HYDRAULIC EQUIPMENT...2201
HYDRAULIC TANK...2203
HYDRAULIC PUMP...2205
HPV95 + 95...2205
LS VALVE...2210
PC VALVE...2210
LS(PC)-EPC VALVE...2223
CONTROL VALVE...2227
SELF PRESSURE REDUCING VALVE...2243
MAIN RELIEF VALVE...2246
VARIABLE PRESSURE COMPENSATION VALVE...2247
CLSS...2249
SWING MOTOR...2250
RELIEF VALVE PORTION...2253
SWING LOCK...2254
REVERSE PREVENTION VALVE...2255
CENTER SWIVEL JOINT...2258
TRAVEL MOTOR...2260
PARKING BRAKE...2265
TRAVEL JUNCTION VALVE...2271
VALVE CONTROL...2273
CONNECTIONS...2273
LEVER POSITIONS...2274
WORK EQUIPMENT . SWING PPC VALVE...2275
TRAVEL PPC VALVE...2280
SERVICE VALVE...2289
SOLENOID VALVE...2292
ATTACHMENT SOLENOID VALVE...2293
PPC ACCUMULATOR...2295
BOOM HYDRAULIC DRIFT PREVENTION VALVE...2296
LIFT CHECK VALVE...2299
HYDRAULIC CYLINDERS...2300
BOOM CYLINDER...2300
ARM CYLINDER...2300
BUCKET CYLINDER...2300
WORK EQUIPMENT...2302
100 HOURS...2303
500 HOURS...2303
DIMENSION OF ARM...2304
DIMENSION OF BUCKET...2306
AIR CONDITIONER...2308
PIPING...2308
ENGINE CONTROL...2309
FUEL CONTROL DIAL...2311
GOVERNOR MOTOR...2312
ENGINE THROTTLE AND PUMP CONTROLLER...2314
INPUT AND OUTPUT SIGNALS...2315
ELECTRONIC CONTROL SYSTEM...2317
MACHINE CONTROL SYSTEM DIAGRAM...2318
ENGINE AND PUMP CONTROL FUNCTION...2320
SWING CONTROL FUNCTION WITH SOFT SWING...2335
MULTI MONITOR SYSTEM...2343
MONITOR PANEL...2344
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION...2346
MONITOR ITEMS AND DISPLAY...2347
MAINTENANCE FUNCTION...2356
SENSORS...2361
ENGINE OIL LEVEL SENSOR...2362
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)...2362
COOLANT TEMPERATURE SENSOR...2362
HYDRAULIC OIL TEMPERATURE SENSOR...2362
FUEL LEVEL SENSOR...2363
AIR CLEANER CLOGGING SENSOR...2363
CAB RISER AND RELATED PARTS...2364
POWER CONTROL...2365
CAB RISER HYDRAULIC SYSTEM...2366
20 TESTING, ADJUSTING AND TROUBLESHOOTING...2381
STANDARD VALUE TABLES...2369
ENGINE...2369
CHASSIS...2370
TESTING AND ADJUSTING...2381
SERVICE TOOLS...2383
ENGINE...2384
COMPRESSION PRESSURE...2384
BLOW-BY PRESSURE...2384
OIL PRESSURE...2384
RPM...2384
SPEED SENSOR...2384
EXHAUST GAS COLOR...2384
FUEL INJECTION TIMING...2384
VALVE CLEARANCE...2384
BELT TENSION - AIR COMPRESSOR...2385
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE...2386
SWING CIRCLE BEARINGS...2387
TRACK SHOE TENSION...2388
SPROCKET...2388
OIL PRESSURE...2389
WORK EQUIPMENT, SWING AND TRAVEL...2389
CONTROL CIRCUIT...2393
PUMP PC CONTROL CIRCUIT...2394
PUMP LS CONTROL CIRCUIT...2397
SOLENOID VALVE OUTPUT PRESSURE...2402
TABLE FOR FUNCTIONING CONDITIONS...2403
PPC LOCK SOLENOID VALVE...2403
SWING AND PARKING BRAKE SOLENOID...2403
TRAVEL INTERCONNECTION SOLENOID VALVE...2403
ATTACHMENT SOLENOID VALVE OUTPUT...2406
PPC VALVE OUTPUT PRESSURE...2407
ATTACHMENT PPC VALVE OUTPUT...2408
WORK EQUIPMENT AND SWING PPC VALVE...2409
WORK EQUIPMENT - HYDRAULIC DRIFT...2410
RELEASING PRESSURE IN HYDRAULIC CIRCUIT...2412
OIL LEAKAGE...2413
AIR BLEEDING OF VARIOUS PARTS...2416
SOFT SWING ADJUSTMENTS...2418
DIODE INSPECTION PROCEDURES...2419
CAB DOOR STOP ADJUSTMENT...2421
MULTI-MONITOR PANEL...2422
TABLE FOR SERVICE AND FAILURE CODE NUMBERS...2429
SERVICE MENU...2431
WAY OF SWITCHING TO SERVICE MENU...2431
ELECTRICAL SYSTEM TROUBLESHOOTING...2447
PM TUNE UP SERVICE...2448
TROUBLESHOOTING...2453
TROUBLESHOOTING GENERAL...2453
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2455
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2457
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...2458
CHECKS BEFORE TROUBLESHOOTING...2466
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...2467
CLASSIFICATION OF TROUBLESHOOTING...2467
STEPS FOR TROUBLESHOOTING...2467
FAILURE-LOOKING PHENOMENON AND TROUBLESHOOTING NO...2468
CONNECTOR LOCATION CHART...2471
CONNECTOR TABLE...2471
CONNECTOR LOCATION DIAGRAM...2478
ELECTRICAL CIRCUIT DIAGRAMS...2483
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2484
CONNECTOR REPAIR PROCEDURES...2507
CONTACT TERMINAL REMOVAL (HD30 TYPE)...2507
STRIPPING INSULATION...2508
CRIMPING CONTACT TERMINAL (HD30 TYPE)...2509
INSERTION OF CONTACT TERMINAL (HD30 TYPE)...2510
CONTACT TERMINAL REMOVAL (DT TYPE)...2511
STRIPPING INSULATION...2512
CRIMPING CONTACT TERMINAL (DT TYPE)...2513
INSERTION OF CONTACT TERMINAL (DT TYPE)...2514
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)...2515
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...2519
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...2519
USER CODE MEMORY RETENTION FUNCTION...2519
INFORMATION CONTAINED IN TESTING PROCEDURES...2520
(E101)...2522
ABNORMAL DATA IN ERROR HISTORY...2522
(E112)...2524
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION...2524
SHORT IN GUARD WIPER MOTOR DRIVE FORWARD ROTATION...2525
(E113)...2527
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION...2527
SHORT IN GUARD WIPER MOTOR DRIVE REVERSE ROTATION...2528
(E114)...2530
SHORT OR OPEN IN WINDOW WASHER SYSTEM...2530
SHORT OR OPEN IN GUARD WASHER SYSTEM...2531
(E115)...2533
ABNORMAL WINDSHIELD WIPER MOTION...2533
ABNORMAL GUARD WIPER MOTION...2534
(E116)...2536
ABNORMALITY IN PARKING WIPER ARM...2536
ABNORMALITY IN PARKING WIPER ARM (GUARD)...2537
(E201)...2540
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID...2540
(E203)...2542
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM...2542
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM (WITH SOFT SWING)...2544
(E204)...2546
SHORT IN MERGE/DIVIDE SOLENOID...2546
(E205)...2548
SHORT IN 2 STAGE RELIEF SOLENOID...2548
(E206)...2550
SHORT IN TRAVEL SPEED SHIFT SOLENOID...2550
(E211)...2552
OPEN IN TRAVEL INTERLOCKING SOLENOID...2552
(E213)...2554
OPEN IN SWING PARKING BRAKE SOLENOID...2554
OPEN IN SWING PARKING BRAKE SOLENOID (WITH SOFT SWING)...2556
NO CODE...2558
SHORT OR OPEN IN SOFT SWING SOLENOID SYSTEM...2558
(E214)...2562
OPEN OF MERGE/DIVIDE SOLENOID...2562
(E215)...2564
OPEN IN 2 STAGE RELIEF SOLENOID...2564
(E216)...2566
OPEN IN TRAVEL SPEED SOLENOID...2566
(E217)...2568
ABNORMAL INPUT FOR MODEL CODE...2568
(E218)...2570
OPEN IN S-NET SIGNAL...2570
(E222)...2572
SHORT IN LS-EPC SOLENOID...2572
(E223)...2574
OPEN IN LS-EPC SOLENOID SYSTEM...2574
(E224)...2576
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL...2576
(E225)...2578
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL...2578
(E226)...2580
ABNORMAL PRESSURE SENSOR POWER SUPPLY...2580
(E227)...2582
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER...2582
(E228)...2584
SHORT IN ATTACHMENT RETURN SWITCHING RELAY...2584
NO CODE...2586
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM...2586
NO CODE...2590
OPEN IN CAB TILT SYSTEM...2590
(E232)...2592
SHORT IN PC-EPC SOLENOID...2592
(E233)...2594
OPEN IN PC-EPC SOLENOID SYSTEM...2594
(E238)...2596
OPEN IN ATTACHMENT RETURN SWITCH RELAY...2596
(E245)...2598
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM...2598
(E246)...2600
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM...2600
(E256)...2602
INCORRECT NON-VOLATILE MEMORY DATA...2602
(E306)...2604
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS...2604
(E308)...2606
ABNORMAL FUEL DIAL SIGNALS...2606
(E315)...2608
SHORT IN BATTERY RELAY SYSTEM...2608
(E316)...2610
STEP OUT IN GOVERNOR MOTOR...2610
(E317)...2612
OPEN IN GOVERNOR MOTOR PHASE "A" AND "B"...2612
(E318)...2614
SHORT IN GOVERNOR MOTOR PHASE "A" AND "B"...2614
(E501)...2616
MODEL SELECTION FUNCTION NOT PROVIDED...2616
(E502)...2617
MODEL SELECTING SIGNAL FAULT...2617
(A000N1)...2618
ENGINE SPEED OUT OF RANGE AT HIGH IDLE...2618
(A000N2)...2619
ENGINE SPEED OUT OF RANGE AT LOW IDLE...2619
(AA10NX)...2620
AIR CLEANER CLOG INDICATOR FAILURE...2620
(AB00KE)...2622
LOW CHARGING VOLTAGE INDICATED...2622
(B@BAZG)...2624
ABNORMAL ENGINE OIL PRESSURE...2624
(B@BAZK)...2626
ABNORMAL ENGINE OIL LEVEL...2626
(B@BCNS)...2628
ENGINE COOLANT INDICATING OVERHEAT CONDITION...2628
(B@BCZK)...2630
ABNORMAL COOLANT LEVEL INDICATION...2630
(B@HANS)...2632
HYDRAULIC OIL OVERHEAT INDICATION...2632
TROUBLESHOOTING MONITOR ELECTRICAL (E-MODE)...2635
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...2637
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...2637
USER CODE MEMORY RETENTION FUNCTION...2637
INFORMATION CONTAINED IN TESTING PROCEDURES...2638
(E-1)...2640
ENGINE WILL NOT CRANK...2640
(E-2)...2642
ENGINE STOPS WHILE IN OPERATION...2642
(E-3)...2644
ENGINE SPEED IRREGULAR, OR HUNTING...2644
(E-4)...2646
ENGINE DOES NOT STOP...2646
(E-5)...2648
AUTO DECELERATOR DOES NOT WORK...2648
(E-6)...2649
AUTO ENGINE WARM UP DEVICE DOES NOT WORK...2649
(E-7)...2650
COLD START PREHEATER DOES NOT WORK...2650
(E-8)...2652
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE...2652
(E-9)...2654
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE...2654
(E-10)...2656
NO DISPLAY ON MONITOR PANEL...2656
(E-11)...2658
PART OF DISPLAY ON MONITOR PANEL IS MISSING...2658
(E-12)...2659
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL...2659
(E-13)...2660
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL...2660
(E-14)...2662
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY...2662
(E-15)...2664
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...2664
(E-16)...2666
FUEL GAUGE DOES NOT DISPLAY CORRECTLY...2666
(E-17)...2668
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY...2668
(E-18)...2670
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS...2670
(E-19)...2672
WINDSHIELD WIPER DOES NOT WORK...2672
GUARD WIPER DOES NOT WORK...2673
(E-20)...2676
ALARM BUZZER CANNOT BE CANCELLED...2676
(E-21)...2678
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR...2678
(E-22)...2680
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR...2680
(E-23)...2682
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR...2682
(E-24)...2684
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR...2684
(E-25)...2686
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR...2686
(E-26)...2688
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR...2688
(E-27)...2690
SWING NOT CORRECTLY DISPLAYED ON MONITOR...2690
(E-28)...2692
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR...2692
(E-29)...2694
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR...2694
(E-30)...2696
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR...2696
(E-31)...2698
AIR CONDITIONER SYSTEM DOES NOT WORK...2698
(E-32)...2702
TRAVEL ALARM DOES NOT SOUND...2702
30 DISASSEMBLY AND ASSEMBLY...2705
METHOD OF USING MANUAL...2709
PRECAUTIONS DURING OPERATION...2710
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...2710
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...2711
PRECAUTIONS WHEN COMPLETING THE OPERATIONS...2712
OTHER PRECAUTIONS...2712
SPECIAL TOOL LIST...2713
SKETCHES OF SPECIAL TOOLS...2717
ENGINE...2718
ALTERNATOR...2718
CYLINDER HEAD...2718
ENGINE FRONT SEAL...2718
ENGINE OIL COOLER...2718
ENGINE REAR SEAL...2718
FUEL INJECTION PUMP...2718
NOZZLE HOLDER...2718
STARTING MOTOR...2718
THERMOSTAT...2718
TURBOCHARGER...2718
WATER PUMP...2718
RADIATOR...2719
REMOVAL...2719
INSTALLATION...2720
HYDRAULIC OIL COOLER...2721
REMOVAL...2721
INSTALLATION...2722
ENGINE AND HYDRAULIC PUMPS...2723
REMOVAL...2723
INSTALLATION...2728
TRAVEL MOTOR AND FINAL DRIVE...2730
REMOVAL...2730
INSTALLATION...2730
FINAL DRIVE...2731
DISASSEMBLY...2731
ASSEMBLY...2736
REMOVAL...2741
INSTALLATION...2742
DISASSEMBLY...2743
ASSEMBLY...2746
TRACK AND CARRIER ROLLER...2752
REMOVAL...2752
INSTALLATION...2752
DISASSEMBLY...2753
ASSEMBLY...2754
IDLER AND RECOIL SPRING...2757
REMOVAL...2757
INSTALLATION...2757
IDLER...2758
DISASSEMBLY...2758
ASSEMBLY...2759
RECOIL SPRING...2762
DISASSEMBLY...2762
ASSEMBLY...2763
TRACK ROLLER...2764
REMOVAL...2764
INSTALLATION...2764
DISASSEMBLY...2765
ASSEMBLY...2766
SPROCKET...2769
REMOVAL...2769
INSTALLATION...2769
TRACK SHOE...2770
EXPANSION OF TRACK SHOE...2770
ASSEMBLY...2771
SWING CIRCLE...2772
REMOVAL...2772
INSTALLATION...2772
REVOLVING FRAME...2773
REMOVAL...2773
INSTALLATION...2775
CENTER SWIVEL JOINT...2776
REMOVAL...2776
INSTALLATION...2777
DISASSEMBLY...2778
ASSEMBLY...2779
HYDRAULIC TANK...2780
REMOVAL...2780
INSTALLATION...2782
CONTROL VALVE...2783
REMOVAL...2783
INSTALLATION...2786
DISASSEMBLY...2787
ASSEMBLY...2788
HYDRAULIC PUMP...2789
REMOVAL...2789
INSTALLATION...2791
HYDRAULIC PUMP INPUT SHAFT - OIL SEAL...2792
REMOVAL...2792
INSTALLATION...2792
PPC VALVE...2793
WORK EQUIPMENT...2793
ASSEMBLY...2793
TRAVEL...2794
ASSEMBLY...2794
HYDRAULIC CYLINDER...2795
DISASSEMBLY...2795
ASSEMBLY...2797
WORK EQUIPMENT...2801
REMOVAL...2801
INSTALLATION...2803
AIR CONDITIONER...2804
REMOVAL...2804
INSTALLATION...2807
COUNTERWEIGHT...2808
REMOVAL...2808
INSTALLATION...2808
CAB...2809
REMOVAL...2809
INSTALLATION...2811
MONITOR...2812
REMOVAL...2812
INSTALLATION...2812
GOVERNOR PUMP CONTROLLER...2813
REMOVAL...2813
INSTALLATION...2813
90 OTHERS...2815
ELECTRICAL...2817
CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3)...2817
CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3)...2819
CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3)...2821
CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1)...2823
CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2)...2825
CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2)...2827
CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2)...2829
CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2)...2831
HYDRAULIC...2835
HYDRAULIC DIAGRAM (SHEET 1 OF 4) - FOLDOUT 11...2835
HYDRAULIC DIAGRAM (SHEET 2 OF 4) - FOLDOUT 12...2837
HYDRAULIC DIAGRAM (SHEET 3 OF 4) - FOLDOUT 13...2839
Komatsu Hydraulic Excavator PC270LC-LE, PC270LC-L, PC270LL-L Repair Service Manuals
