Komatsu Hydraulic Excavator PC270, PC270LC Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC270-8, PC270LC-8, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC270-8, PC270LC-8 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.
CEBM007202 - Hydraulic Excavator PC270LC-8 Shop Manual.pdf
SEN00420-13 - Hydraulic Excavator PC270-8, PC270LC-8 Shop Manual.pdf
CEAM003400 - Hydraulic Excavator PC270LC-6 Operation & Maintenance Manual.pdf
CEAM007202 - Hydraulic Excavator PC270LC-8 Operation & Maintenance Manual.pdf
TEN00148-03 - Hydraulic Excavator GALEO PC270-8 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,134 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
CEAM003400 - Hydraulic Excavator PC270LC-6 Operation & Maintenance Manual...2
COVER...2
INTRODUCTION...5
1. FORWARD...6
2. SAFETY INFORMATION...7
3. INTRODUCTION...8
3.1 INTENDED USE...8
3.2 FEATURES...8
3.3 BREAKING IN THE MACHINE...8
4. LOCATION OF PLATES, TABLE TO ENTER P.I.N AND DISTRIBUTOR...9
4.1 P.I.N. PLATE LOCATION...9
4.2 ENGINE SERIAL NUMBER PLATE...9
4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR...9
5. TABLE OF CONTENTS...10
SAFETY...17
6. GENERAL PRECAUTIONS...18
7. PRECAUTIONS DURING OPERATION...26
7.1 BEFORE STARTING ENGINE...26
7.2 OPERATING MACHINE...28
7.3 TRANSPORTATION...34
7.4 BATTERY...36
7.5 TOWING...38
7.6 BUCKET WITH HOOK...39
8. PRECAUTIONS FOR MAINTENANCE...40
8.1 BEFORE CARRYING OUT MAINTENANCE...40
8.2 DURING MAINTENANCE...44
9. POSITION FOR ATTACHING SAFETY LABELS...50
OPERATION...54
10. GENERAL VIEW...55
10.1 GENERAL VIEW OF MACHINE...55
10.2 GENERAL VIEW OF OPERATORS COMPARTMENT...56
10.3 GENERAL VIEW OF MONITOR PANEL...57
11. EXPLANATION OF COMPONENTS...58
11.1 MACHINE MONITOR...58
11.1.1 MONITOR LIGHT GROUP...60
11.1.2 METER DISPLAY PORTION...62
11.1.3 SWITCHES...65
11.2 SWITCHES...68
11.2.1 STARTING SWITCH...68
11.2.2 FUEL CONTROL DIAL...69
11.2.3 CIGARETTE LIGHTER...69
11.2.4 SWING LOCK SWITCH...69
11.2.5 WIPER SWITCH...69
11.2.6 LIGHT SWITCH...70
11.2.7 ALARM BUZZER STOP SWITCH...70
11.2.8 CAB HEATER FAN SWITCH...70
11.2.9 HORN SWITCH...70
11.2.10 KNOB SWITCH...70
11.2.11 CAB LIGHT SWITCH...70
11.2.12 PUMP CONTROL OVERRIDE SWITCH...71
11.2.13 SWING LOCK OVERRIDE SWITCH...71
11.3 CONTROL LEVERS AND PEDALS...72
11.3.1 SAFETY LOCK LEVER...72
11.3.2 TRAVEL LEVERS...73
11.3.3 LEFT WORK EQUIPMENT CONTROL LEVER...73
11.3.4 RIGHT WORK EQUIPMENT CONTROL LEVER...74
11.3.5 ATTACHMENT CONTROL PEDAL...75
11.3.6 SELECTOR VALVES FOR BREAKER AND GENERAL ATTACHMENT (crusher etc.)...75
11.4 SEAT BELT...76
11.4.1 FASTEN THE BELT AND REMOVE IT...76
11.4.2 ADJUST THE BELT LENGTH...77
11.5 ROOF VENT...77
11.6 FRONT WINDOW WARNING...78
11.6.1 WHEN OPENING...78
11.6.2 WHEN CLOSING...79
11.6.3 FRONT BOTTOM WINDOW...80
11.7 DOOR LOCK...81
11.8 CAP, COVER WITH LOCK...81
11.8.1 METHOD OF OPENING AND CLOSING LOCK CAP...81
11.8.2 METHOD OF OPENING AND CLOSING COVER LOCK...82
11.9 HOT AND COOL BOX...82
11.10 STORAGE BOX...82
11.11 ASHTRAY...82
11.12 AIR CONDITIONER...83
11.12.1 GENERAL LOCATIONS ON CONTROL PANEL...83
11.12.2 PRECAUTIONS WHEN USING AIR CONDITIONER...85
11.12.3 CHECK, MAINTAIN AIR CONDITIONER...85
11.13 CAB HEATER...86
11.13.1 GENERAL LOCATIONS...86
11.14 PREPARATION FOR CAB HEATER...87
11.15 AM/FM RADIO...88
11.15.1 EXPLANATION OF COMPONENTS...88
11.15.2 METHOD OF OPERATION...90
11.15.3 PRECAUTIONS WHEN USING...91
11.15.4 SPECIFICATIONS...92
11.16 ELECTRIC POWER TAKE OUT ADAPTER...92
11.17 FUSE...93
11.18 FUSIBLE LINK...94
11.19 CONTROLLERS...94
11.20 TOOL BOX...94
11.21 GREASE GUN HOLDER...94
11.22 HANDLING ACCUMULATOR WARNING...95
12. OPERATION...96
12.1 CHECK BEFORE STARTING ENGINE...96
12.1.1 WALK AROUND CHECK...96
12.1.2 CHECK BEFORE STARTING...98
12.1.3 ADJUST BEFORE OPERATION...101
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...105
12.2 STARTING ENGINE...107
12.2.1 NORMAL STARTING...107
12.2.2 STARTING IN COLD WEATHER...108
12.3 OPERATIONS AND CHECKS AFTER ENGINE STARTS WARNING...110
12.3.1 WHEN NORMAL...110
12.3.2 IN COLD AREAS (AUTOMATIC WARM UP OPERATION)...112
12.4 MOVING MACHINE...116
12.4.1 MOVING MACHINE FORWARD...116
12.4.2 MOVING MACHINE REARWARD...118
12.5 STEERING MACHINE...120
12.5.1 STEERING (CHANGING DIRECTION)...120
12.6 STOPPING MACHINE WARNING...122
12.7 SWINGING WARNING...123
12.8 OPERATION OF WORK EQUIPMENT WARNING...124
12.9 HANDLING ACTIVE MODE...125
12.10 HANDLING WORKING MODE...127
12.10.1 WORKING MODE...127
12.10.2 POWER MAX., SWIFT SLOW DOWN...128
12.11 PROHIBITED OPERATIONS WARNING...129
12.11.1 USING SWING FORCE...129
12.11.2 USING TRAVEL FORCE...129
12.11.3 OPERATE CYLINDERS TO END OF STROKE...129
12.11.4 USING DROPPING FORCE OF BUCKET...130
12.11.5 USING DROPPING FORCE OF MACHINE...130
12.11.6 DIGGING ROCKY GROUND...130
12.11.7 SUDDEN LEVER SHIFT DURING HI-SPEED TRAVEL...130
12.12 PRECAUTIONS FOR OPERATION...131
12.12.1 PRECAUTIONS WHEN TRAVELING...131
12.12.2 PRECAUTIONS AT HI-SPEED TRAVEL...131
12.12.3 PERMISSIBLE WATER DEPTH...131
12.13 PRECAUTIONS WHEN TRAVELING ON HILLS WARNING...132
12.13.1 BRAKING WHEN TRAVELING DOWNHILL...133
12.13.2 IF SHOES SLIP...133
12.13.3 IF ENGINE STOPS...133
12.13.4 PRECAUTIONS ON SLOPES...133
12.14 HOW TO ESCAPE FROM MUD...134
12.14.1 WHEN ONE SIDE IS STUCK...134
12.14.2 WHEN BOTH SIDES ARE STUCK...134
12.15 WORK POSSIBLE WITH HYDRAULIC EXCAVATOR...134
12.15.1 BACKHOE WORK...134
12.15.2 SHOVEL WORK...135
12.15.3 DITCHING WORK...135
12.15.4 LOADING WORK...135
12.16 REPLACE OR INVERT BUCKET WARNING...136
12.16.1 REPLACEMENT...136
12.16.2 INVERSION...137
12.17 PARKING MACHINE WARNING...138
12.18 CHECK AFTER FINISHING WORK...139
12.19 STOPPING ENGINE...140
12.20 CHECK AFTER STOPPING ENGINE...140
12.21 LOCKING...141
13.TRANSPORTATION...142
13.1 TRANSPORTATION PROCEDURE...142
13.2 LOADING, UNLOADING OF TRAILERS WARNING...142
13.2.1 LOADING...143
13.2.2 UNLOADING...144
13.2.3 SECURING MACHINE...145
13.2.4 REMOVAL, INSTALLATION OF MIRRORS...146
13.2.5 METHOD OF LIFTING MACHINE...147
13.3 PRECAUTIONS FOR TRANSPORTATION...148
14. COLD WEATHER OPERATION...149
14.1 PRECAUTIONS FOR LOW TEMPERATURE...149
14.1.1 FUEL AND LUBRICANTS...149
14.1.2 COOLANT...149
14.1.3 BATTERY...149
14.2 PRECAUTIONS AFTER COMPLETION OF WORK ...151
14.3 AFTER COLD WEATHER...151
15. LONG TERM STORAGE...152
15.1 BEFORE STORAGE...152
15.2 DURING STORAGE WARNING...152
15.3 AFTER STORAGE...153
15.4 STARTING MACHINE AFTER LONG TERM STORAGE...153
16. TROUBLESHOOTING...154
16.1 PHENOMENA THAT ARE NOT FAILURES...154
16.2 METHOD OF TOWING MACHINE WARNING...154
16.3 METHOD FOR LIGHT WEIGHT TOWING WARNING...154
16.4 PRECAUTION ON PARTICULAR JOB SITES...154
16.5 IF BATTERY IS DISCHARGED WARNING...155
16.5.1 REMOVING AND INSTALLING BATTERY...155
16.5.2 PRECAUTIONS FOR CHARGING BATTERY...156
16.5.3 STARTING ENGINE WITH BOOSTER CABLE...156
16.6 OTHER TROUBLE...158
16.6.1 ELECTRICAL SYSTEM...158
16.6.2 CHASSIS...159
16.6.3 ENGINE...160
16.6.4 ELECTRONIC CONTROL SYSTEM...161
MAINTENANCE...162
17. GUIDES TO MAINTENANCE...163
18. OUTLINES OF SERVICE...165
18.1 OUTLINE OF OIL, FUEL, COOLANT...165
18.1.1 OIL...165
18.1.2 FUEL...165
18.1.3 COOLANT...166
18.1.4 GREASE...166
18.1.5 STORING OIL AND FUEL...166
18.1.6 FILTERS...166
18.2 OUTLINE OF ELECTRICAL SYSTEM...167
18.3 OUTLINE OF HYDRAULIC SYSTEM...167
18.4 OUTLINE OF FUEL SYSTEM...168
18.4.1 FUEL INJECTION PUMP...168
18.4.2 FUEL TANK...168
19. WEAR PARTS LIST...169
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...170
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...170
20.2 ENGINE OIL SPECIFICATIONS...171
20.2.1 NORMAL OPERATION...171
20.2.2 ARCTIC OPERATION...172
20.3 DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFIC...172
20.4 FINAL DRIVE OIL SPECIFICATIONS...172
20.5 DIESEL FUEL SPECIFICATIONS WARNING...172
20.6 COOLANT SPECIFICATIONS...173
20.6.1 GENERAL...173
20.6.2 WATER...173
20.6.3 ANTIFREEZE...174
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...176
21.1 INTRODUCTION OF NECESSARY TOOLS...176
21.2 TORQUE LIST...177
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...178
23. MAINTENANCE SCHEDULE CHART...181
23.1 SCHEDULED MAINTENANCE CHART...181
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...183
24. SERVICE PROCEDURE...184
24.1 INITIAL 250 HOURS SERVICE...184
24.1.1 REPLACE FUEL FILTER CARTRIDGE...184
24.2 WHEN REQUIRED...185
24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...185
24.2.2 CLEAN INSIDE OF COOLING SYSTEM...188
24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS...192
24.2.4 CHECK AND ADJUST TRACK TENSION...193
24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER...194
24.2.6 INSTALLATION OF BUCKET TEETH...195
24.2.7 REMOVAL OF BUCKET TEETH...197
24.2.8 ADJUST BUCKET CLEARANCE...199
24.2.9 CHECK WINDOW WASHER FLUID...200
24.2.10 CHECK, MAINTAIN AIR CONDITIONER...201
24.2.11 REPLACE ADD ON BREAKER FILTER ELEMENT...202
24.2.12 CLEAN IN LINE FILTER...203
24.3 CHECK BEFORE STARTING...204
24.3.1 CHECK COOLANT LEVEL, ADD COOLANT...204
24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN...204
24.3.3 CHECK FUEL LEVEL...205
24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK...205
24.3.5 CHECK AIR CLEANER FOR CLOGGING...206
24.3.6 CHECK ELECTRICAL WIRING...206
24.3.7 CHECK FUNCTION OF HORN...206
24.3.8 DRAIN WATER FROM FUEL WATER SEPARATOR...207
24.4 EVERY 100 HOURS SERVICE...208
24.4.1 LUBRICATION...208
24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE...210
24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK...210
24.5 EVERY 250 HOURS SERVICE...211
24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...211
24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE...211
24.5.3 REPLACE HYDRAULIC FILTER ELEMENT...212
24.5.4 LUBRICATE SWING CIRCLE (3 POINTS)...213
24.5.5 CHECK FAN BELT TENSION, ADJUST...214
24.5.6 AIR CONDITIONER COMPRESSOR BELT TENSION...215
24.6 EVERY 500 HOURS SERVICE...216
24.6.1 REPLACE FUEL FILTER CARTRIDGE AND FUEL- WATER SEPARATOR...216
24.6.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE...218
24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AI...219
24.6.4 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER...220
24.6.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT...220
24.6.6 CHANGE ENGINE OIL, REPLACE FILTER...221
24.6.7 REPLACE IN LINE FUEL STRAINER...223
24.7 EVERY 1000 HOURS SERVICE...224
24.7.1 CHANGE OIL IN SWING MACHINERY CASE...224
24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...225
24.7.3 CHECK TIGHTENING PARTS OF TURBOCHARGER...225
24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR...225
24.7.5 CHECK DRIVE BELT, TENSIONER BEARING AND FAN HUB...226
24.8 EVERY 2000 HOURS SERVICE...227
24.8.1 CHANGE OIL IN FINAL DRIVE CASE...227
24.8.2 CLEAN HYDRAULIC TANK STRAINER...228
24.8.3 CLEAN, CHECK TURBOCHARGER...228
24.8.4 CHECK ALTERNATOR, STARTING MOTOR...228
24.8.5 CHECK VIBRATION DAMPER...228
24.8.6 CHANGE ANTIFREEZE...228
24.8.7 CHECK AND ADJUST VALVE CLEARANCE...229
24.9 EVERY 4000 HOURS SERVICE...231
24.9.1 CHECK WATER PUMP...231
24.10 EVERY 5000 HOURS SERVICE...232
24.10.1 CHANGE OIL IN HYDRAULIC TANK...232
SPECIFICATIONS...236
25. MACHINE SPECIFICATIONS...237
25.1 GENERAL...237
25.2 WORKING RANGE...239
OPTIONS, ATTACHMENTS...241
26. GENERAL PRECAUTIONS...242
26.1 PRECAUTIONS RELATED TO SAFETY...242
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS WARNING...243
27. BUCKET WITH HOOK...244
27.1 CHECKING FOR DAMAGE...244
27.2 PROHIBITED OPERATIONS...244
27.3 PRECAUTIONS DURING OPERATIONS...244
28. HANDLING HEATER...245
28.1 GENERAL LOCATIONS...245
28.2 PREPARATION FOR CAR HEATER...246
29. HANDLING AIR CONDITIONER...247
29.1 DEFROSTER SELECTOR LEVER...247
29.2 PRECAUTIONS WHEN USING AIR CONDITIONER...248
30. MACHINES READY FOR ATTACHMENT...249
30.1 GENERAL LOCATIONS...249
30.1.1 STOP VALVE...249
30.1.2 SELECTOR VALVE...250
30.1.3 CONTROL PEDAL...250
30.1.4 LOCK PIN...250
30.1.5 ADDITIONAL FILTER FOR BREAKER...250
30.1.6 ACCUMULATOR...251
30.2 HYDRAULIC CIRCUIT...251
30.2.1 SWITCHING TO FILTER CIRCUIT...251
30.2.2 CONNECTING HYDRAULIC CIRCUIT...252
30.2.3 PATH OF OIL FLOW...252
30.3 PROCEDURE FOR REMOVAL AND...252
30.3.1 PROCEDURE FOR REMOVAL...253
30.3.2 PROCEDURE FOR INSTALLATION...253
30.4 OPERATION WARNING...254
30.4.1 WHEN USING BREAKER...254
30.4.2 WHEN USING GENERAL ATTACHMENT...255
30.5 LONG TERM STORAGE...255
30.6 SPECIFICATIONS...255
31. INTRODUCTION OF ATTACHMENTS...256
31.1 BUCKET SELECTION...256
31.1.1 STANDARD DUTY PLATE BUCKET...256
31.1.2 HEAVY DUTY PLATE BUCKET...256
31.1.3 HEAVY DUTY CAST LIP BUCKET...256
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...257
31.2.1 PC270LC-6...257
31.3 SELECTION OF TRACK SHOES...258
31.4 BACKHOE CONTROL PATTERN CONVERSION...259
32. EXTENDING MACHINE SERVICE LIFE...260
32.1 HYDRAULIC BREAKER...260
32.1.1 MAIN FIELDS OF APPLICATION...260
32.1.2 MISTAKEN METHODS OF USE...261
32.1.3 GREASING POSITION FOR HYDRAULIC BREAKER...263
32.2 CRUSHER...263
32.2.1 MAIN FIELDS OF APPLICATION...263
32.2.2 MISTAKEN METHODS OF USE...264
32.3 GRAB FORK...265
32.3.1 MAIN FIELDS OF APPLICATION...265
32.3.2 MISTAKEN METHODS OF USE...265
32.4 GRAPPLE BUCKET...266
32.4.1 MAIN FIELDS OF APPLICATION...266
32.4.2 MISTAKEN METHODS OF USE...266
32.5 SCRAP GRAPPLE...267
32.5.1 MAIN FIELDS OF APPLICATION...267
32.5.2 MISTAKEN METHODS OF USE...267
32.6 CRUSHER AND CUTTER...268
32.6.1 MAIN FIELDS OF APPLICATION...268
32.6.2 MISTAKEN METHODS OF USE...268
32.7 HYDRAULIC PILE DRIVER...269
32.7.1 MAIN FIELDS OF APPLICATION...269
32.7.2 MISTAKEN METHODS OF USE...269
CEAM007202 - Hydraulic Excavator PC270LC-8 Operation & Maintenance Manual...272
INTRODUCTION...274
FORWARD...275
SAFETY INFORMATION...276
INTRODUCTION...278
Directions of Machine...278
Breaking-in the New Machine...279
Product Information...280
Product Identification Number (Pin) / Machine Serial No. Plate...280
EPA* Regulations, Engine Number Plate...280
Service Meter Location...281
Your Machine Serial Numbers and Distributor...281
TABLE OF CONTENTS...282
SAFETY...292
SAFETY LABELS...293
Location of Safety Labels...294
Safety Labels...295
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...302
Precautions Before Starting Operation...302
Ensuring Safe Operation...302
Understanding the Machine...302
Preparations for Safe Operation...302
Precautions Regarding Safety-Related Equipment...302
Inspecting Machine...302
Clothing and Personal Protective Items...302
Keep Machine Clean...303
Keep Operator's Compartment Clean...303
Fire Extinguisher and First Aid Kit...303
Safety Equipment...303
If Problems are Found...303
Fire Prevention and Explosion Prevention...304
Action if Fire Occurs...304
Handrails and Steps...305
Mounting and Dismounting...305
No Persons on Attachments...305
Leaving Operator's Seat with Lock...306
Emergency Exit from Operator's Cab...306
Do Not Get Caught in Work Equipment...307
Precautions Related to Protective Structures...307
Falling Objects, Flying Objects and Intruding Objects Prevention...307
Unauthorized Modification...308
Precautions Related to Attachments and Options...308
Precautions Related to Cab Glass...308
Precautions When Running Engine Inside Building...308
Burn Prevention...309
Hot coolant...309
Hot oil...309
Windshield Washer Fluid...309
Safety at Jobsite...310
Working on Loose Ground...310
Distance to High Voltage Cables...310
Ensure Good Visibility...311
Signalman's Signal and Signs...311
Asbestos Dust Hazard Prevention...312
SAFETY MACHINE OPERATION...313
Starting Engine...313
Checks Before Starting Engine...313
Safety Rules for Starting Engine...314
Starting Engine in Cold Weather...314
Starting Engine with Booster Cables...314
Operation...315
Checks Before Operation...315
Safety Rules for Changing Machine Directions...315
Safety Rules for Traveling...316
Traveling on Slopes...317
Operations on Slopes...318
Prohibited Operations...318
Operations on Snow or Frozen Surfaces...320
Parking Machine...320
TRANSPORTATION...321
Loading and Unloading...321
Shipping the Machine...321
TOWING...322
Safety Rules for Towing...322
LIFTING OBJECTS WITH BUCKET...323
Safety Rules for Lifting Objects...323
SAFETY MAINTENANCE INFORMATION...324
Warning Tag...324
Keep Work Place Clean and Tidy...324
Select Suitable Place for Inspection and Maintenance...324
Only Authorized Personnel...324
Appoint Leader when Working with Others...324
Stop Engine before Carrying Out Maintenance...325
Precautions when Working at High Places...325
Two Workers for Maintenance when Engine is Running...326
Proper Tools...326
Accumulator...326
Battery...327
Battery Hazard Prevention...327
Handling Gas Spring...328
Precautions when using...328
Precautions when discarding...328
Personnel...328
Attachments...329
Work Under the Machine...329
Noise...329
When using Hammer...329
Welding...329
Removing Battery Terminals...330
Safety First when using High-Pressure Grease to Adjust Track Tension...330
Do Not Disassemble Recoil Springs...330
Precautions with High-temperature Coolant...331
Precautions with High-temperature Oil...331
Safety Rules for High-pressure Oil...331
Precaution for High Fuel Pressure...332
Safety Handling High-pressure Hoses...332
Precaution for High Voltage...332
Waste Materials...332
Air Conditioner Maintenance...333
Compressed Air...333
Periodic Replacement of Safety Critical Parts...333
OPERATION...334
MACHINE VIEW ILLUSTRATIONS...335
Overall Machine View...335
CONTROLS AND GAUGES...336
Machine Monitors...337
DETAILED CONTROLS AND GAUGES...338
Monitoring System...338
Basic Operation of Machine Monitor...339
Emergency Monitors...344
Caution Monitors...346
Basic Check Monitors...349
Meter Display Portion...351
Pilot Display...351
Gauges and Meter...355
Function Switches...367
Handling Function Switches...368
Service Meter/Clock Display Selector Switch...374
Maintenance Selector Switch...375
User Mode Selector Switch...378
SWITCHES...408
Starting Switch...408
Fuel Control Dial...409
Cigarette Lighter...409
Swing Lock Switch...409
Lamp Switch...410
Horn Switch...410
One Touch Power Max. Switch...410
Room Lamp Switch...410
Emergency Pump Drive Switch...411
Swing Brake Cancel Switch...411
Revolving Warning Lamp Switch...411
Large Capacity Airflow Air Conditioner Blower Switch...412
CONTROL LEVERS AND PEDALS...413
Lock Lever...413
Travel Levers...414
Work Equipment Control Lever...415
SUN ROOF...416
WINDSHIELD...416
EMERGENCY ESCAPE HAMMER...422
DOOR LOCK...423
COVER WITH LOCK...423
CAP WITH LOCK...424
DRINK BOX...425
MAGAZINE BOX...425
ASHTRAY...425
AIR CONDITIONER CONTROLS...426
Air Conditioner Control Panel...426
Method of Operation...431
Automatic Operation...431
Stopping Automatic Operation...432
Manual Operation...432
Stopping Manual Operation...434
Operation with Cold Air to Face and Warm Air to Feet...434
Defroster Operation...436
Use Air Conditioner with Care...438
Air Conditioner Maintenance...438
RADIO...439
Control Panel...439
Controls of Radio...441
Preset Station Buttons...441
Method of Operating Mode...442
Setting Correct Time...442
Use Radio with Care...443
AUXILIARY ELECTRIC POWER...444
24 V power source...444
12 V power source...444
FUSE...445
FUSIBLE LINK...446
CONTROLLER...446
TOOL BOX...446
GREASE GUN HOLDER...446
FIRE EXTINGUISHER...447
MACHINE OPERATIONS AND CONTROLS...448
Before Starting Engine...448
Walk-around Checks...448
Checks Before Starting...449
Adjustment...458
Seat Belt Inspection...464
Operations Before Starting Engine...466
STARTING ENGINE...468
Turbo Protect Function...471
AFTER STARTING ENGINE...472
Engine Warm Up...474
Hydraulic System Warm-Up...476
Operation After Completion of Warming-Up Operation...482
STOPPING THE ENGINE...484
MACHINE OPERATION...485
Preparations for Moving the Machine...485
Moving Machine Forward...486
Moving Machine Backward...487
Stopping Machine...488
STEERING THE MACHINE...489
Steering...489
Steering the Machine when Stopped...489
Changing Direction of the Machine...490
Counter-rotation Turn (Spin Turn)...490
SWINGING...491
WORK EQUIPMENT CONTROLS AND OPERATIONS...492
WORKING MODE...494
Working Mode Switch...494
One-Touch Power Max. Switch...495
PROHIBITED OPERATIONS...496
GENERAL OPERATION INFORMATION...498
Traveling...498
High Speed Travel...498
Permissible Water Depth...499
TRAVELING ON SLOPES...500
ESCAPE FROM MUD...502
Track on One Side Stuck...502
Tracks on Both Sides Stuck...502
RECOMMENDED APPLICATIONS...503
Backhoe Work...503
Shovel Work...503
Ditching Work...503
Loading Work...504
BUCKET REPLACEMENT AND INVERSION...505
Replacement...505
Inversion...507
PARKING MACHINE...509
MACHINE INSPECTION AFTER DAILY WORK...511
LOCKING...511
TRANSPORTATION...511
Transportation Procedure...511
Loading And Unloading With Trailer...512
Loading...513
Securing Machine...516
Stowing Radio Antenna...517
Rearview Mirrors...517
Unloading...519
LONG DISTANCE TRANSPORT MODE...521
Normal Mode Display...521
Long Distance Transport Mode Display...521
LIFTING MACHINE...523
COLD WEATHER OPERATION...525
Cold Weather Operation Information...525
Fuel and Lubricants...525
Cooling System Coolant...525
Battery...526
AFTER DAILY WORK COMPLETION...527
AFTER COLD WEATHER SEASON...527
LONG TERM STORAGE...528
Before Storage...528
During Storage...528
After Storage...529
Starting Machine After Long-term Storage...529
TROUBLES AND ACTIONS...530
Running Out Of Fuel...530
Phenomena That Are Not Failures...530
Towing the Machine...531
Lightweight Towing Hole...532
Severe Job Condition...532
Discharged Battery...533
Battery Removal and Installation...533
Battery Charges...534
Starting Engine with Booster Cables...535
OTHER TROUBLE...537
Electrical System...537
Chassis...538
Engine...539
Electronic Control System...540
Point of Contact to Telephone when Error Occurs...541
MAINTENANCE...542
MAINTENANCE INFORMATION...543
OUTLINE OF SERVICE...545
Handling Oil, Fuel, Coolant, and Performing Oil Clinic...545
Oil...545
Fuel...546
Coolant and Water for Dilution...546
Grease...547
Carrying Out KOWA (Komatsu Oil Wear Analysis)...547
Storing Oil and Fuel...548
Filters...548
Electric System Maintenance...548
WEAR PARTS...549
Wear Parts List...549
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...550
Recommended Brands, Recommended Quality for Products Other Than Komatsu Genuine Oil...552
TORQUE SPECIFICATIONS...553
Torque List...553
Torque of Bolts...553
Torque of Hose Nuts...554
Torque of Split Flange Bolts...554
Torque for Flared Nuts...555
Torque for O-ring Boss Piping Joints...555
Torque for O-ring Boss Plugs...556
Torque for Hoses (Taper Seal Type And Face Seal Type)...556
SAFETY CRITICAL PARTS...557
Safety Critical Parts List...558
MAINTENANCE SCHEDULE...559
Maintenance Schedule Chart...559
Maintenance Interval for Hydraulic Breaker...561
MAINTENANCE PROCEDURE...562
Initial 10 Hours Maintenance...562
Initial 250 Hours Maintenance (Only After the First 250 Hours)...562
Initial 500 Hours Maintenance (Only After the First 500 Hours)...562
When Required...563
Check, Clean and Replace Air Cleaner Element...563
Clean Inside of Cooling System...570
Check and Tighten Track Shoe Bolts...574
Check and Adjust Track Tension...575
Replace Bucket Teeth (Vertical Pin Type)...577
Replace Bucket Teeth (Horizontal Pin Type)...580
Adjust Bucket Clearance...582
Check Window Washer Fluid Level, Add Fluid...583
Check and Maintenance Air Conditioner...584
Wash Washable Floor...585
Check Gas Spring...589
Bleeding Air From Hydraulic System...590
Check Before Starting...592
Every 100 Hours Maintenance...593
Lubricating...593
Every 250 Hours Maintenance...595
Check Level of Battery Electrolyte...595
Check Air Conditioner Compressor Belt Tension, Adjust...597
Every 500 Hours Maintenance...599
Lubricating...599
Change Oil in Engine Oil Pan...601
Replace Engine Oil Filter Cartridge...601
Replace Fuel Pre-filter Cartridge...603
Check Swing Pinion Grease Level, Add Grease...605
Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins (Only Machines Equipped With Air Conditioner)...606
Clean Air Conditioner Fresh/Recirc Filters...609
Replace Breather Element in Hydraulic Tank...610
Replace Hydraulic Tank Additional Breather Element...611
Check Oil Level in Swing Machinery Case, Add Oil...612
Check Oil Level in Final Drive Case, Add Oil...613
Every 1000 Hours Maintenance...614
Replace Hydraulic Oil Filter Element...614
Change Oil in Swing Machinery Case...615
Check Oil Level in Damper Case, Add Oil...616
Replace Fuel Main Filter Cartridge...617
Check All Tightening Points of Engine Exhaust Pipe Clamps...619
Check Fan Belt Tension and Replace Fan Belt...619
Check Nitrogen Gas Charge Pressure in Accumulator (For Breaker)...619
Every 2000 Hours Maintenance...620
Change Oil in Final Drive Case...620
Clean Hydraulic Tank Strainer...621
Checking Charge Pressure of Nitrogen Gas in Accumulator (for Control Circuit)...622
Check Alternator, Starting Motor...625
Check Engine Valve Clearance, Adjust...625
Every 4000 Hours Maintenance...626
Check Water Pump...626
Check Vibration Damper...626
Check Starting Motor...626
Replace Accumulator (for Control Circuit)...627
Check for Looseness of High-pressure Piping Clamp, Hardening Of Rubber...628
Check for Missing Fuel Spray Prevention Cap, Hardening Of Rubber...628
Check Operating Condition of Compressor...629
Every 5000 Hours Maintenance...630
Change Oil in Hydraulic Tank...630
Every 8000 Hours Maintenance...631
Replace Fuel Spray Prevention Cap...631
Replace High-pressure Piping Clamp...631
SPECIFICATIONS...632
SPECIFICATIONS...633
OPTIONS, ATTACHMENTS...636
GENERAL PRECAUTIONS FOR SAFETY...637
Precautions When Selecting...637
Read the Instruction Manual Thoroughly...637
Precautions When Removing or Installing...637
Precautions When Using...637
BUCKET WITH HOOK...638
Hook Condition...638
Prohibited Operations...638
MACHINE READY FOR ATTACHMENT...639
Locations...639
Stop Valve...639
Selector Valve...640
Attachment Control Pedal...640
Lock Pin...641
Breaker Circuit Additional Oil Filter...641
Accumulator...642
HYDRAULIC CIRCUIT...643
Switching Hydraulic Circuit...643
Adjusting Oil Flow...643
Switching Between Breaker and General Attachment...643
Hydraulic Circuit Connection...644
Oil Flow Path...645
Replace Additional Breaker Filter Element...646
Replace Additional Breaker Pilot Filter Element...649
ATTACHMENT REMOVAL AND INSTALLATION...652
Attachment Removal...652
Attachment Installation...654
ATTACHMENT OPERATIONS...656
When Using Breaker...656
When Using General Attachment Such as Crusher...658
LONG TERM STORAGE...660
Specifications...660
Attachment Guide...661
Attachment Combinations...661
TRACK SHOES SELECTION...663
BUCKET TEETH SELECTION...664
Selection Guide for Horizontal or Vertical Pin Type Tooth...664
RECOMMENDED ATTACHMENT OPERATIONS...665
Hydraulic Breaker...665
Prohibited Works...667
HANDLING MACHINES EQUIPPED WITH KOMTRAX...670
Basic Precautions...670
CEBM007202 - Hydraulic Excavator PC270LC-8 Shop Manual...672
CEBM007202 - PC270LC-8 sn A87001 and up...672
CONTENTS...673
REVISED PAGES...674
SAFETY...684
SAFETY NOTICE...684
IMPORTANT SAFETY NOTICE...684
GENERAL PRECAUTIONS...684
PREPARATIONS FOR WORK...684
PRECAUTIONS DURING WORK...684
GENERAL...687
HOW TO READ THE SHOP MANUAL...688
VOLUMES...688
DISTRIBUTION AND UPDATING...688
FILING METHOD...688
REVISED EDITION MARK...688
REVISIONS...688
SYMBOLS...688
HOISTING INSTRUCTIONS...689
HOISTING...689
WIRE ROPES...689
PUSH PULL COUPLER...690
TYPE 1...690
DISCONNECTION...690
CONNECTION...690
TYPE 2...691
DISCONNECTION...691
CONNECTION...691
TYPE 3...692
DISCONNECTION...692
CONNECTION...692
COATING MATERIALS...693
EXPLANATION OF MAINTENANCE STANDARD TERMS...695
STANDARD TIGHTENING TORQUE...697
Bolts and Nuts...697
Hose Nuts...698
Split Flange Bolts...698
Flared Nuts...698
O-ring Boss Piping Joints...699
O-ring Boss Plugs...699
Hoses (Taper Seal Type and Face Seal Type)...699
ELECTRIC WIRE CODE...700
Classification by Thickness...700
Classification by Color and Code...700
How To Read Electric Wire Code...701
CONVERSION TABLES...704
Method of Using the Conversion Table...704
01 GENERAL...710
SPECIFICATION AND TECHNICAL DATA...711
Specification Dimension Drawings...711
Working Range Diagram...712
Specifications...713
Weight table...715
TABLE OF FUEL, COOLANT AND LUBRICANTS...717
Lubrication Chart...719
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD...720
ENGINE AND COOLING...722
Engine related parts...722
Radiator, oil cooler, aftercooler and fuel cooler...723
POWER TRAIN...724
Power train...724
Final drive...725
Swing machinery...729
Swing circle...731
UNDERCARRIAGE AND FRAME...733
Track frame and recoil spring...733
Standard shoe...734
Idler...735
Carrier roller...737
Track roller...738
Track shoe...741
Triple grouser shoe...743
HYDRAULIC SYSTEM...745
Hydraulic equipment layout drawing...745
Hydraulic tank and filter...747
Hydraulic pump...749
Type: HPV95+95...749
Pilot oil filter...771
For breaker...771
Control valve...773
Sectional view (1/5)...775
Sectional view (2/5)...777
Sectional view (3/5)...779
Sectional view (4/5)...781
Sectional view (5/5)...783
CLSS...785
Functions and operation by valve...789
Unload valve...791
Introduction of LS pressure...793
LS bypass plug...794
Pressure compensation valve...795
Pressure compensation valve inner shuttle valve...798
Boom regeneration circuit...800
Arm regeneration circuit...802
Merge-divider valve...804
LS select valve...806
Self pressure reducing valve...807
Travel junction valve...810
Travel PPC shuttle valve...812
Boom drift preventive valve...814
Arm drift preventive valve (if equipped)...817
When abnormally high pressure is generated...820
Quick return valve...821
Lift check valve...823
Main relief valve...824
2-stage safety-suction valve...825
Swing Motor...827
Center swivel joint...837
Travel motor...839
PPC valve...852
Work equipment and swing PPC valve...852
Travel PPC valve...857
Service PPC valve (with EPC valve)...867
Service PPC valve...873
Control valve...875
Solenoid valve...877
PPC Accumulator...879
Return oil filter...880
For breaker...880
Attachment circuit selector valve...881
Hydraulic cylinder...883
Boom cylinder...883
Arm cylinder...883
Bucket cylinder...883
WORK EQUIPMENT...885
Dimensions of components...885
CAB AND ITS ATTACHMENTS...891
Air conditioner piping...891
ELECTRICAL SYSTEM...892
Engine control...892
Engine controller...895
Coolant temperature sensor...898
Oil pressure switch...898
Rotation sensor...899
Boost pressure and temperature sensor...899
WIF (water-in-fuel detection) sensor...900
Engine oil level sensor...900
Electrical control system...901
Machine control system diagram...901
MONITOR SYSTEM...925
Machine monitor...926
Monitor control, display portion...929
Switches...935
SENSORS...952
Fuel level sensor...952
Air cleaner clogging sensor...953
Coolant level sensor...953
KOMTRAX TERMINAL SYSTEM...954
KOMTRAX communication modem...955
20 STANDARD VALUE TABLES...956
STANDARD SERVICE VALUE TABLE...957
Engine related parts...957
Chassis related parts...958
30 TESTING AND ADJUSTING...972
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...974
Sketch of special tool...978
ENGINE SPEED...979
INTAKE AIR PRESSURE (BOOST PRESSURE)...981
EXHAUST GAS COLOR...982
VALVE CLEARANCE...984
COMPRESSION PRESSURE...986
Determining A Defective Cylinder...989
Procedures...989
Determining Cylinder Group...989
Isolating The Defective Cylinder...989
BLOW-BY PRESSURE...990
ENGINE OIL PRESSURE...991
HANDLING FUEL SYSTEM PARTS...992
Releasing Residual Pressure From Fuel System...992
Fuel Pressure...993
Fuel Return Rate And Leakage...996
Bleeding Air From Fuel Circuit...1001
Fuel Circuit - Checking For Leakage...1002
AIR CONDITIONER COMPRESSOR BELT...1003
FAN BELT...1004
SWING CIRCLE BEARING...1005
TRACK CHAIN TENSION...1006
WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS OIL PRESSURE...1007
CONTROL CIRCUIT BASIC PRESSURE...1011
OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...1013
Measuring...1013
Adjusting...1015
OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...1016
Measuring...1016
Adjusting...1020
SOLENOID VALVE OUTPUT PRESSURE...1021
Measuring...1021
PPC Lock Solenoid Valve Operation Table...1023
2-Stage Relief Solenoid Valve Operation Table...1023
Swing Holding Brake Solenoid Valve Operation Table...1023
Travel Speed Shifting Solenoid Valve Operation Table...1023
Travel Junction Solenoid Valve Operation Table...1024
ATT Return Selector Solenoid Valve Operation Table...1024
PPC VALVE OUTPUT PRESSURE...1025
WORK EQUIPMENT AND SWING PPC VALVES...1028
HYDRAULIC DRIFT OF WORK EQUIPMENT...1029
RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...1030
OIL LEAKAGE...1031
BLEEDING AIR FROM EACH PART...1034
CAB TIPPING STOPPER...1037
MIRRORS...1038
SPECIAL FUNCTIONS OF MACHINE MONITOR...1042
Long Distance Transport Mode...1105
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...1107
PREPARATION WORK FOR ELECTRICAL SYSTEM...1108
PROCEDURE FOR TESTING DIODES...1113
PM CLINIC SERVICE...1115
40 TROUBLESHOOTING...1124
GENERAL INFORMATION...1128
Points To Remember...1128
Sequence Of Events In Troubleshooting...1130
Handling Electric Equipment and Hydraulic Components...1131
New Connectors for Tier 3 Engines...1139
Check Before Troubleshooting...1143
Classification And Troubleshooting Steps...1144
Troubleshooting Classification...1144
Troubleshooting steps...1144
Information In Troubleshooting Table...1145
Related Circuit Diagram...1146
Possible Problems and Troubleshooting No...1147
How To Read Electric Wire Code...1150
Connection Table For Connector Pin Numbers...1153
T-branch boxes and T-branch adapters Table...1189
FAILURE CODE (DISPLAY OF CODE)...1192
Failure Codes Table...1192
Before Troubleshooting With Failure Code Displayed...1197
Fuse Box Connection Table...1197
Locations Of Fusible Links...1198
Location Of Fuse Box And Fuse Nos...1198
Trouble That Occurs When Power Supply Of Pump Controller Is Defective...1199
989L00 Engine Controller Lock Caution 1...1201
989M00 Engine Controller Lock Caution 2...1201
989N00 Engine Controller Lock Caution 3...1202
AA10NX Air Cleaner Clogging...1202
AB00KE Charge Voltage Low...1203
B@BAZG Eng Oil Press. Low...1205
B@BAZK Eng Oil Level Low...1205
B@BCNS Eng Water Overheat...1206
B@BCZK Eng Water Level Low...1206
B@HANS Hyd Oil Overheat...1207
CA111 EMC Critical Internal Failure...1207
CA115 Eng Ne and Bkup Speed Sens Error...1208
CA122 Chg Air Press Sensor High Error...1209
CA123 Chg Air Press Sensor Low Error...1211
CA131 Throttle Sensor High Error...1213
CA132 Throttle Sensor Low Error...1215
CA144 Coolant Temp Sens High Error...1217
CA145 Coolant Temp Sens Low Error...1219
CA153 Chg Air Temp Sensor High Error...1221
CA154 Chg Air Temp Sensor Low Error...1223
CA155 Chg Air Temp High Speed Derate...1225
CA187 Sens Supply 2 Volt Low Error...1227
CA221 Ambient Press Sens High Error...1229
CA222 Ambient Press Sens Low Error...1231
CA227 Sens Supply 2 Volt High Error...1233
CA234 Eng Overspeed...1234
CA238 Ne Speed Sens Supply Volt Error...1235
CA271 IMV/PCV1 Short Error...1236
CA272 IMV/PCV1 Open Error...1237
CA322 Inj #1 Open/Short Error...1239
CA323 Inj #5 Open/Short Error...1241
CA324 Inj #3 Open/Short Error...1243
CA325 Inj #6 Open/Short Error...1245
CA331 Inj #2 Open/Short Error...1247
CA332 Inj #4 Open/Short Error...1249
CA342 Calibration Code Incompatibility...1251
CA351 Injectors Drive Circuit Error...1253
CA352 Sens Supply 1 Volt Low Error...1255
CA386 Sens Supply 1 Volt High Error...1257
CA428 Water in Fuel Sensor High Error...1259
CA429 Water in Fuel Sensor Low Error...1261
CA435 Eng Oil Press Sw Error...1263
CA441 Battery Voltage Low Error...1264
CA442 Battery Voltage High Error...1267
CA449 Rail Press Very High Error...1269
CA451 Rail Press Sensor High Error...1271
CA452 Rail Press Sensor Low Error...1273
CA488 Chg Air Temp High Torque Derate...1275
CA553 Rail Press High Error...1275
CA559 Rail Press Low Error...1276
CA689 Eng Ne Speed Sensor Error...1277
CA731 Eng Bkup Speed Sens Phase Error...1279
CA757 All Continuous Data Lost Error...1281
CA778 Eng Bkup Speed Sensor Error...1283
CA1633 KOMNET Datalink Timeout Error...1285
CA2185 Throt Sens Sup Volt High Error...1286
CA2186 Throt Sens Sup Volt Low Error...1287
CA2249 Rail Press Very Low Error...1288
CA2311 IMV Solenoid Error...1289
CA2555 Grid Htr Relay Volt High Error...1291
CA2556 Grid Htr Relay Volt Low Error...1293
D19JKZ Personal Code Relay Abnormality...1295
D862KA GPS Antenna Discon...1297
DA22KK Pump Solenoid Power Low Error...1299
DA25KP 5 V Sensor 1 Power Abnormality...1301
DA29KQ Model Selection Abnormality...1307
DA2RMC CAN Discon (Pump Con Detected)...1309
DAF8KB Short Circuit In Camera Power Supply...1317
DAFGMC GPS Module Error...1319
DAFRMC CAN Discon (Monitor Detected)...1320
DGH2KB Hydr Oil Sensor Short...1327
DHPAMA F Pump Press Sensor Abnormality...1329
DHPBMA R Pump Press Sensor Abnormality...1331
DHS3MA Arm Curl PPC Press Sensor Abnormality...1333
DHS4MA Bucket Curl PPC Press Sensor Abnormality...1335
DHS8MA Boom Raise PPC Press Sensor Abnormality...1337
DHSAMA Swing RH PPC Press Sensor Abnormality...1339
DHSBMA Swing LH PPC Press Sensor Abnormality...1341
DHSDMA Bucket Dump PPC Press Sensor Abnormality...1343
DHX1MA Overload Sensor Abnormality (Analog)...1345
DW43KA Travel Speed Sol Discon...1349
DW43KB Travel Speed Sol Short...1351
DW45KA Swing Brake Sol Discon...1353
DW45KB Swing Brake Sol Short...1355
DW91KA Travel Junction Sol Discon...1357
DW91KB Travel Junction Sol Short...1359
DWA2KA Service Sol Discon...1361
DWA2KB Service Sol Short...1362
DWK0KA 2-Stage Relief Sol Discon...1363
DWK0KB 2-Stage Relief Sol Short...1365
DXA8KA PC-EPC (F) Sol Discon...1367
DXA8KB PC-EPC (F) Sol Short...1369
DXA9KA PC-EPC (R) Sol Discon...1371
DXA9KB PC-EPC (R) Sol Short...1373
DXE0KA LS-EPC Sol Discon...1375
DXE0KB LS-EPC Sol Short...1377
DXE4KA Service Current EPC Discon...1379
DXE4KB Service Current EPC Short...1381
DXE5KA Merge-divider Main Sol Discon...1383
DXE5KB Merge-divider Main Sol Short...1385
DXE6KA Merge-divider LS Sol Discon...1387
DXE6KB Merge-divider LS Sol Short...1389
DY20KA Wiper Working Abnormality...1391
DY20MA Wiper Parking Abnormality...1393
DY2CKA Washer Drive Discon...1395
DY2CKB Washer Drive Short...1397
DY2DKB Wiper Drive (For) Short...1399
DY2EKB Wiper Drive (Rev) Short...1401
ELECTRICAL SYSTEM (E-MODE)...1403
Troubleshooting Table...1403
E-1 No Machine Monitor Display When Starting Switch Is Turned On...1405
E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine)...1407
E-3 Engine Does Not Start...1410
E-4 Preheater Does Not Operate...1415
E-5 Automatic Warm-up System Does Not Operate (In Cold Season)...1419
E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked...1421
E-7 Precaution Lights Up While Engine Is Running...1423
E-8 Emergency Stop Item Lights Up While Engine Is Running...1428
E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally...1429
E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally...1431
E-11 Fuel Level Gauge Does Not Indicate Normally...1435
E-12 Machine Monitor Content Displays Are Different From Applicable Machine...1438
E-13 Machine Monitor Does Not Display Some Items...1438
E-14 Function Switch Does Not Work...1438
E-15 Auto-decelerator Does Not Operate Normally...1439
E-16 Working Mode Does Not Change...1440
E-17 Travel Speed Does Not Change...1441
E-18 Alarm Buzzer Cannot be Stopped...1442
E-19 Windshield Wiper and Window Washer Do Not Operate...1443
E-20 Power Maximizing Function Does Not Operate Normally...1445
E-21 Swing Holding Brake Does Not Operate Normally...1447
E-22 Travel Alarm Does Not Sound or Does Not Stop...1449
E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)...1451
E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position...1463
E-25 Machine Monitor Cannot Be Set In Service Mode...1463
E-26 Monitoring Function Does Not Display Lever Control Signal Normally...1464
E-27 KOMTRAX System Does Not Operate Normally...1473
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...1475
System Diagram of Hydraulic and Mechanical System...1475
Information In Troubleshooting Table...1477
H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow...1478
H-2 Engine Speed Drops Sharply or Engine Stalls...1480
H-3 Work Equipment, Swing, and Travel Systems Do Not Work...1481
H-4 Abnormal Noise Is Heard Around Hydraulic Pump...1481
H-5 Auto-decelerator Does Not Work...1482
H-6 Fine Control Mode Does Not Function or Responds Slow...1482
H-7 Boom Moves Slowly or Lacks Power...1483
H-8 Arm Moves Slowly or Lacks Power...1484
H-9 Bucket Moves Slowly or Lacks Power...1485
H-10 Work Equipment Does Not Move In Its Single Operation...1485
H-11 Work Equipment Hydraulic Drift Is Too Fast...1486
H-12 Work Equipment Has Big Time Lag...1488
H-13 Other Work Equipment Moves When Relieving Single Circuit...1488
H-14 Power Maximizing Function Does Not Work...1489
H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly...1489
H-16 In Swing and Boom Raise Operation, Boom Moves Slowly...1490
H-17 In Swing and Travel Operation, Travel Speed Drops Sharply...1490
H-18 Machine Swerves In Travel...1491
H-19 Machine Travels Slowly...1492
H-20 Machine Steers With Difficulty or Lacks Power...1493
H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast...1494
H-22 Track Shoe Does Not Turn (On One Side Only)...1495
H-23 Machine Does Not Swing...1496
H-24 Swing Acceleration Is Poor or Swing Speed Is Slow...1498
H-25 Excessive Overrun When Stopping Swing...1500
H-26 The Machine Jerks When Stopping Swing...1501
H-27 Loud Sound Occurs When Upper Structure Stops Swinging...1501
H-28 Swing Hydraulic Drift Is Too Big...1502
H-29 Attachment Circuit Is Not Changed...1503
H-30 Oil Flow In Attachment Circuit Cannot Be Controlled...1503
50 DISASSEMBLY AND ASSEMBLY...1504
HOW TO READ THIS SECTION...1508
Removal And Installation Of Assemblies...1508
Removal...1508
Installation...1508
Disassembly And Assembly Of Assemblies...1509
Disassembly...1509
Assembly...1510
SPECIAL TOOLS LIST...1511
SKETCHES OF SPECIAL TOOLS...1516
CONNECTOR REPAIR PROCEDURES...1520
Stripping Insulation...1520
Wire Inspection...1520
Contact Terminal Removal (HD30 Type)...1521
Crimping Contact Terminal (HD30 Type)...1522
Insertion Of Contact Terminal (HD30 Type)...1523
Contact Terminal Removal (DT Type)...1524
Crimping Contact Terminal (DT Type)...1525
Insertion Of Contact Terminal (DT Type)...1526
ENGINE AND COOLING SYSTEM...1527
Fuel Supply Pump...1527
Removal...1527
Installation...1531
Fuel Injector Assembly...1533
Removal...1533
Installation...1538
Engine Front Seal...1544
Removal...1544
Installation...1546
Engine Rear Seal...1548
Removal...1548
Installation...1549
Cylinder Head Assembly...1552
Removal...1552
Installation...1560
Radiator Assembly...1570
Removal...1570
Installation...1572
Hydraulic Oil Cooler Assembly...1574
Removal...1574
Installation...1576
Aftercooler Assembly...1577
Removal...1577
Installation...1579
Fuel Cooler Assembly...1580
Removal...1580
Installation...1580
Engine And Hydraulic Pump Assembly...1581
Removal...1581
Installation...1590
POWER TRAIN...1594
Final Drive Assembly...1594
Removal...1594
Installation...1595
Final Drive...1596
Disassembly...1596
Assembly...1600
Swing Motor and Swing Machinery Assembly...1607
Removal...1607
Installation...1609
Swing Motor and Swing Machinery Assembly...1610
Disassembly...1610
Assembly...1615
Swing Circle Assembly...1621
Removal...1621
Installation...1621
UNDERCARRIAGE AND FRAME...1622
Carrier Roller...1622
Assembly...1622
Track Roller...1623
Assembly...1623
Idler, Recoil Spring...1624
Removal...1624
Installation...1624
Idler...1625
Disassembly...1625
Assembly...1626
Recoil Spring...1629
Disassembly...1629
Assembly...1630
Sprocket...1632
Removal...1632
Installation...1632
Track Shoe...1633
Expanding Track Shoe...1633
Installation...1634
Revolving Frame...1635
Removal...1635
Installation...1637
Counterweight...1638
Removal...1638
Installation...1640
HYDRAULIC SYSTEM...1641
Center Swivel Joint...1641
Removal...1641
Installation...1643
Disassembly...1644
Assembly...1645
Hydraulic Tank Assembly...1646
Removal...1646
Installation...1649
Control Valve...1650
Removal...1650
Installation...1655
Precautions for Replacing Pressure Compensation Valve Seal...1657
Precautions for Assembling Control Valve...1659
Hydraulic Pump...1662
Removal...1662
Installation...1666
Oil Seal In Hydraulic Pump Input Shaft...1667
Removal...1667
Installation...1667
Work Equipment PPC Valve...1668
Disassembly...1668
Assembly...1668
Travel PPC Valve...1670
Disassembly...1670
Assembly...1671
Hydraulic Cylinder...1673
Disassembly...1674
Assembly...1676
WORK EQUIPMENT...1680
Work Equipment...1680
Removal...1680
Installation...1682
CAB AND ITS ATTACHMENTS...1683
Operator's Cab...1683
Removal...1683
Installation...1686
Operator Cab Glass (Fixed Glass)...1687
Removal...1688
Installation...1689
Front Window...1698
Removal...1698
Installation...1701
Floor Frame...1706
Removal...1706
Installation...1710
ELECTRICAL SYSTEM...1711
Air Conditioner Unit...1711
Removal...1711
Installation...1715
KOMTRAX Communication Modem...1716
Removal...1716
Installation...1716
Monitor...1717
Removal...1717
Installation...1718
Pump Controller...1719
Removal...1719
Installation...1720
Engine Controller...1722
Removal...1722
Installation...1723
60 AIR CONDITIONER...1724
STRUCTURE AND FUNCTION...1727
Air Conditioner Component...1727
Configuration and Function of Refrigerating cycle...1729
Outline of Refrigerating Cycle...1730
Air Conditioner Unit...1733
Functions of Major Components in the Air Conditioner Unit...1735
Control Plate...1737
Compressor...1740
Condenser and Receiver Drier...1741
TESTING AND ADJUSTING...1742
Caution About Refrigerant...1742
Troubleshooting Procedure...1743
Block Diagram...1744
Circuit Diagram and Arrangement of Connector Pins...1745
Detail of Air Conditioner Unit...1747
Part and Connector Locations...1749
Testing Air Leakage (Ducts)...1753
Testing with Self-diagnosis Function...1755
Testing Temperature Control...1758
Testing Vent (Mode) Changeover...1761
Testing Recirc/Fresh Changeover...1765
Testing Inner Sensor...1767
Testing Evaporator Temperature Sensor...1768
Testing Sunlight Sensor...1770
Testing (Dual) Pressure Switch for Refrigerant...1771
Testing Relays...1773
TROUBLESHOOTING...1775
Troubleshooting Chart 1...1775
Troubleshooting Chart 2...1776
Troubleshooting for Electrical System (E mode)...1779
E-1 Power Supply System (Air Conditioner does not Operate)...1780
E-2 Compressor System (Air is Not Cooled)...1784
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)...1787
E-4 Temperature Cannot be Controlled...1791
E-5 Vent (Mode) Cannot be Changed Over...1794
E-6 Recirc/Fresh Air Cannot be Changed Over...1797
Troubleshooting With Gauge Pressure...1800
Connection of Service Tool...1803
Precautions for connecting air conditioner piping...1805
Handling of Compressor Oil...1806
Control of Compressor Oil...1806
Adding of Compressor Oil...1806
Compressor Replacement...1807
Applying Compressor Oil for O-ring...1807
Desiccant Replacement Procedure...1808
90 DIAGRAMS AND SCHEMATICS...1810
HYDRAULIC SYSTEM...1812
Hydraulic Circuit Diagram...1812
ELECTRICAL SYSTEM...1813
Electrical Circuit Diagram (1/5)...1813
Electrical Circuit Diagram (2/5)...1814
Electrical Circuit Diagram (3/5)...1815
Electrical Circuit Diagram (4/5)...1816
Electrical Circuit Diagram (5/5)...1817
Electrical Connector Arrangement Diagram...1818
SEN00420-13 - Hydraulic Excavator PC270-8, PC270LC-8 Shop Manual...1819
COVER...1819
00 Index and foreword...0
Index...1821
Composition of shop manual...1822
Table of contents...1824
Foreword and general information...1833
Safety notice...1834
How to read the shop manual...1839
Explanation of terms for maintenance standard...1841
Handling of electric equipment and hydraulic component...1843
Handling of connectors newly used for engines...1852
How to read electric wire code...1855
Precautions when carrying out operation...1858
Method of disassembling and connecting push-pull type coupler...1861
Standard tightening torque table...1864
Conversion table...1868
01 Specification...0
Specification and technical data...1875
Specification dimension drawings...1876
Working range diagram...1877
Specifications...1878
Weight table...1880
Table of fuel, coolant and lubricants...1882
10 Structure, function and maintenance standard...0
Engine and cooling system...1885
Engine and cooling system...1886
Engine related parts...1886
Radiator, oil cooler, aftercooler and fuel cooler...1887
Power train...1889
Power train...1890
Final drive...1892
Swing machinery...1894
Swing circle...1896
Undercarriage and frame...1899
Undercarriage and frame...1900
Track frame and recoil spring...1900
Idler...1902
Carrier roller...1904
Track roller...1905
Track shoe...1906
Hydraulic system, Part 1...1911
Hydraulic system, Part 1...1912
Hydraulic equipment layout drawing...1912
Hydraulic tank and filter...1914
Hydraulic pump...1916
Pilot oil filter...1938
Hydraulic system, Part 2...1941
Hydraulic system, Part 2...1942
Control valve...1942
CLSS...1953
Functions and operation by valve...1958
Hydraulic system, Part 3...1997
Swing motor...1998
Center swivel joint...2008
Travel motor...2011
PPC valve...2024
Valve control...2046
Solenoid valve...2048
PPC accumulator...2050
Return oil filter...2051
Attachment circuit selector valve...2052
Hydraulic cylinder...2054
Work equipment...2057
Work equipment...2058
Dimensions of components...2058
Cab and its attachments...2065
Air conditioner piping...2066
Electrical system...2069
Engine control...2070
Electrical control system...2078
Monitor system...2101
Sensor...2128
KOMTRAX system...2131
20 Standard value table...0
Standard service value table...2135
Standard service value table...2136
Standard value table for engine related parts...2136
Standard value table for chassis related parts...2137
30 Testing and adjusting...0
Testing and adjusting, Part 1...2149
Testing and adjusting, Part 1...2151
Tools for testing, adjusting, and troubleshooting...2151
Sketch of special tool...2155
Testing engine speed...2156
Testing intake air pressure (boost pressure)...2157
Checking exhaust gas color...2158
Adjusting valve clearance...2159
Testing compression pressure...2161
Testing blow-by pressure...2163
Testing engine oil pressure...2164
Handling fuel system parts...2165
Releasing residual pressure from fuel system...2165
Testing fuel pressure...2166
Testing fuel delivery, return and leak amount...2169
Bleeding air from fuel circuit...2172
Checking fuel circuit for leakage...2173
Checking and adjusting air conditioner compressor belt tension...2174
Replacing fan belt...2175
Testing swing circle bearing clearance...2176
Checking and adjusting track shoe tension...2177
Testing and adjusting oil pressure in work equipment, swing, and travel circuits...2179
Testing control circuit basic pressure...2182
Testing and adjusting oil pressure in pump PC control circuit...2183
Testing and adjusting oil pressure in pump LS control circuit...2186
Testing solenoid valve output pressure...2191
Testing PPC valve output pressure...2194
Adjusting play of work equipment and swing PPC valves...2196
Checking parts which cause hydraulic drift of work equipment...2197
Releasing residual pressure from hydraulic circuit...2199
Testing oil leakage...2200
Bleeding air from each part...2203
Checking cab tipping stopper...2205
Installation and adjustment of mirrors...2206
Testing and adjusting, Part 2...2211
Special functions of machine monitor...2212
Testing and adjusting, Part 3...2269
Testing and adjusting, Part 3...2270
Handling voltage circuit of engine controller...2270
Preparation work for troubleshooting of electrical system...2271
Procedure for testing diodes...2276
Pm Clinic service...2277
40 Troubleshooting...0
Failure code table and fuse locations...2285
Failure codes table...2286
Fuse locations...2291
General Information on troubleshooting...2297
General information on troubleshooting...2298
Points to remember when troubleshooting...2298
Sequence of events in troubleshooting...2299
Check before troubleshooting...2300
Classification and procedures for troubleshooting...2301
How to read electric wire code...2305
Information in troubleshooting table...2308
Connection table for connector pin numbers...2310
T- branch box and T- branch adapter table...2346
Troubleshooting by failure code (Display of code), Part 1...2351
Failure code [989L00] Engine Controller Lock Caution 1...2354
Failure code [989M00] Engine Controller Lock Caution 2...2354
Failure code [989N00] Engine Controller Lock Caution 3...2355
Failure code [AA10NX] Air Cleaner Clogging...2355
Failure code [AB00KE] Charge Voltage Low...2356
Failure code [B@BAZG] Eng Oil Press. Low...2358
Failure code [B@BAZK] Eng Oil Level Low...2358
Failure code [B@BCNS] Eng Water Overheat...2359
Failure code [B@BCZK] Eng Water Level Low...2359
Failure code [B@HANS] Hydr Oil Overheat...2360
Failure code [CA111] EMC Critical Internal Failure...2360
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...2361
Failure code [CA122] Chg Air Press Sensor High Error...2362
Failure code [CA123] Chg Air Press Sensor Low Error...2364
Failure code [CA131] Throttle Sensor High Error...2366
Failure code [CA132] Throttle Sensor Low Error...2368
Failure code [CA144] Coolant Temp Sens High Error...2370
Failure code [CA145] Coolant Temp Sens Low Error...2372
Failure code [CA153] Chg Air Temp Sensor High Error...2374
Failure code [CA154] Chg Air Temp Sensor Low Error...2376
Failure code [CA155] Chg Air Temp High Speed Derate...2378
Failure code [CA187] Sens Supply 2 Volt Low Error...2380
Failure code [CA221] Ambient Press Sens High Error...2382
Failure code [CA222] Ambient Press Sens Low Error...2384
Failure code [CA227] Sens Supply 2 Volt High Error...2386
Failure code [CA234] Eng Overspeed...2387
Failure code [CA238] Ne Speed Sens Supply Volt Error...2388
Failure code [CA271] IMV/PCV1 Short Error...2389
Failure code [CA272] IMV/PCV1 Open Error...2390
Failure code [CA322] Inj #1 Open/Short Error...2392
Failure code [CA323] Inj #5 Open/Short Error...2394
Failure code [CA324] Inj #3 Open/Short Error...2396
Failure code [CA325] Inj #6 Open/Short Error...2398
Failure code [CA331] Inj #2 Open/Short Error...2400
Failure code [CA332] Inj #4 Open/Short Error...2402
Troubleshooting by failure code (Display of code), Part 2...2405
Troubleshooting by failure code (Display of code), Part 2...2407
Failure code [CA342] Calibration Code Incompatibility...2407
Failure code [CA351] Injectors Drive Circuit Error...2408
Failure code [CA352] Sens Supply 1 Volt Low Error...2410
Failure code [CA386] Sens Supply 1 Volt High Error...2412
Failure code [CA428] Water in Fuel Sensor High Error...2414
Failure code [CA429] Water in Fuel Sensor Low Error...2416
Failure code [CA435] Eng Oil Press Sw Error...2418
Failure code [CA441] Battery Voltage Low Error...2419
Failure code [CA442] Battery Voltage High Error...2422
Failure code [CA449] Rail Press Very High Error...2424
Failure code [CA451] Rail Press Sensor High Error...2426
Failure code [CA452] Rail Press Sensor Low Error...2428
Failure code [CA488] Chg Air Temp High Torque Derate...2430
Failure code [CA553] Rail Press High Error...2431
Failure code [CA559] Rail Press Low Error...2432
Failure code [CA689] Eng Ne Speed Sensor Error...2434
Failure code [CA731] Eng Bkup Speed Sens Phase Error...2436
Failure code [CA757] All Continuous Data Lost E...2438
Failure code [CA778] Eng Bkup Speed Sensor Error...2440
Failure code [CA1633] KOMNET Datalink Timeout Error...2442
Failure code [CA2185] Throt Sens Sup Volt High Error...2443
Failure code [CA2186] Throt Sens Sup Volt Low Error...2444
Failure code [CA2249] Rail Press Very Low Error...2445
Failure code [CA2311] IMV Solenoid Error...2446
Failure code [CA2555] Grid Htr Relay Volt High Error...2448
Failure code [CA2556] Grid Htr Relay Volt Low Error...2450
Failure code [D19JKZ] Personal Code Relay Abnormality...2452
Failure code [D862KA] GPS Antenna Discon...2454
Failure code [DA22KK] Pump Solenoid Power Low Error...2456
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...2458
Failure code [DA29KQ] Model Selection Abnormality...2464
Troubleshooting by failure code (Display of code), Part 3...2467
Troubleshooting by failure code (Display of code), Part 3...2469
Failure code [DA2RMC] CAN Discon (Pump Con Detected)...2469
Failure code [DAF8KB] Short circuit in camera power supply...2476
Failure code [DAFGMC] GPS Module Error...2478
Failure code [DAFRMC] CAN Discon (Monitor Detected)...2479
Failure code [DGH2KB] Hydr Oil Sensor Short...2484
Failure code [DHPAMA] F Pump Press Sensor Abnormality...2486
Failure code [DHPBMA] R Pump Press Sensor Abnormality...2488
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...2490
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...2492
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality...2494
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality...2496
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality...2498
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...2500
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)...2502
Failure code [DW43KA] Travel Speed Sol Discon...2506
Failure code [DW43KB] Travel Speed Sol Short...2508
Failure code [DW45KA] Swing Brake Sol Discon...2510
Failure code [DW45KB] Swing Brake Sol Short...2512
Failure code [DW91KA] Travel Junction Sol Discon...2514
Failure code [DW91KB] Travel Junction Sol Short...2516
Failure code [DWA2KA] Service Sol Discon...2518
Failure code [DWA2KB] Service Sol Short...2519
Failure code [DWK0KA] 2-stage Relief Sol Discon...2520
Failure code [DWK0KB] 2-stage Relief Sol Short...2522
Troubleshooting by failure code (Display of code), Part 4...2525
Troubleshooting by failure code (Display of code), Part 4...2526
Failure code [DXA8KA] PC-EPC (F) Sol Discon...2526
Failure code [DXA8KB] PC-EPC (F) Sol Short...2528
Failure code [DXA9KA] PC-EPC (R) Sol Discon...2530
Failure code [DXA9KB] PC-EPC (R) Sol Short...2532
Failure code [DXE0KA] LS-EPC Sol Discon...2534
Failure code [DXE0KB] LS-EPC Sol Short...2536
Failure code [DXE4KA] Service Current EPC Discon...2538
Failure code [DXE4KB] Service Current EPC Short...2540
Failure code [DXE5KA] Merge-divider Main Sol Discon...2542
Failure code [DXE5KB] Merge-divider Main Sol Short...2544
Failure code [DXE6KA] Merge-divider LS Sol Discon...2546
Failure code [DXE6KB] Merge-divider LS Sol Short...2548
Failure code [DY20KA] Wiper Working Abnormality...2550
Failure code [DY20MA] Wiper Parking Abnormality...2552
Failure code [DY2CKA] Washer Drive Discon...2554
Failure code [DY2CKB] Washer Drive Short...2556
Failure code [DY2DKB] Wiper Drive (For) Short...2558
Failure code [DY2EKB] Wiper Drive (Rev) Short...2560
Troubleshooting of electrical system (E-mode)...2563
Troubleshooting of electrical system (E-mode)...2565
Before carrying out troubleshooting of electrical system...2565
Information in troubleshooting table...2567
E-1 When starting switch turned ON, machine monitor displays nothing...2568
E-2 When starting switch turned ON (before starting engine), basic check item lights up...2570
E-3 Engine does not start (Engine does not turn)...2573
E-4 Preheater does not operate...2577
E-5 Automatic warm-up system does not operate (in cold season)...2581
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked...2582
E-7 Precaution lights up while engine is running...2584
E-8 Emergency stop item lights up while engine is running...2589
E-9 Engine coolant temperature gauge does not indicate normally...2590
E-10 Hydraulic oil temperature gauge does not indicate correctly...2591
E-11 Fuel level gauge does not indicate correctly...2594
E-12 Contents of display by machine monitor are different from applicable machine...2596
E-13 Machine monitor does not display some items...2596
E-14 Function switch does not work...2596
E-15 Auto-decelerator does not operate normally...2597
E-16 Working mode does not change...2598
E-17 Travel speed does not change...2599
E-18 Alarm buzzer cannot be stopped...2600
E-19 Windshield wiper and window washer do not operate...2601
E-20 Power maximizing function does not operate normally...2603
E-21 Swing holding brake does not operate normally...2605
E-22 Travel alarm does not sound or does not stop sounding...2607
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)...2609
E-24 While starting switch is in OFF position, service meter is not displayed...2621
E-25 Machine monitor cannot be set in service mode...2621
E-26 Monitoring function does not display lever control signal normally...2622
E-27 KOMTRAX system does not operate normally...2630
Troubleshooting of hydraulic and mechanical system (H-mode)...2633
Troubleshooting of hydraulic and mechanical system (H-mode)...2636
System diagram of hydraulic and mechanical system...2636
Information in troubleshooting table...2638
H-1 Speed or power of whole work equipment, swing, and travel is low...2639
H-2 Engine speed lowers extremely or engine stalls...2641
H-3 Work equipment, swing, and travel systems do not work...2642
H-4 Abnormal sound comes out from around hydraulic pump...2642
H-5 Auto-decelerator does not operate...2643
H-6 Fine control performance or response is low...2643
H-7 Speed or power of boom is low...2644
H-8 Speed or power of arm is low...2645
H-9 Speed or power of bucket is low...2646
H-10 Work equipment does not move singly...2646
H-11 Hydraulic drift of work equipment is large...2647
H-12 Time lag of work equipment is large...2649
H-13 When part of work equipment is relieved singly, other parts of work equipment move...2649
H-14 Power maximizing function does not work...2650
H-15 In compound operation of work equipment, speed of part loaded more is low...2650
H-16 When machine swings and raises boom simultaneously, boom rising speed is low...2651
H-17 When machine swings and travels simultaneously, travel speed is low...2651
H-18 Machine deviates during travel...2652
H-19 Travel speed is low...2653
H-20 Machine is not steered well or steering power is low...2654
H-21 Travel speed does not change or travel speed is low/high...2655
H-22 Travel system does not move (only one side)...2656
H-23 Upper structure does not swing...2657
H-24 Swing acceleration or swing speed is low...2659
H-25 Upper structure overruns remarkably when it stops swinging...2660
H-26 Large shock is made when upper structure stops swinging...2661
H-27 Large sound is made when upper structure stops swinging...2661
H-28 Hydraulic drift of swing is large...2662
H-29 Attachment circuit is not changed...2663
H-30 Oil flow in attachment circuit cannot be controlled...2663
Troubleshooting of engine (S-mode)...2665
Troubleshooting of engine (S-mode)...2668
Method of using troubleshooting chart...2668
S-1 Starting performance is poor...2672
S-2 Engine does not start...2673
S-3 Engine does not pick up smoothly...2676
S-4 Engine stops during operations...2677
S-5 Engine does not rotate smoothly...2678
S-6 Engine lack output (or lacks power)...2679
S-7 Exhaust smoke is black (incomplete combustion)...2680
S-8 Oil consumption is excessive (or exhaust smoke is blue)...2681
S-9 Oil becomes contaminated quickly...2682
S-10 Fuel consumption is excessive...2683
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...2684
S-12 Oil pressure drops...2685
S-13 Oil level rises (Entry of coolant/fuel)...2686
S-14 Coolant temperature becomes too high (overheating)...2687
S-15 Abnormal noise is made...2688
S-16 Vibration is excessive...2689
50 Disassembly and assembly...0
General information on disassembly and assembly...2691
How to read this manual...2692
Coating materials list...2694
Special tools list...2697
Sketches of special tools...2701
Engine and cooling system...2707
Removal and installation of fuel supply pump assembly...2708
Removal and installation of fuel injector assembly...2712
Removal and installation of engine front seal...2721
Removal and installation of engine rear seal...2724
Removal and installation of cylinder head assembly...2727
Removal and installation of radiator assembly...2741
Removal and installation of hydraulic oil cooler assembly...2744
Removal and installation of aftercooler assembly...2746
Removal and installation of fuel cooler assembly...2748
Removal and installation of engine and hydraulic pump assembly...2749
Power train...2759
Removal and installation of final drive assembly...2760
Disassembly and assembly of final drive assembly...2761
Removal and installation of swing motor and swing machinery assembly...2770
Disassembly and assembly of swing motor and swing machinery assembly...2772
Removal and installation of swing circle assembly...2781
Undercarriage and frame...2783
Disassembly and assembly of carrier roller assembly...2784
Disassembly and assembly of track roller assembly...2785
Disassembly and assembly of idler assembly...2786
Disassembly and assembly of recoil spring assembly...2789
Removal and installation of sprocket...2791
Expansion and installation of track shoe assembly...2792
Removal and installation of revolving frame assembly...2794
Removal and installation of counterweight assembly...2796
Hydraulic system...2799
Removal and installation of center swivel joint assembly...2800
Disassembly and assembly of center swivel joint assembly...2802
Removal and installation of hydraulic tank assembly...2803
Removal and installation of control valve assembly...2807
Disassembly and assembly of control valve assembly...2812
Removal and installation of hydraulic main pump assembly...2816
Removal and installation of oil seal in hydraulic pump input shaft...2820
Disassembly and assembly of work equipment PPC valve assembly...2821
Disassembly and assembly of travel PPC valve assembly...2823
Disassembly and assembly of hydraulic cylinder assembly...2826
Work equipment...2833
Work equipment...2834
Removal and installation of work equipment assembly...2834
Cab and its attachments...2838
Removal and installation of operator's cab assembly...2839
Removal and installation of operator cab glass (stuck glass)...2842
Removal and installation of front window assembly...2852
Removal and installation of floor frame assembly...2859
Electrical system...2864
Removal and installation of air conditioner unit assembly...2865
Removal and installation of KOMTRAX communication modem assembly...2868
Removal and installation of monitor assembly...2869
Removal and installation of pump controller assembly...2871
90 Diagrams and drawings...0
Hydraulic diagrams and drawings...2874
Hydraulic circuit diagram PC270, 270LC-8...2876
Electrical diagrams and drawings...2879
Electrical circuit diagram...2881
Connector arrangement diagram...2886
TEN00148-03 - Hydraulic Excavator GALEO PC270-8 Operation & Maintenance Manual...2889
COVER...2889
FOREWORD...2890
FOREWORD...2891
SAFETY INFORMATION...2894
INTRODUCTION...2896
DIRECTIONS OF MACHINE...2896
BREAKING-IN THE NEW MACHINE...2896
PRODUCT INFORMATION...2897
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...2897
EPA REGULATIONS, ENGINE NUMBER PLATE...2897
SERVICE METER LOCATION...2898
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...2898
CONTENTS...2899
SAFETY...2902
SAFETY INFORMATION...2903
SAFETY LABELS...2905
LOCATION OF SAFETY LABELS...2906
SAFETY LABELS...2907
SAFETY INFORMATION...2913
SAFETY RULES...2913
IF PROBLEMS ARE FOUND...2913
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...2913
FIRE EXTINGUISHER AND FIRST AID KIT...2913
SAFETY EQUIPMENT...2913
KEEP MACHINE CLEAN...2914
KEEP OPERATOR'S COMPARTMENT CLEAN...2914
LEAVING OPERATOR'S SEAT WITH LOCK...2914
HANDRAILS AND STEPS...2915
PRECAUTIONS WHEN WORKING IN HIGH PLACES...2915
MOUNTING AND DISMOUNTING...2915
NO PERSONS ON ATTACHMENTS...2915
DO NOT GET CAUGHT IN ARTICULATED PORTION...2916
BURN PREVENTION...2916
FIRE PREVENTION AND EXPLOSION PREVENTION...2917
ACTION IF FIRE OCCURS...2918
WINDSHIELD WASHER FLUID...2918
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...2918
ATTACHMENT INSTALLATION...2918
ATTACHMENT COMBINATIONS...2918
CAB WINDOW GLASSES...2918
UNAUTHORIZED MODIFICATIONS...2919
SAFETY AT JOBSITE...2919
WORKING ON LOOSE GROUND...2919
DISTANCE TO HIGH VOLTAGE CABLES...2920
ENSURE GOOD VISIBILITY...2920
VENTILATION FOR ENCLOSED AREA...2921
SIGNALMAN'S SIGNAL AND SIGNS...2921
EMERGENCY EXIT FROM OPERATOR'S CAB...2921
ASBESTOS DUST HAZARD PREVENTION...2921
SAFETY MACHINE OPERATION...2922
STARTING ENGINE...2922
CHECKS BEFORE STARTING ENGINE...2922
SAFETY RULES FOR STARTING ENGINE...2923
STARTING ENGINE IN COLD WEATHER...2923
OPERATION...2924
CHECKS BEFORE OPERATION...2924
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...2924
SAFETY RULES FOR TRAVELING...2925
TRAVELING ON SLOPES...2925
OPERATIONS ON SLOPES...2926
PROHIBITED OPERATIONS...2927
OPERATIONS ON SNOW...2928
PARKING MACHINE...2929
TRANSPORTATION...2930
LOADING AND UNLOADING...2930
SHIPPING THE MACHINE...2930
BATTERY...2931
BATTERY HAZARD PREVENTION...2931
STARTING ENGINE WITH BOOSTER CABLES...2932
TOWING...2933
SAFETY RULES FOR TOWING...2933
LIFTING OBJECTS WITH BUCKET...2934
SAFETY RULES FOR LIFTING OBJECTS...2934
SAFETY MAINTENANCE INFORMATION...2935
WARNING TAG...2935
KEEP WORK PLACE CLEAN AND TIDY...2935
APPOINT LEADER WHEN WORKING WITH OTHERS...2935
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...2936
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...2937
PROPER TOOLS...2937
ACCUMULATOR, GAS SPRING...2938
PERSONNEL...2938
ATTACHMENTS...2938
WORK UNDER THE MACHINE...2938
NOISE...2938
WHEN USING HAMMER...2939
WELDING WORKS...2939
REMOVING BATTERY TERMINALS...2939
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...2939
DO NOT DISASSEMBLE RECOIL SPRINGS...2940
SAFETY RULES FOR HIGH-PRESSURE OIL...2940
PRECAUTION FOR HIGH FUEL PRESSURE...2940
SAFETY HANDLING HIGH-PRESSURE HOSES...2940
PRECAUTION FOR HIGH VOLTAGE...2941
WASTE MATERIALS...2941
AIR CONDITIONER MAINTENANCE...2941
COMPRESSED AIR...2941
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2941
OPERATION...2942
MACHINE VIEW ILLUSTRATIONS...2943
OVERALL MACHINE VIEW...2943
CONTROLS AND GAUGES...2944
DETAILED CONTROLS AND GAUGES...2946
MONITORING SYSTEM...2946
SWITCHES...3012
CONTROL LEVERS AND PEDALS...3017
SUN ROOF...3020
WINDSHIELD...3020
EMERGENCY ESCAPE HAMMER...3026
DOOR LOCK...3026
CAP WITH LOCK...3027
DRINK BOX...3029
MAGAZINE BOX...3029
ASHTRAY...3029
AIR CONDITIONER CONTROLS...3030
RADIO...3043
AUXILIARY ELECTRIC POWER...3048
FUSE...3049
FUSIBLE LINK...3050
CONTROLLER...3050
TOOL BOX...3050
GREASE PUMP HOLDER...3050
FIRE EXTINGUISHER...3051
MACHINE OPERATIONS AND CONTROLS...3052
BEFORE STARTING ENGINE...3052
STARTING ENGINE...3069
AFTER STARTING ENGINE...3072
STOPPING THE ENGINE...3083
MACHINE OPERATION...3084
STEERING THE MACHINE...3088
SWINGING...3090
WORK EQUIPMENT CONTROLS AND OPERATIONS...3091
WORKING MODE...3093
PROHIBITED OPERATIONS...3095
GENERAL OPERATION INFORMATION...3097
TRAVELING ON SLOPES...3099
ESCAPE FROM MUD...3101
RECOMMENDED APPLICATIONS...3102
BUCKET REPLACEMENT AND INVERSION...3104
PARKING MACHINE...3108
MACHINE INSPECTION AFTER DAILY WORK...3109
LOCKING...3110
TRANSPORTATION...3111
TRANSPORTATION PROCEDURE...3111
LOADING AND UNLOADING WITH TRAILER...3112
LIFTING MACHINE...3121
COLD WEATHER OPERATION...3124
COLD WEATHER OPERATION INFORMATION...3124
AFTER DAILY WORK COMPLETION...3126
AFTER COLD WEATHER SEASON...3126
LONG TERM STORAGE...3127
BEFORE STORAGE...3127
DURING STORAGE...3127
AFTER STORAGE...3128
STARTING MACHINE AFTER LONG-TERM STORAGE...3128
TROUBLES AND ACTIONS...3129
RUNNING OUT OF FUEL...3129
PHENOMENA THAT ARE NOT FAILURES...3129
TOWING THE MACHINE...3130
LIGHTWEIGHT TOWING HOLE...3131
SEVERE JOB CONDITION...3131
DISCHARGED BATTERY...3132
OTHER TROUBLE...3136
MAINTENANCE...3141
MAINTENANCE INFORMATION...3142
OUTLINE OF SERVICE...3144
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...3144
ELECTRIC SYSTEM MAINTENANCE...3147
WEAR PARTS...3148
WEAR PARTS LIST...3148
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...3149
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...3151
TIGHTENING TORQUE SPECIFICATIONS...3152
TIGHTENING TORQUE LIST...3152
SAFETY CRITICAL PARTS...3153
SAFETY CRITICAL PARTS LIST...3154
MAINTENANCE SCHEDULE...3155
MAINTENANCE SCHEDULE CHART...3155
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...3157
MAINTENANCE PROCEDURE...3158
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...3158
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)...3158
WHEN REQUIRED...3159
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...3159
CLEAN INSIDE OF COOLING SYSTEM...3165
CHECK AND TIGHTEN TRACK SHOE BOLTS...3169
CHECK AND ADJUST TRACK TENSION...3170
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...3172
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...3175
ADJUST BUCKET CLEARANCE...3177
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...3178
CHECK AND MAINTENANCE AIR CONDITIONER...3179
WASH WASHABLE FLOOR...3180
CHECK GAS SPRING...3183
BLEEDING AIR FROM HYDRAULIC SYSTEM...3184
CHECK BEFORE STARTING...3186
EVERY 100 HOURS MAINTENANCE...3187
LUBRICATING...3187
EVERY 250 HOURS MAINTENANCE...3189
CHECK LEVEL OF BATTERY ELECTROLYTE...3189
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...3191
EVERY 500 HOURS MAINTENANCE...3192
LUBRICATE SWING CIRCLE...3192
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...3193
REPLACE FUEL PRE-FILTER CARTRIDGE...3195
CHECK SWING PINION GREASE LEVEL, ADD GREASE...3197
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS...3198
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...3200
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...3202
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT...3203
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...3204
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...3205
EVERY 1000 HOURS MAINTENANCE...3206
REPLACE HYDRAULIC OIL FILTER ELEMENT...3206
CHANGE OIL IN SWING MACHINERY CASE...3207
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...3208
REPLACE FUEL MAIN FILTER CARTRIDGE...3209
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...3211
REPLACE CORROSION RESISTOR CARTRIDGE...3211
CHECK FAN BELT TENSION AND REPLACE FAN BELT...3211
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)...3211
EVERY 2000 HOURS MAINTENANCE...3212
CHANGE OIL IN FINAL DRIVE CASE...3212
CLEAN HYDRAULIC TANK STRAINER...3213
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...3214
CHECKING FUNCTION OF ACCUMULATOR...3215
CHECK ALTERNATOR...3218
CHECK ENGINE VALVE CLEARANCE, ADJUST...3218
EVERY 4000 HOURS MAINTENANCE...3219
CHECK WATER PUMP...3219
CHECK VIBRATION DAMPER...3219
CHECK STARTING MOTOR...3219
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...3220
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER...3221
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...3221
CHECK OPERATING CONDITION OF COMPRESSOR...3222
EVERY 5000 HOURS MAINTENANCE...3223
CHANGE OIL IN HYDRAULIC TANK...3223
EVERY 8000 HOURS MAINTENANCE...3224
REPLACE HIGH-PRESSURE PIPING CLAMP...3224
REPLACE FUEL SPRAY PREVENTION CAP...3224
SPECIFICATIONS...3225
SPECIFICATIONS...3226
ATTACHMENTS, OPTIONS...3228
GENERAL PRECAUTIONS FOR SAFETY...3229
PRECAUTIONS WHEN SELECTING...3229
READ THE INSTRUCTION MANUAL THOROUGHLY...3229
PRECAUTIONS WHEN REMOVING OR INSTALLING...3229
PRECAUTIONS WHEN USING...3229
BUCKET WITH HOOK...3230
HOOK CONDITION...3230
PROHIBITED OPERATIONS...3230
MACHINE READY FOR ATTACHMENT...3231
LOCATIONS...3231
HYDRAULIC CIRCUIT...3235
ATTACHMENT REMOVAL AND INSTALLATION...3242
ATTACHMENT OPERATIONS...3246
LONG TERM STORAGE...3249
SPECIFICATIONS...3249
ATTACHMENT GUIDE...3250
ATTACHMENT COMBINATIONS...3250
TRACK SHOES SELECTION...3251
BUCKET TEETH SELECTION...3252
RECOMMENDED ATTACHMENT OPERATIONS...3253
HYDRAULIC BREAKER...3253
HANDLING MACHINES EQUIPPED WITH KOMTRAX...3257
BASIC PRECAUTIONS...3257
INDEX...3258
Komatsu Hydraulic Excavator PC270, PC270LC Repair Service Manuals
