Komatsu PC270LC-7L Galeo Hydraulic Excavator Service Repair Shop Manual (A86001 and up) - CEBM005903

This complete service repair workshop manual PDF download for the PC270LC-7L Galeo Komatsu Hydraulic Excavator (SN: A86001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : PC270LC-7L
Serial Numbers : A86001 and up


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM005903
Total Pages : 678


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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FOREWORD
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
PRECAUTIONS DURING WORK
GENERAL
HOW TO READ THE SHOP MANUAL
VOLUMES
DISTRIBUTION AND UPDATING
FILING METHOD
REVISED EDITION MARK
REVISIONS
SYMBOLS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
COATING MATERIALS
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
TIGHTENING TORQUE OF HOSE NUTS
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
TIGHTENING TORQUE FOR FLARED NUTS
ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE

01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
WORKING RANGES
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE AND FUNCTION
ENGINE RELATED PARTS
RADIATOR • OIL COOLER • AFTERCOOLER
POWER TRAIN
FINAL DRIVE
SWING MACHINERY
SWING CIRCLE
TRACK FRAME • RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
TRIPLE GROUSER SHOE
HYDRAULIC EQUIPMENT LAYOUT DRAWING
HYDRAULIC TANK
HYDRAULIC PUMP
HPV95 + 95
LS VALVE
PC VALVE
LS(PC)-EPC VALVE
CONTROL VALVE
SELF PRESSURE REDUCING VALVE
MAIN RELIEF VALVE
VARIABLE PRESSURE COMPENSATION VALVE
CLSS
SWING MOTOR
RELIEF VALVE PORTION
REVERSE PREVENTION VALVE
CENTER SWIVEL JOINT
TRAVEL MOTOR
MOTOR OPERATION
PARKING BRAKE OPERATION
BRAKE VALVE OPERATION
TRAVEL JUNCTION VALVE
TRAVEL PPC SHUTTLE VALVE
VALVE CONTROL
WORK EQUIPMENT • SWING PPC VALVE
TRAVEL PPC VALVE
SERVICE VALVE
SOLENOID VALVE
PPC ACCUMULATOR
RETURN OIL FILTER
FOR BREAKER
BOOM HYDRAULIC DRIFT PREVENTION VALVE
LIFT CHECK VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
HYDRAULIC CYLINDERS
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
WORK EQUIPMENT
DIMENSION OF ARM
DIMENSION OF BUCKET
AIR CONDITIONER
PIPING
ENGINE CONTROL
FUEL CONTROL DIAL
GOVERNOR MOTOR
ENGINE THROTTLE AND PUMP CONTROLLER
INPUT AND OUTPUT SIGNALS
ELECTRONIC CONTROL SYSTEM
TOTAL SYSTEM DIAGRAM
MULTI MONITOR SYSTEM
MONITOR PANEL
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION
MAINTENANCE FUNCTION
SENSORS
ENGINE OIL LEVEL SENSOR
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)
COOLANT TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
FUEL LEVEL SENSOR
AIR CLEANER CLOGGING SENSOR

20 TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLES
ENGINE
CHASSIS
TESTING AND ADJUSTING
SERVICE TOOLS
ENGINE
COMPRESSION PRESSURE
BLOW-BY PRESSURE
OIL PRESSURE
RPM
SPEED SENSOR
EXHAUST GAS COLOR
FUEL INJECTION TIMING
VALVE CLEARANCE
BELT TENSION - AIR COMPRESSOR
EMERGENCY ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
SWING CIRCLE BEARINGS
TRACK SHOE TENSION
SPROCKET
OIL PRESSURE
WORK EQUIPMENT, SWING AND TRAVEL
CONTROL CIRCUIT
PUMP PC CONTROL CIRCUIT
PUMP LS CONTROL CIRCUIT
SOLENOID VALVE OUTPUT PRESSURE
PPC VALVE OUTPUT PRESSURE
WORK EQUIPMENT AND SWING PPC VALVE
WORK EQUIPMENT - HYDRAULIC DRIFT
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
OIL LEAKAGE
AIR BLEEDING OF VARIOUS PARTS
DIODE INSPECTION PROCEDURES
MULTI-MONITOR PANEL
TABLE FOR SERVICE AND FAILURE CODE NUMBERS
SERVICE MENU
WAY OF SWITCHING TO SERVICE MENU
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARATIONS
PM TUNE UP SERVICE
TROUBLESHOOTING GENERAL
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION OF TROUBLESHOOTING
STEPS FOR TROUBLESHOOTING
FAILURE-LOOKING PHENOMENON AND TROUBLESHOOTING NO.
CONNECTOR LOCATION CHART
CONNECTOR TABLE
CONNECTOR LOCATION DIAGRAM
ELECTRICAL CIRCUIT DIAGRAMS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF
USER CODE MEMORY RETENTION FUNCTION
INFORMATION CONTAINED IN TESTING PROCEDURES
(E101) ABNORMAL DATA IN ERROR HISTORY
(E112) SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION
(E113) SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION
(E114) SHORT OR OPEN IN WINDOW WASHER SYSTEM
(E115) ABNORMAL WINDSHIELD WIPER MOTION
(E116) ABNORMALITY IN PARKING WIPER ARM
(E201) SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID
(E203) SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM
(E204) SHORT IN MERGE/DIVIDE SOLENOID
(E205) SHORT IN 2 STAGE RELIEF SOLENOID
(E206) SHORT IN TRAVEL SPEED SHIFT SOLENOID
(E211) OPEN IN TRAVEL INTERLOCKING SOLENOID
(E213) OPEN IN SWING PARKING BRAKE SOLENOID
(E214) OPEN OF MERGE/DIVIDE SOLENOID
(E215) OPEN IN 2 STAGE RELIEF SOLENOID
(E216) OPEN IN TRAVEL SPEED SOLENOID
(E217) ABNORMAL INPUT FOR MODEL CODE
(E218) OPEN IN S-NET SIGNAL
(E222) SHORT IN LS-EPC SOLENOID
(E223) OPEN IN LS-EPC SOLENOID SYSTEM
(E224) ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL
(E225) ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL
(E226) ABNORMAL PRESSURE SENSOR POWER SUPPLY
(E227) ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER
(E228) SHORT IN ATTACHMENT RETURN SWITCHING RELAY
(E232) SHORT IN PC-EPC SOLENOID
(E233) OPEN IN PC-EPC SOLENOID SYSTEM
(E238) OPEN IN ATTACHMENT RETURN SWITCH RELAY
(E245) SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM
(E246) OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM
(E256) INCORRECT NON-VOLATILE MEMORY DATA
(E306) ABNORMAL GOVERNOR POTENTIOMETER SIGNALS
(E308) ABNORMAL FUEL DIAL SIGNALS
(E315) SHORT IN BATTERY RELAY SYSTEM
(E316) STEP OUT IN GOVERNOR MOTOR
(E317) OPEN IN GOVERNOR MOTOR PHASE "A" AND "B"
(E318) SHORT IN GOVERNOR MOTOR PHASE "A" AND "B"
(E501) MODEL SELECTION FUNCTION NOT PROVIDED
(E502) MODEL SELECTING SIGNAL FAULT
(A000N1) ENGINE SPEED OUT OF RANGE AT HIGH IDLE
(A000N2) ENGINE SPEED OUT OF RANGE AT LOW IDLE
(AA10NX) AIR CLEANER CLOG INDICATOR FAILURE
(AB00KE) LOW CHARGING VOLTAGE INDICATED
(B@BAZG) ABNORMAL ENGINE OIL PRESSURE
(B@BAZK) ABNORMAL ENGINE OIL LEVEL
(B@BCNS) ENGINE COOLANT INDICATING OVERHEAT CONDITION
(B@BCZK) ABNORMAL COOLANT LEVEL INDICATION
(B@HANS) HYDRAULIC OIL OVERHEAT INDICATION
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E-MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF
USER CODE MEMORY RETENTION FUNCTION
INFORMATION CONTAINED IN TESTING PROCEDURES
(E-1) ENGINE WILL NOT CRANK
(E-2) ENGINE STOPS WHILE IN OPERATION
(E-3) ENGINE SPEED IRREGULAR, OR HUNTING
(E-4) ENGINE DOES NOT STOP
(E-5) AUTO DECELERATOR DOES NOT WORK
(E-6) AUTO ENGINE WARM UP DEVICE DOES NOT WORK
(E-7) COLD START PREHEATER DOES NOT WORK
(E-8) ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE
(E-9) ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE
(E-10) NO DISPLAY ON MONITOR PANEL
(E-11) PART OF DISPLAY ON MONITOR PANEL IS MISSING
(E-12) MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL
(E-13) FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL
(E-14) ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY
(E-15) HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY
(E-16) FUEL GAUGE DOES NOT DISPLAY CORRECTLY
(E-17) SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY
(E-18) WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS
(E-19) WINDSHIELD WIPER DOES NOT WORK
(E-20) ALARM BUZZER CANNOT BE CANCELLED
(E-21) BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR
(E-22) BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR
(E-23) ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR
(E-24) ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR
(E-25) BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR
(E-26) BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR
(E-27) SWING NOT CORRECTLY DISPLAYED ON MONITOR
(E-28) TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR
(E-29) TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR
(E-30) SERVICE NOT CORRECTLY DISPLAYED ON MONITOR
(E-31) AIR CONDITIONER SYSTEM DOES NOT WORK
(E-32) TRAVEL ALARM DOES NOT SOUND
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM H-MODE
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP
H-5 AUTO-DECELERATOR DOES NOT WORK
H-6 FINE CONTROL MODE DOES NOT FUNCTION
H-7 BOOM MOVES SLOWLY OR LACKS POWER
H-8 ARM MOVES SLOWLY OR LACKS POWER
H-9 BUCKET MOVES SLOWLY OR LACKS POWER
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION
H-11 WORK EQUIPMENT HAS TO MUCH HYDRAULIC DRIFT
H-12 WORK EQUIPMENT HAS BIG TIME LAG
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT
H-14 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY
H-18 MACHINE SWERVES IN TRAVEL
H-19 MACHINE TRAVELS SLOWLY
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST.
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)
H-23 MACHINE DOES NOT SWING
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-26 THERE IS A SHOCK WHEN STOPPING SWING
H-27 THERE IS ABNORMAL NOISE CAUSED WHEN STOPPING SWING
H-28 SWING NATURAL DRIFT IS TOO BIG

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS DURING OPERATION
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
OTHER PRECAUTIONS
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
ENGINE
ALTERNATOR
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE OIL COOLER
ENGINE REAR SEAL
FUEL INJECTION PUMP
NOZZLE HOLDER
STARTING MOTOR
THERMOSTAT
TURBOCHARGER
WATER PUMP
RADIATOR
REMOVAL
INSTALLATION
HYDRAULIC OIL COOLER
REMOVAL
INSTALLATION
ENGINE AND HYDRAULIC PUMPS
REMOVAL
INSTALLATION
FINAL DRIVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING MOTOR AND SWING MACHINERY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER
ASSEMBLY
TRACK ROLLER
ASSEMBLY
IDLER
DISASSEMBLY
ASSEMBLY
RECOIL SPRING
DISASSEMBLY
ASSEMBLY
SPROCKET
REMOVAL
INSTALLATION
TRACK SHOE
EXPANSION OF TRACK SHOE
ASSEMBLY
SWING CIRCLE
REMOVAL
INSTALLATION
REVOLVING FRAME
REMOVAL
INSTALLATION
CENTER SWIVEL JOINT
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC TANK
REMOVAL
INSTALLATION
CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC PUMP
REMOVAL
INSTALLATION
HYDRAULIC PUMP INPUT SHAFT - OIL SEAL
REMOVAL
INSTALLATION
PPC VALVE
WORK EQUIPMENT
ASSEMBLY
TRAVEL
ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
AIR CONDITIONER
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
CAB
REMOVAL
INSTALLATION
MONITOR
REMOVAL
INSTALLATION
GOVERNOR PUMP CONTROLLER
REMOVAL
INSTALLATION

90 OTHERS
ELECTRICAL
CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3)
CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3)
CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3)
CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1)
CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2)
CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2)
CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2)
CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2)
HYDRAULIC
DIAGRAM (SHEET 1 OF 3)
DIAGRAM (SHEET 2 OF 3)
DIAGRAM (SHEET 3 OF 3)

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