Komatsu Hydraulic Excavator PC150, PC150LC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC150-3, PC150LC-3, PC150-5, PC150LC-5, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC150-3, PC150LC-3, PC150-5, PC150LC-5 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.
PRODUCT DETAILS:
Total Pages: 1,575 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM021K0304 - Hydraulic Excavator PC150-3, PC150LC-3 Shop Manual.pdf
SEBM021K0502 - Hydraulic Excavator PC150-5 Shop Manual.pdf
SEBMA021KD500 - Hydraulic Excavator PC150LC-5 Shop Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
10 STRUCTURE AND FUNCTION...17
POWER TRAIN...18
FINAL DRIVE...19
SWING CIRCLE...20
SWING MACHINERY...21
TRACK FRAME...22
IDLER...23
IDLER CUSHION...23
CARRIER ROLLER...24
TRACK ROLLER...24
TRACK SHOE...25
HYDRAULIC PIPING...27
HYDRAULIC CIRCUIT DIAGRAM...28
HYDRAULIC TANK...29
OLSS (OPEN CENTER LOAD SENSING SYSTEM)...30
HYDRAULIC PUMP...32
L.H. 6-SPOOL CONTROL VALVE...51
R.H. 5-SPOOL CONTROL VALVE...54
SWING MOTOR...57
CENTER SWIVEL JOINT...60
TRAVEL MOTOR...61
VALVE CONTROL...68
PPC VALVE...69
ACCUMULATOR...73
SAFETY LOCK VALVE...73
SOLENOID VALVE...74
SHUTTLE VALVE...78
BOOM HOLDING VALVE...79
HYDRAULIC CYLINDER...82
ELECTRICAL WIRING DIAGRAM...84
ELECTRICAL CIRCUIT DIAGRAM...86
ENGINE CONTROL SYSTEM...88
PEMC SYSTEM...99
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)...126
20 TESTING AND ADJUSTING...133
TABLE OF JUDGEMENT STANDARD VALUE...134
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...146
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...157
ADJUSTING VALVE CLEARANCE...158
MEASURING COMPRESSION PRESSURE...159
TESTING AND ADJUSTING FUEL INJECTION TIMING...160
ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER...161
ADJUSTING ENGINE SPEED SENSOR...162
ADJUSTING TRAVEL LIMIT SWITCH...162
INSPECTION OF SWING CIRCLE BEARING CLEARANCE...163
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...164
TESTING AND ADJUSTING CHARGING PUMP PRESSURE...166
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE...168
MEASURING STROKE OF SERVO PISTON...175
TESTING AND ADJUSTING TRAVEL DEVIATION...176
MEASURING OUTPUT PRESSURE OF PPC VALVE...178
ADJUSTING PPC VALVE...179
TESTING PPC SHUTTLE VALVE...180
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE...181
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...182
BLEEDING AIR...184
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...186
TROUBLESHOOTING...187
POINTS TO REMEMBER WHEN TROUBLESHOOTING...188
SEQUENCE OF EVENTS IN TROUBLESHOOTING...189
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...190
CHECKS BEFORE TROUBLESHOOTING...197
ELECTRICAL CIRCUIT DIAGRAM...198
POSITION OF CONNECTORS FOR TROUBLESHOOTING...201
CONNECTION TABLE FOR CONNECTOR...203
HANDLING CONNECTORS...211
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM...212
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER...215
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE...219
METHOD OF USING JUDGEMENT TABLE...222
METHOD OF USING TROUBLESHOOTING CHARTS...224
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)...226
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS...227
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM...228
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)...229
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED...231
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED...232
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED...233
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED...234
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED...236
E-7 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED...237
E-8 ENGINE DOES NOT START...239
E-9 ENGINE ROTATION IS IRREGULAR...241
a) IDLING ROTATION IS IRREGULAR...241
b) THERE IS HUNTING...243
E-10 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW)...245
E-11 ENGINE DOES NOT STOP...247
E-12 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE...249
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)...250
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS...251
C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP...252
C-2 [01] [SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED...253
C-3 [03] [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED...254
C-4 [04] [SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED...255
C-5 [05] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED...256
C-6 [07] [SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED...257
C-7 [08] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1) ] IS DISPLAYED...258
C-8 [09] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (2) ] IS DISPLAYED...259
C-9 [11] [DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED...260
C-10 [13] [DISCONNECTION IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED...261
C-11 [14] [DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED...262
C-12 [15] [DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED...263
C-13 [17] [DISCONNECTION IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED...264
C-14 [18] [DISCONNECTION IN TVC SOLENOID SYSTEM] IS DISPLAYED...265
C-15 [21] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED...266
C-16 [22] [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED...267
C-17 [23] [ABNORMALITY IN PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED...268
C-18 [25] [ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED...270
C-19 [26] [ABNORMALITY DISCONNECTION IN WIRING IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED...271
C-20 [28] [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED...272
C-21 [29] [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED...273
C-22 [88] [CONTROLLER ABNORMAL SYSTEM] IS DISPLAYED...274
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)...275
F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P1] [WORK EQUIPMENT OIL PRESSURE SWITCH]...276
F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P2] [SWING OIL PRESSURE SWITCH]...277
F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P6] [TRAVEL LIMIT SWITCH]...278
F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [b5] [SWING LOCK SWITCH]...279
F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Hi] OR [Lo] [TRAVEL SPEED SWITCH]...280
F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Ad] [AUTO-DECELERATION SWITCH]...281
F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [88] [DECIMAL POINT OF ENGINE SPEED SENSOR]...282
F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH...283
F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH...284
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...285
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW...286
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...288
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW...290
H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER...292
H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH...292
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...293
H-7 AUTO-DECELERATION DOES NOT ACTUATED...293
H-8 BOOM, ARM SPEED IS EXTREMELY SLOW...294
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW...295
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER...297
H-11 EXCESSIVE HYDRAULIC DRIFT...297
H-12 EXCESSIVE TIME LAG...299
H-13 DOES NOT ENTER FINISHING OPERATION (F.O) MODE...299
H-14 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE...300
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE...300
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE...302
H-15 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS...303
H-16 EXCESSIVE DEVIATION WHEN STARTING...304
H-17 TRAVEL LACKS POWER (OR SPEED IS SLOW)...306
H-18 TRAVEL SPEED DOES NOT SWITCH...306
H-19 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...307
H-20 TRAVEL LEVER IS HEAVY...307
H-21 DOES NOT SWING...308
H-22 SWING SPEED IS SLOW OR ACCELERATION IS POOR...310
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...311
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING...311
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...312
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING...312
H-27 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW...312
TABLE OF FAILURE MODES AND CAUSES...313
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...314
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON...315
a) NO MONITOR PANEL LAMPS LIGHT UP...315
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP...315
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT...316
P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED)...317
a) COOLANT LEVEL FLASHES...317
b) ENGINE OIL LEVEL FLASHES...318
P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP...319
P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH...320
a) ALTERNATOR SYSTEM...320
b) ENGINE OIL PRESSURE SYSTEM...320
P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH...321
P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE)...322
a) ENGINE OIL PRESSURE FLASHES...322
b) COOLANT LEVEL FLASHES...322
c) COOLANT TEMPERATURE FLASHES...323
d) CHARGE FLASHES...323
e) FUEL LEVEL FLASHES...324
P-8...325
(a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND...325
(b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS...325
P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)...326
P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE...327
P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION,ON LEVEL OF GAUGE IS DISPLAYED)...327
P-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL...328
P-13 FUEL GAUGE GIVES NO DISPLAY...328
P-14...329
(a) LAMPS DO NOT LIGHT UP...329
(b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NO OPERATED...329
P-15 ...331
(a) WIPERS DO NOT WORK...331
(b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED...331
P-16...333
(a) FAN DOES NOT WORK...333
(b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED...333
P-17 WORKING MODE DOES NOT SWITCH...335
P-18 POWER SET DOES NOT SWITCH...336
P-19 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED)...337
