Komatsu PC150-6K, PC150LC-6K Hydraulic Excavators Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu PC150-6K, PC150LC-6K Hydraulic Excavator, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu PC150-6K, PC150LC-6K Hydraulic Excavator 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: 2,095 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM001601 - Hydraulic Excavator PC150-6K, PC150LC-6K Shop Manual.pdf
UEBD000701 - Hydraulic Excavator PC150-6K, PC150LC-6K Shop Manual.pdf
EEAM008801 - Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual.pdf
UEAD000401 - Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual.pdf
UEAM000403 - Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...6
SAFETY NOTICE...6
FOREWORD...8
GENERAL...8
HOW TO READ THE SHOP MANUAL...9
HOISTING INSTRUCTIONS...10
COATING MATERIALS...11
STANDARD TIGHTENING TORQUE...12
ELECTRIC WIRE CODE...14
CONVERSION TABLE...15
01 GENERAL...22
SPECIFICATIONS...23
SPECIFICATON DRAWINGS...26
WEIGHT TABLE...27
FUEL, COOLANT AND LUBRICANTS...29
10 STRUCTURE AND FUNCTION...32
ENGINE RELATED PARTS...33
RADIATOR ? OIL COOLER...34
POWER TRAIN...35
FINAL DRIVE...36
SWING CIRCLE...37
SWING MACHINERY...38
TRACK FRAME, RECOIL SPRING...40
TRACK SHOE...41
HYDRAULIC CIRCUIT DIAGRAM...44
HYDRAULIC TANK...45
HYDRAULIC PUMP...47
CONTROL VALVE...54
CLSS...60
SWING MOTOR...97
CENTER SWIVEL JOINT...99
TRAVEL MOTOR...100
VALVE CONTROL...108
WORK EQUIPMENT - SWING PPC VALVE...109
TRAVEL PPC PEDAL...113
TRAVEL PPC VALVE PEDAL...117
SAFETY LOCK VALVE...120
PPC ACCUMULATOR...120
PPC SHUTTLE ? TRAVEL JUNCTION VALVE...121
EPC ? SOLENOID VALVE...128
HYDRAULIC CYLINDER...133
ADDITIONAL FILTER FOR BREAKING...135
BOOM HOLDING VALVE...136
WORK EQUIPMENT...143
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...144
ENGINE CONTROL SYSTEM...145
ELECTRONIC CONTROL SYSTEM...151
MACHINE MONITOR SYSTEM...175
20 TESTING AND ADJUSTING...187
TABLE OF JUDGEMENT STANDARD VALUE...188
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...198
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSORR...206
ADJUSTING ENGINE SPEED SENSOR...207
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...208
TESTING CLEARANCE OF SWING CIRCLE BEARING...210
TESTING AND ADJUSTING TRACK SHOE TENSION...211
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...212
TESTING AND ADJUSTING TVC VALVE OUTPUT (SERVO PISTON INPUT PRESSURE)...220
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL...222
TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE...225
TESTING AND ADJUSTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE...227
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...229
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...231
TESTING TRAVEL DEVIATION...232
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...233
MEASURING OIL LEAKAGE...235
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...237
BLEEDING AIR...238
TROUBLESHOOTING...241
POINTS TO REMEMBER WHEN TROUBLESHOOTING...242
SEQUENCE OF EVENTS IN TROUBLESHOOTING...243
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...244
CHECKS BEFORE TROUBLESHOOTING...251
CONNECTOR TYPES AND MOUNTING LOCATIONS...252
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...257
EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM...270
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...271
METHOD OF USING JUDGEMENT TABLE...279
METHOD OF USING TROUBLESHOOTING CHARTS...281
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...283
SERVICE CODE TABLE...288
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)...289
N-1 [E218] COMMUNICATION ABNOMALITY...290
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...292
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...293
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...294
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...298
ELECTRICAL CIRCUIT DIAGRAM OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) ...300
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...302
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...303
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...304
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED...305
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...306
E-6 [E315] ABNORMALITY (SHORT CIRCUIT IN BATTERY RELAY OUTPUT)...307
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED...308
E-8 ENGINE DOES NOT START...310
E-9 ENGINE SPEED IS IRREGULAR...312
A) IDLING SPEED IS IRREGULAR...312
B) THERE IS HUNTING...314
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...316
E-11 ENGINE DOES NOT STOP...318
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...320
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...323
METHOD OF USING TROUBLESHOOTING CHARTS...324
S-1 STARTING PERFORMANE IS POOR (STARTING ALWAYS TAKES TIME)...328
S-2 ENGINE DOES NOT START...329
(1) ENGINE DOES NOT RUN...329
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...330
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...331
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...332
S-4 ENGINE STOP DURING OPERATIONS...333
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...334
S-6 ENGINE LACKS OUTPUT (NO POWER)...335
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...336
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...337
S-9 OIL BECOMES CONTAMINATED QUICKLY...338
S-10 FUEL CONSUMPTION IS EXCESSIVE...339
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR LEVEL GOES DOWN...340
S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)...341
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...342
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...343
S-15 ABNORMAL NOISE IS MADE...344
S-16 VIBRATION IS EXCESSIVE...345
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)...346
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...347
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...348
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...354
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...356
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...358
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED...359
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED...361
C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...363
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...365
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...367
C-10 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...369
C-11 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENIOD SYSTEM IS DISPLAYED...370
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...371
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED...372
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...373
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...375
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS...376
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...377
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED...378
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...379
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)...381
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...383
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...385
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...386
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...387
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...388
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...389
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...390
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...391
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...392
F-9 BIT PATTERN 21-(3) SWING LOCK DOES NOT LIGHT UP...393
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...394
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP...395
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...396
TABLE OF FAILURE MODES AND CAUSES...397
ALL WORK EQUIPMENT, TRAVEL, SWING...401
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...401
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...403
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...404
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...404
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)...405
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...405
WORK EQUIPMENT...407
H-7 BOOM IS SLOW OR LACKS POWER...407
H-8 ARM IS SLOW OR LACKS POWER...409
H-9 BUCKET IS SLOW OR LACKS POWER...411
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE...412
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...412
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING...413
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...413
H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED...414
H-15 LACK OF POWER WHEN PRESSURE RISES...414
COMPOUND OPERATIONS...414
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...414
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...415
TRAVEL SYSTEM...416
H-20 TRAVEL DEVIATION...416
H-21 TRAVEL SPEED IS SLOW...417
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER...419
