Komatsu PC150-3 PC150LC-3 PC150-5 PC150LC-5 Hydraulic Excavator Workshop Repair Service Manual PDF - MKMTSPC150PC150LC.zip

A full service and repair manual featuring Electrical Wiring Diagrams for the Komatsu Hydraulic Excavator PC150-3, PC150LC-3, PC150-5, and PC150LC-5, containing every technical detail needed to service, troubleshoot, and rebuild these machines the way professional technicians do.

Covered inside the Komatsu Hydraulic Excavator PC150-3, PC150LC-3, PC150-5, PC150LC-5 workshop service repair manual:

* 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

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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