PC270LC-6LE HYDRAULICEXCAVATOR
MACHINEMODELSERIALNUMBERS
PC270LC-6LEA83001andup
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PRODUCTPUBLICATIONSINFORMATION
PC270LC-6
VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOP MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALS INFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
COMPLETEFORM ANDRETURNTOKomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications FaxNo.(847)970-4186
TelNo.(847)970-5887
COMPANYNAME
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONSPREPARATIONSFORWORK
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthe OperationandMaintenanceManualcarefullyBEFOREmachineonhard,levelground,andblockthewheels operatingthemachine.ortrackstopreventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readall
8.Beforestartingwork,lowerblade,ripper,bucketor theprecautionsgivenonthedecalswhicharefixedtoanyotherworkequipmenttotheground.Ifthisisnot themachine.possible,insertthesafetypinoruseblockstoprevent
2.Whencarryingoutanyoperation,alwayswearsafetytolockallthecontrolleversandhangwarningsigns shoesandhelmet.Donotwearlooseworkclothes,onthem. orclotheswithbuttonsmissing.
9.Whendisassemblingorassembling,support Alwaysthe wearsafetyglasseswhenhittingpartswith ahammer.
theworkequipmentfromfalling.Inaddition,besure machinewithblocks,jacksorstandsbeforestarting work.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.10.Removeallmudandoilfromthestepsorother
placesusedtogetonandoffthemachine.Always
3.Ifweldingrepairsareneeded,alwayshaveatrained,usethehandrails,laddersorstepswhengettingonor experiencedweldercarryoutthework.Whenoffthemachine.Neverjumponoroffthemachine. carryingoutweldingwork,alwayswearweldingIfitisimpossibletousethehandrails,laddersor gloves,apron,glasses,capandotherclothessuitedsteps,useastandtoprovidesafefooting. forweldingwork.
PRECAUTIONSDURINGWORK
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure11.Whenremovingtheoilfillercap,drainplugor beforestarting.Alwaysinformyourfellowworkershydraulicpressuremeasuringplugs,loosenthem beforestartinganystepoftheoperation.Beforeslowlytopreventtheoilfromspurtingout.Before startingwork,hangUNDERREPAIRsignsonthedisconnectingorremovingcomponentsoftheoil, controlsintheoperator'scompartment.wateroraircircuits,firstremovethepressure
completelyfromthecircuit.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.12.Thewaterandoilinthecircuitsarehotwhenthe
engineisstopped,sobecarefulnottogetburned.
6.DecideaplaceintherepairworkshoptokeeptoolsWaitfortheoilandwatertocoolbeforecarryingout andremovedparts.Alwayskeepthetoolsandpartsanyworkontheoilorwatercircuits. intheircorrectplaces.Alwayskeeptheworkarea cleanandmakesurethatthereisnodirtoroilonthe13.Beforestartingwork,removetheleadsfromthe floor.Smokeonlyintheareasprovidedforsmoking.battery.ALWAYSremovetheleadfromthenegative Neversmokewhileworking.(-)terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipment whichhasamplecapacity.Installthelifting equipmentatthecorrectplaces.Useahoistorcrane andoperateslowlytopreventthecomponentfrom hittinganyotherpart.Donotworkwithanypartstill raisedbythehoistorcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnottobreak ordamagethewiring.Damagedwiringmaycause electricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Fueloroilonthefloorisflammableand slippery,ahealthandsafetyhazard.Cleanupany spilledfueloroilimmediately.
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofflammable liquidswhencleaningelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesurethat theyarenottwisted.Damagedtubesaredangerous, sobeextremelycarefulwheninstallingtubesforhigh pressurecircuits.Alsocheckthatconnectingparts arecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtina hole.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurements.
24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyonestand ateitherendofthetrack.
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingof thestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemade atcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealso includedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMESREVISEDEDITIONMARK
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engineelectricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributors.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume):
10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberfor eachitem
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example: 10-4
10-4-1Addedpages10-4-2 10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety Specialsafetyprecautionsare necessarywhenperformingthe work.
Caution
Weight
Tightening torque
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhenperformingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecialattention fortighteningtorqueduring assembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,water
Placeswhereoil,waterorfuelmust beadded,andthecapacity.
DrainPlaceswhereoilorwatermustbe drained,andquantitytobedrained.