Komatsu Hydraulic Excavator PC20, PC25, PC30, PC40, PC45 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC20-3, PC20-6, PC25-1, PC30-3, PC30-6, PC30-7, PC40-6, PC40-7, PC45-1, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC20-3, PC20-6, PC25-1, PC30-3, PC30-6, PC30-7, PC40-6, PC40-7, PC45-1 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: 1,522 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM020R0604 - Hydraulic Excavator PC20-6, PC30-6, PC40-6 Shop Manual.pdf
SEBM020S0707 - Hydraulic Excavator PC25-1, PC30-7, PC40-7, PC45-1 Shop Manual.pdf
SEBM0225C01 - Hydraulic Excavator PC20-3, PC30-3 Shop Manual.pdf
SEAM020P0700 - Hydraulic Excavator PC20-7 Operation & Maintenance Manual.pdf
SEAM006600 - Hydraulic Excavator PC25-1, PC30-7, PC40-7, PC45-1 Operation & Maintenance Manual.pdf
SEAM009502T - Hydraulic Excavator PC40-7 Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...5
SAFETY NOTICE...5
FOREWARD...7
GENERAL...7
HOW TO READ THE SHOP MANUAL...8
HOISTING INSTRUCTIONS...9
COATING MATERIALS...10
STANDARD TIGHTENING TORQUE...11
ELECTRIC WIRE CODE...13
CONVERSION TABLE...14
WEIGHT TABLE...21
WEIGHT TABLE...22
LIST OF LUBRICANT AND WATER...25
10 STRUCTURE AND FUNCTION...28
POWER TRAIN...29
SWING CIRCLE...30
SWING MACHINERY...31
TRACK FRAME AND RECOIL SPRING...33
HYDRAULIC PIPING...36
HYDRAULIC CIRCUIT DIAGRAM...37
HYDRAULIC TANK AND FUEL TANK...41
HYDRAULIC PUMP...42
CONTROL PUMP...50
7 - SPOOL CONTROL VALVE...51
2 - SPOOL CONTROL VALVE...55
SWING MOTOR...59
CENTER SWIVEL JOINT...62
TRAVEL MOTOR...63
HYDRAULIC CYLINDER...68
VALVE CONTROL...72
PPC VALVE...73
SOLENOID VALVE...79
WORK EQUIPMENT...81
HYDRAULIC BREAKER...82
ELECTRICAL CIRCUIT DIAGRAM...85
MONITOR SYSTEM...88
20 TESTING AND ADJUSTING...97
TABLE OF JUDGEMENT STANDARD VALUE...98
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...116
TOOL FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...118
ADJUSTING VALVE CLEARANCE...119
MEASURING COMPRESSION PRESSURE...121
ADJUSTING FUEL INJECTION TIMING...122
MEASURING ENGINE OIL PRESSURE...123
ADJUSTING FUEL CONTROL LEVER...125
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...126
TESTING CONTROL CIRCUIT PRESSURE...129
MEASURING OUTPUT PRESSURE OF PPC VALVE...130
ADJUSTING PPC VALVE...131
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...132
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE...134
ADJUSTING BLADE CONTROL LEVER...135
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...136
BLEEDING AIR FROM HYDRAULIC CIRCUIT...137
RELEASING REMAINING FROM HYDRAULIC CIRCUIT...139
TESTING HYDRAULIC BREAKER GAS PRESSURE...140
TROUBLESHOOTING...142
SEQUENCE OF EVENTS IN TROUBLESHOOTING...143
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...144
CHECKS BEFORE TROUBLESHOOTING...151
ELECTRICAL CIRCUIT DIAGRAM...152
POSITION OF CONNECTORS FOR TROUBLESHOOTING...155
CONNECTION TABLE FOR CONNECTOR...159
METHOD OF USING TROUBLESHOOTING CHARTS...166
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...168
E-1 THE ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF...169
E-2 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELEASED...172
E-3 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED...173
E-4 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS DEPRESSED...174
E-5 TRAVEL SPEED INCREASES EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS NOT DEPRESSED...175
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...176
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW...177
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...178
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW...179
a) NONE OF WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS SLOW...179
b) ONLY TRAVEL IS NORMAL, OR DROP IN SPEED IS COMPARATIVELY SMALL...180
H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER...180
H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...180
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW...181
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER...182
H-8 EXCESSIVE HYDRAULIC DRIFT...182
H-9 EXCESSIVE TIME LAG...182
H-10 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE...183
a) DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND REVERSE...183
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE...187
H-11 EXCESSIVE DEVIATION WHEN STARTING (PC30, 40)...188
H-12 TRAVEL LACKS POWER (OR SPEED IS SLOW)...189
H-13 TRAVEL SPEED DOES NOT SWITCH...190
H-14 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...190
H-15 TRAVEL LEVER IS HEAVY...191
H-16 DOES NOT SWING...191
H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR...193
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING...193
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING...194
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...194
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING...195
H-22 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING...196
TABLE OF FAILURE MODES AND CAUSES...197
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)...198
M-1 MONITOR PANEL DOES NOT WORK...199
M-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON, OR ALL LAMPS STAY...200
M-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...201
M-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...201
M-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING...202
M-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)...202
M-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...203
M-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING...203
M-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY...204
a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE...204
b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY. ENTERS RED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING...204
M-10 ABNORMALITY IN FUEL GAUGE DISPLAY...205
a) ALL SEGMENTS OF FUEL GAUGE GO OUT...205
b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN...205
c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED...206
M-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND...206
M-12 ABNORMALITY IN SERVICE METER DISPLAY...207
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING...207
b) SERVICE METER PILOT LAMP DOES NOT FLASH...207
M-13 NIGHT LIGHTING DOES NOT LIGHT UP...208
a) WHEN LAMP SWITCH IS AT POSITION 1 OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP...208
b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP IS NOT BLOWN BEFORE STARTING TROUBLESHOOTING...208
M-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)...209
TROUBLESHOOTING OF HYDRAULIC BREAKER...210
30 DISASSEMBLY AND ASSEMBLY...213
METHOD OF USING MANUAL...214
PRECAUTIONS WHEN CARRYING OUT OPERATION...215
SPECIAL TOOL LIST...217
WEIGHT TABLE...222
TIGHTENING TORQUES AND STANDARD VALUES TABLE...223
LUBRICANT AND COOLANT TABLE...224
ENGINE, HYDRAULIC PUMP ASSEMBLY...226
REMOVAL...226
INSTALLATION...229
HYDRAULIC PUMP ASSEMBLY...230
HYDRAULIC PUMP ASSEMBLY (PC30-7)...230
DISASSEMBLY...230
ASSEMBLY...232
HYDRAULIC PUMP ASSEMBLY (PC45-1)...238
DISASSEMBLY...238
ASSEMBLY...242
GEAR PUMP ASSEMBLY...249
DISASSEMBLY AND ASSEMBLY...249
CENTER SWIVEL JOINT ASSEMBLY...250
REMOVAL AND INSTALLATION...250
DISASSEMBLY AND ASSEMBLY...251
TRAVEL MOTOR ASSEMBLY ...252
TRAVEL MOTOR ASSEMBLY (PC25-1, PC30-7, PC40-7)...252
DISASSEMBLY...252
ASSEMBLY...258
TRAVEL MOTOR ASSEMBLY (PC45-1)...264
DISASSEMBLY...264
ASSEMBLY...273
SWING MOTOR ASSEMBLY...284
DISASSEMBLY...284
ASSEMBLY...286
SWING MACHINERY ASSEMBLY...290
DISASSEMBLY...290
ASSEMBLY...292
REVOLVING FRAME ASSEMBLY...294
REMOVAL AND INSTALLATION...294
RECOIL SPRING ASSEMBLY...295
DISASSEMBLY...295
ASSEMBLY...297
2 SPOOL CONTROL VALVE ASSEMBLY...300
DISASSEMBLY...300
ASSEMBLY...301
7 SPOOL CONTROL VALVE ASSEMBLY...302
DISASSEMBLY...302
ASSEMBLY...304
PPC VALVE ASSEMBLY...306
DISASSEMBLY...306
ASSEMBLY...307
HYDRAULIC CYLINDER ASSEMBLY...308
DISASSEMBLY...308
ASSEMBLY...310
WORK EQUIPMENT ASSEMBLY...312
REMOVAL AND INSTALLATION...312
BUCKET ASSEMBLY...313
REMOVAL AND INSTALLATION...313
HYDRAULIC BREAKER ASSEMBLY...314
REMOVAL AND INSTALLATION...314
DISASSEMBLY...315
ASSEMBLY...318
HYDRAULIC BREAKER BUSHING...322
REMOVAL...322
CHISEL...323
REMOVAL AND INSTALLATION...323
40 MAINTENANCE STANDARD...326
SWING CIRCLE...327
SWING MACHINERY...328
SPROCKET...330
TRACK FRAME AND RECOIL FRAME...333
IDLER...337
TRACK ROLLER...343
CARRIER ROLLER...349
TRACK SHOE...351
HYDRAULIC PUMP...355
7 SPOOL CONTROL VALVE...357
2 SPOOL CONTROL VALVE...359
SWING MOTOR...360
CENTER SWIVEL JOINT...361
PPC VALVE...362
HYDRAULIC CYLINDER...365
WORK EQUIPMENT...369
HYDRAULIC BREAKER...373
PISTON, CHISEL...375
MAIN MENU...0
COVER...1
1. FOREWORD...2
2. SAFETY INFORMATION...3
3. INTRODUCTION...4
3.1 INTENDED USE...4
3.2 FEATURES...4
3.3 BREAKING IN THE MACHINE...4
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...5
4.1 MACHINE SERIAL NO. PLATE POSITION...5
4.2 ENGINE SERIAL NO. PLATE POSITION...5
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...5
CONTENTS...6
SAFETY...10
6. GENERAL PRECAUTIONS...11
7. PRECAUTIONS DURING OPERATION...16
7.1 BEFORE STARTING ENGINE...16
7.2 OPERATING MACHINE...18
7.3 TRANSPORTATION...23
7.4 BATTERY...24
7.5 TOWING...25
7.6 BUCKET WITH HOOK...26
8. PRECAUTIONS FOR MAINTENANCE...29
8.1 BEFORE CARRYING OUT MAINTENANCE...29
8.2 DURING MAINTENANCE...32
9. POSITION FOR ATTACHING SAFETY LABELS...36
OPERATION...40
10. GENERAL VIEW...41
10.1 GENERAL VIEW OF MACHINE...41
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...42
11. EXPLANATION OF COMPONENTS...43
11.1 MACHINE MONITOR...43
11.2 SWITCHES...48
11.3 CONTROL LEVERS AND PEDALS...51
11.4 ENGINE HOOD...55
11.5 FRONT WINDOW (MACHINES EQUIPPED WITH CAB)...56
11.6 DOOR LOCK...58
11.7 FUSE...59
11.8 FUSIBLE LINK...59
11.9 CAP, COVER WITH LOCK...60
11.10 CANOPY (MACHINES EQUIPPED WITH CANOPY)...61
12. OPERATION...62
12.1 CHECK BEFORE STARTING ENGINE...62
12.2 STARTING ENGINE...70
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...72
12.4 MOVING MACHINE OFF...74
12.5 STEERING MACHINE...77
12.6 STOPPING MACHINE...79
12.7 SWINGING...80
12.8 OPERATION OF WORK EQUIPMENT...81
