Komatsu Hydraulic Excavator PC20MR Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC20MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC20MR-2 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: 886 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...6
SAFETY NOTICE...6
FOREWORD...8
GENERAL...8
HOISTING INSTRUCTIONS...10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...11
COATING MATERIALS...13
STANDARD TIGHTENING TORQUE...15
ELECTRIC WIRE CODE...18
CONVERSION TABLE...19
UNITS...25
01 GENERAL...26
SPECIFICATION DIMENSION DRAWING...27
WORKING RANGE DRAWING...28
SPECIFICATIONS...29
WEIGHT TABLE...32
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS...34
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...36
PTO...37
COOLING SYSTEM...39
POWER TRAIN...41
SWING CIRCLE...42
TRACK FRAME...43
IDLER CUSHION...44
IDLER...45
TRACK ROLLER...47
CARRIER ROLLER...48
SPROCKET...49
TRACK SHOE...50
HYDRAULIC COMPONENTS LAYOUT DRAWING...51
HYDRAULIC TANK...52
CENTER SWIVEL JOINT...53
TRAVEL MOTOR...54
HYDRAULIC CYLINDER...63
SOLENOID VALVE...66
MULTI-CONTROL VALVE (IF EQUIPPED)...69
HYDRAULIC PUMP...71
CONTROL VALVE...77
CLSS...90
OPERATION FOR EACH FUNCTION AND VALVE...93
SWING MOTOR...113
PPC VALVE...123
WORK EQUIPMENT...132
DIMENSIONS OF EACH PART OF WORK EQUIPMENT...135
FLOOR...138
ENGINE CONTROL...139
ELECTRIC CONTROL SYSTEM...141
COMPONENT PART OF SYSTEM...146
MONITOR SYSTEM...147
MONITOR PANEL...148
SENSORS...150
20 TESTING AND ADJUSTING...152
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...153
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...154
TESTING AND ADJUSTING...164
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS...165
MEASURING ENGINE SPEED...167
MEASUREMENT OF EXHAUST GAS COLOR...168
ADJUSTING VALVE CLEARANCE...169
MEASURING COMPRESSION PRESSURE...170
MEASURING ENGINE OIL PRESSURE...171
TESTING AND ADJUSTING FUEL INJECTION TIMING...172
BLEEDING AIR FROM FUEL CIRCUIT...174
TESTING AND ADJUSTING FAN BELT TENSION...175
ADJUSTING FUEL CONTROL LEVER LINKAGE...176
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...177
TESTING AND ADJUSTING TRACK SHOE TENSION...178
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, SWING, AND BLADE CIRCUITS...180
MEASURING CONTROL CIRCUIT BASIC PRESSURE...183
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE...184
MEASURING SOLENOID VALVE OUTPUT PRESSURE...186
MEASURING PPC VALVE OUTPUT PRESSURE...188
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...190
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE...190
MEASURING OF OIL LEAKAGE FROM CYLINDER...192
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...194
BLEEDING AIR FROM CYLINDER...194
PRESSURIZING HYDRAULIC TANK...195
HOW TO OPEN AND CLOSE (TILT) FLOOR...196
INSPECTION PROCEDURES FOR DIODE...198
TROUBLESHOOTING...200
POINTS TO REMEMBER WHEN TROUBLESHOOTING...201
SEQUENCE OF EVENTS IN TROUBLESHOOTING...202
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...203
CHECKS BEFORE TROUBLESHOOTING...211
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING...212
CONNECTORS LIST AND STEREOGRAM...215
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...223
T-ADAPTER-BOXES AND T-ADAPTER TABLE...246
TROUBLESHOOTING OF ELECTRICAL SYSTEM (EXCEPT MONITOR PANEL E-MODE)...250
BEFORE STARTING E-MODE TROUBLESHOOTING...251
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...253
E-1 ENGINE DOES NOT START...254
E-2 ENGINE DOES NOT STOP...260
E-3 WHEN SAFETY LOCK LEVER IS IN FREE POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE SYSTEMS DO NOT WORK...262
E-4 WHEN SAFETY LOCK LEVER IS IN LOCK POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING AND BLADE SYSTEMS WORK...265
E-5 WHEN MACHINE STARTS TRAVELING, TRAVEL ALARM DOES NOT SOUND...267
E-6 WHEN MACHINE STOPS TRAVELING, TRAVEL ALARM DOES NOT STOP SOUNDING...269
E-7 WINDSHIELD WIPER DOES NOT OPERATE [CAB SPECIFICATION]...271
E-8 WINDSHIELD WASHER DOES NOT OPERATE [CAB SPECIFICATION]...273
E-9 HEATER DOES NOT OPERATE...275
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...278
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...279
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW...280
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS...283
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK ...284
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP...287
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW...287
H-6 SPEED OR POWER OF BOOM IS LOW...288
H-7 SPEED OR POWER OF ARM IS LOW...289
H-8 SPEED OR POWER OF BUCKET IS LOW...290
H-9 SPEED OR POWER OF BOOM SWING IS LOW...291
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY...291
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE...292
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE...293
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW...293
H-14 MACHINE DEVIATES DURING TRAVEL...294
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW...296
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...296
H-17 TRAVEL SPEED DOES NOT CHANGE...297
H-18 TRAVEL MOTOR DOES NOT WORK (ONE SIDE ONLY)...297
H-19 SPEED OR POWER OF SWING IS LOW...298
H-20 MACHINE DOES NOT SWING...300
H-21 SWING ACCELERATION PERFORMANCE IS LOW...302
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING...303
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING...304
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND...304
H-25 HYDRAULIC DRIFT OF SWING IS LARGE...305
H-26 SPEED OR POWER OF BLADE IS LOW...306
H-27 BLADE DOES NOT MOVE...307
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE...307
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)...308
BEFORE STARTING M-MODE TROUBLESHOOTING...309
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...311
M-1 WHEN STARTING SWITCH IS TURNED ON, NO MONITOR/GAUGE OPERATES...313
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME MONITORS/GAUGES DO NO OPERATE...315
M-3 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING...317
M-4 WHILE ENGINE IS RUNNING, ENGINE OIL PRESSURE MONITOR FLASHES...319
M-5 WHILE ENGINE IS RUNNING, CHARGE LEVEL MONITOR FLASHES...321
M-6 PREHEATING SYSTEM DOES NOT OPERATE...323
M-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...326
M-8 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY...329
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING...331
M-10 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY...332
M-11 MONITOR PANEL NIGHT LAMP AND WORKING LAMP DO NOT LIGHT UP...335
TROUBLESHOOTING OF ENGINE (S MODE)...340
TROUBLESHOOTING OF ENGINE (S-MODE)...341
30 DISASSEMBLY AND ASSEMBLY...348
HOW TO READ THIS MANUAL...349
PRECAUTIONS WHEN PERFORMING OPERATION...351
SPECIAL TOOL LIST...353
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...355
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY...357
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY...362
REMOVAL AND INSTALLATION TRACK SHOE ASSEMBLY...364
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY...365
DISASSEMBLY AND ASSEMBLYOF RECOIL SPRING ASSEMBLY...367
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...370
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY...371
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...373
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY...375
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...380
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...381
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...383
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...385
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY...386
DISASSEMBLY AND ASSEMBLY OF HDYRAULIC CYLINDER ASSEMBLY...390
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...394
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)...395
90 OTHERS...404
HYDRAULIC CIRCUIT DIAGRAM...406
ELECTRICAL CIRCUIT DIAGRAM (1/2)...407
ELECTRICAL CIRCUIT DIAGRAM (2/2)...408
COVER...1
FOREWORD...2
FOREWORD...3
SAFETY INFORMATION...6
INTRODUCTION...8
DIRECTIONS OF MACHINE...8
PRODUCT INFORMATION...9
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...9
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...9
EPA NAMEPLATE...10
SERVICE METER LOCATION...10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...11
CONTENTS...12
SAFETY...15
SAFETY INFORMATION...16
SAFETY LABELS...18
LOCATION OF SAFETY LABELS...18
SAFETY LABELS...19
SAFETY INFORMATION...24
SAFETY RULES...24
IF PROBLEMS ARE FOUND...24
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...24
FIRE EXTINGUISHER AND FIRST AID KIT...24
SAFETY EQUIPMENT...25
KEEP MACHINE CLEAN...25
KEEP OPERATOR'S COMPARTMENT CLEAN...25
LEAVING OPERATOR'S SEAT WITH LOCK...25
HANDRAILS AND STEPS...26
MOUNTING AND DISMOUNTING...26
NO PERSONS ON ATTACHMENTS...26
BURN PREVENTION...27
FIRE PREVENTION AND EXPLOSION PREVENTION...27
ACTION IF FIRE OCCURS...28
WINDSHIELD WASHER FLUID...28
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...29
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)...29
ATTACHMENT INSTALLATION...30
ATTACHMENT COMBINATIONS...30
CAB WINDOW GLASSES...30
UNAUTHORIZED MODIFICATIONS...30
SAFETY AT JOBSITE...30
WORKING ON LOOSE GROUND...30
DISTANCE TO HIGH VOLTAGE CABLES...31
ENSURE GOOD VISIBILITY...31
VENTILATION FOR ENCLOSED AREA...31
SIGNALMAN'S SIGNAL AND SIGNS...31
EMERGENCY EXIT FROM OPERATOR'S CAB...32
ASBESTOS DUST HAZARD PREVENTION...32
SAFETY MACHINE OPERATION...33
STARTING ENGINE...33
CHECKS BEFORE STARTING ENGINE...33
SAFETY RULES FOR STARTING ENGINE...34
STARTING ENGINE IN COLD WEATHER...34
OPERATION...35
CHECKS BEFORE OPERATION...35
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...35
SAFETY RULES FOR TRAVELING...36
TRAVELING ON SLOPES...37
OPERATIONS ON SLOPES...38
PROHIBITED OPERATIONS...38
OPERATIONS ON SNOW...40
PARKING MACHINE...40
TRANSPORTATION...41
LOADING AND UNLOADING...41
SHIPPING THE MACHINE...41
BATTERY...42
BATTERY HAZARD PREVENTION...42
STARTING ENGINE WITH BOOSTER CABLES...43
TOWING...44
SAFETY RULES FOR TOWING...44
LIFTING OBJECTS WITH BUCKET...45
SAFETY RULES FOR LIFTING OBJECTS...45
SAFETY MAINTENANCE INFORMATION...46
WARNING TAG...46
KEEP WORK PLACE CLEAN AND TIDY...46
APPOINT LEADER WHEN WORKING WITH OTHERS...46
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...47
CAUTIONS FOR OPENING (TILTING) FLOOR...48
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...49
PROPER TOOLS...49
PERSONNEL...49
ATTACHMENTS...50
WORK UNDER THE MACHINE...50
NOISE...50
WHEN USING HAMMER...50
WELDING WORKS...50
REMOVING BATTERY TERMINALS...51
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...51
DO NOT DISASSEMBLE RECOIL SPRINGS...51
SAFETY RULES FOR HIGH-PRESSURE OIL...51
SAFETY HANDLING HIGH-PRESSURE HOSES...52
WASTE MATERIALS...52
COMPRESSED AIR...52
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...52
OPERATION...53
MACHINE VIEW ILLUSTRATIONS...54
OVERALL MACHINE VIEW...54
CONTROLS AND GAUGES...55
DETAILED CONTROLS AND GAUGES...56
MONITORING SYSTEM...56
SWITCHES...64
CONTROL LEVERS AND PEDALS...68
WINDSHIELD...74
SLIDING DOOR...78
SLIDING WINDOW...78
EMERGENCY ESCAPE HAMMER...79
CAP WITH LOCK...80
ENGINE REAR COVER...81
COOLING COVER...81
FRONT RIGHT COVER...82
METHOD OF OPENING (TILTING) FLOOR...83
FUSE...88
BLOCK FUSE...89
OPERATION MANUAL STORAGE...89
TOOL BOX...89
GREASE GUN HOLDER...90
ASHTRAY...90
MACHINE OPERATIONS AND CONTROLS...91
BEFORE STARTING ENGINE...91
STARTING ENGINE...106
AFTER STARTING ENGINE...110
STOPPING THE ENGINE...113
MACHINE OPERATION...114
STEERING THE MACHINE...119
SWINGING...121
WORK EQUIPMENT CONTROLS AND OPERATIONS...122
PROHIBITED OPERATIONS...124
GENERAL OPERATION INFORMATION...126
TRAVELING ON SLOPES...128
ESCAPE FROM MUD...130
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR...131
BUCKET REPLACEMENT...133
PARKING MACHINE...134
MACHINE INSPECTION AFTER DAILY WORK...135
LOCKING...136
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)...137
TRANSPORTATION...142
TRANSPORTATION PROCEDURE...142
LOADING AND UNLOADING WITH TRAILER...143
LIFTING MACHINE...149
COLD WEATHER OPERATION...152
COLD WEATHER OPERATION INFORMATION...152
CAB HEATER IN COLD WEATHER...153
AFTER DAILY WORK COMPLETION...154
AFTER COLD WEATHER SEASON...154
LONG TERM STORAGE...155
BEFORE STORAGE...155
DURING STORAGE...155
AFTER STORAGE...155
TROUBLES AND ACTIONS...156
RUNNING OUT OF FUEL...156
PHENOMENA THAT ARE NOT FAILURES...156
TOWING THE MACHINE...157
SEVERE JOB CONDITION...157
DISCHARGED BATTERY...158
OTHER TROUBLE...162
MAINTENANCE...165
MAINTENANCE INFORMATION...166
OUTLINE OF SERVICE...168
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...168
ELECTRIC SYSTEM MAINTENANCE...171
HANDLING HYDRAULIC SYSTEM...171
WEAR PARTS...172
WEAR PARTS LIST...172
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...173
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN...175
TIGHTENING TORQUE SPECIFICATIONS...176
TIGHTENING TORQUE LIST...176
SAFETY CRITICAL PARTS...177
SAFETY CRITICAL PARTS LIST...177
MAINTENANCE SCHEDULE...178
MAINTENANCE SCHEDULE CHART...178
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...179
MAINTENANCE PROCEDURE...180
WHEN REQUIRED...180
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...180
CLEAN INSIDE OF COOLING SYSTEM...183
CHECK LEVEL OF BATTERY ELECTROLYTE...186
CLEAN FUEL FILTER ELEMENT (WITH WATER SEPARATOR)...188
DRAIN WATER AND SEDIMENT FROM FUEL TANK...188
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH STEEL SHOE)...189
CHECK RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)...191
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)...193
REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)...195
REPLACE BUCKET TEETH...198
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...201
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER...202
BLEEDING AIR FROM HYDRAULIC SYSTEM...203
CHECK BEFORE STARTING...204
EVERY 500 HOURS MAINTENANCE...205
LUBRICATING...205
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...208
REPLACE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)...209
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...210
REPLACE FUEL FEED PUMP PRE-FILTER...211
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS...211
CHECK AND ADJUST COOLING FAN BELT TENSION...212
EVERY 1000 HOURS MAINTENANCE...213
CHANGE OIL IN FINAL DRIVE CASE...213
REPLACE HYDRAULIC OIL FILTER ELEMENT...214
CHECK ENGINE VALVE CLEARANCE, ADJUST...215
EVERY 2000 HOURS MAINTENANCE...216
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...216
CHECK ALTERNATOR, STARTING MOTOR...218
SPECIFICATIONS...219
SPECIFICATIONS...220
ATTACHMENTS, OPTIONS...222
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION...223
SAFETY FIRST...223
ATTACHMENT INSTALLATION...224
BUCKET WITH HOOK...225
PROHIBITED OPERATIONS...225
WINDSHIELD WASHER...226
WINDSHIELD WASHER OPERATION...226
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...226
MACHINE READY FOR ATTACHMENT...227
LOCATIONS...227
HYDRAULIC CIRCUIT...229
ATTACHMENT OPERATIONS...231
LONG TERM STORAGE...232
SPECIFICATIONS...232
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE...233
CONTROL PATTERN CHANGE PROCEDURE...233
MACHINE CONTROL PATTERNS...234
ATTACHMENT GUIDE...235
ATTACHMENT COMBINATIONS...235
RECOMMENDED ATTACHMENT OPERATIONS...236
HYDRAULIC BREAKER...236
INDEX...241
