Komatsu Hydraulic Excavator PC15MR Repair Service Manual (SEBM019002) + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC15MR-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC15MR-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: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEAM044900T - Hydraulic Excavator PC15MRX-1 Operation & Maintenance Manual.pdf
SEBM019002 - Hydraulic Excavator PC15MR-1 Shop Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...25
GENERAL ASSEMBLY DRAWING...26
SPECIFICATIONS...27
WEIGHT TABLE...30
LIST OF LUBRICANT AND WATER...32
10 STRUCTURE AND FUNCTION...34
SWING CIRCLE...35
TRACK FRAME, RECOIL SPRING...36
HYDRAULIC EQUIPMENT LAYOUT...37
HYDRAULIC TANK...38
HYDRAULIC PUMP...39
CONTROL VALVE...43
CLSS...51
CENTER SWIVEL JOINT...68
SWING MOTOR...70
TRAVEL MOTOR...72
VALVE CONTROL...78
PPC VALVE...79
PPC LOCK SOLENOID VALVE...83
TRAVEL 2-SPEED SELECTER VALVE...85
ELECTRIC WIRING DIAGRAM...86
MONITOR SYSTEM...88
20 TESTING AND ADJUSTING...91
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...92
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...93
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...101
TESTING AND ADJUSTING...103
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...104
MEASURING ENGINE SPEED...105
MEASURING EXHAUST COLOR...106
ADJUSTING VALVE CLEARANCE...107
MEASURING COMPRESSION PRESSURE...108
TESTING AND ADJUSTING FUEL INJECTION TIMING...109
MEASURING ENGINE OIL PRESSURE...110
TESTING AND ADJUSTING FAN BELT TENSION...111
ADJUSTING FUEL CONTROL LEVER...112
MEASURING SPROCKET WEAR...113
TESTING AND ADJUSTING TRACK SHOE TENSION...114
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...115
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE...117
ADJUSTING PC VALVE SPRING...119
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE...120
TESTING PPC LOCK VALVE...121
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE...122
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...124
TESTING AND ADJUSTING TRAVEL DEVIATION...125
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER...126
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...127
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK...128
PRESSURIZING HYDRAULIC TANK...128
BLEEDING AIR...129
TROUBLESHOOTING...131
POINTS TO REMEMBER WHEN TROUBLESHOOTING...132
SEQUENCE OF EVENTS IN TROUBLESHOOTING...133
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...134
CHECKS BEFORE TROUBLESHOOTING...142
CONNECTOR TYPES AND MOUNTING LOCATIONS...143
CONNECTOR PIN ALLOCATION DRAWING...144
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...146
METHOD OF USING TROUBLESHOOTING CHARTS...156
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...158
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...159
E-1 ENGINE DOES NOT START...161
a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)...161
b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)...163
E-2 ENGINE DOES NOT STOP...165
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED...166
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED...168
E-5 TRAVEL ALARM DOES NOT SOUND...169
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...170
TABLE OF FAILURE MODES AND CAUSES...171
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...173
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...174
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...174
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...175
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...175
H-6 BOOM IS SLOW OR LACKS POWER...176
H-7 ARM IS SLOW OR LACKS POWER...176
H-8 BUCKET IS SLOW OR LACKS POWER...177
H-9 BOOM SWING IS SLOW OR LACKS POWER...177
H-10 BLADE IS SLOW OR LACKS POWER...178
H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL)...178
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE)...179
a) BOOM, BUCKET, BOOM SWING, BLADE...179
b) ARM...179
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...179
a) BOOM, ARM...179
b) BUCKET...179
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...180
H-15 TRAVEL DEVIATION...181
a) DEVIATION IN NORMAL TRAVEL...181
b) DEVIATION WHEN STARTING...181
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER...182
H-17 STEERING DOES NOT TURN EASILY...182
H-18 TRAVEL SPEED DOES NOT SWITCH...182
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...183
H-20 SWING SPEED IS SLOW OR LACKS POWER...183
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS...183
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY...183
H-21 DOES NOT SWING...184
a) DOES NOT SWING IN EITHER DIRECTION...184
b) DOES NOT SWING IN ONE DIRECTION ONLY...184
H-22 SWING ACCELERATION IS POOR...185
a) ACCELERATION IS POOR IN BOTH DIRECTIONS...185
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY...185
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...186
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS...186
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY...186
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY)...186
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...187
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING...187
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...188
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS...189
M-1 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP SYSTEM...190
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON...190
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...190
M-2 ABNORMALITY IN CHARGE CAUTION LAMP SYSTEM...192
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON...192
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (BATTERY CHARGE IS NORMAL)...192
M-3 ABNORMALITY IN ENGINE WATER TEMPERATURE CAUTION LAMP SYSTEM...194
a) LAMP DOES NOT STAY LIGHTED UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON...194
b) LAMP DOES NOT GO OUT AFTER STARTING SWITCH HAS BEEN AN ON FOR 3 SECONDS...194
c) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE WATER TEMPERATURE IS NORMAL)...195
M-4 ABNORMALITY IN PREHEATING PILOT LAMP...196
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO HEAT...196
b) LAMP DOES NOT GO OUT WHEN STARTING SWITCH IS AT HEAT AND PREHEATING TIME (APPROX. 18 SEC.) IS COMPLETED...196
c) LAMP LIGHTS UP WHEN STARTING SWITCH IS AT POSITION OTHER THAN HEAT...197
M-5 ABNORMALITY IN FUEL GAUGE SYSTEM...198
a) GAUGE DOES NOT GO UP FROM E WHEN FUEL IS ADDED TO FUEL TANK...198
b) GAUGE DOES NOT GO DOWN FROM F EVEN WHEN THERE IS NO FUEL IN FUEL TANK...198
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY...199
M-6 ABNORMALITY IN SERVICE METER SYSTEM...200
a) SERVICE METER DOES NOT ADVANCE WHEN STARTING SWITCH IS AT ON...200
b) SERVICE METER ADVANCES WHEN STARTING SWITCH IS AT OFF...200
c) PILOT LAMP DOES NOT FLASH WHEN SERVICE METER IS ADVANCING...200
M-7 ABNORMALITY IN NIGHT LIGHTING SYSTEM...202
a) NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON...202
b) NIGHT LIGHTING LIGHTS UP WHEN LAMP SWITCH IS TURNED OFF...202
30 DISASSEMBLY AND ASSEMBLY...204
METHOD OF USING MANUAL...205
PRECAUTIONS WHEN CARRYING OUT OPERATION...206
SPECIAL TOOL LIST...208
ENGINE AND HYDRAULIC PUMP...209
REMOVAL...209
INSTALLATION...213
CENTER SWIVEL JOINT...214
REMOVAL...214
INSTALLATION...214
DISASSEMBLY...215
ASSEMBLY...215
SWING MOTOR...216
REMOVAL...216
INSTALLATION...216
REVOLVING FRAME...217
REMOVAL...217
INSTALLATION...218
SWING CIRCLE...219
REMOVAL...219
INSTALLATION...219
IDLER...220
ASSEMBLY...220
TRACK ROLLER...221
ASSEMBLY...221
RUBBER SHOE...222
REMOVAL...222
INSTALLATION...222
CONTROL VALVE...223
DISASSEMBLY...223
ASSEMBLY...228
HYDRAULIC CYLINDER...235
ASSEMBLY...235
40 MAINTENANCE STANDARD...238
SWING CIRCLE...239
TRACK FRAME, RECOIL SPRING...240
IDLER...241
TRACK ROLLER...242
TRACK SHOE...243
HYDRAULIC PUMP...245
CONTROL VALVE...246
CENTER SWIVEL JOINT...250
SWING MOTOR...251
TRAVEL MOTOR...252
PPC VALVE...253
HYDRAULIC CYLINDER...254
WORK EQUIPMENT...255
90 OTHERS...257
HYDRAULIC CIRCUIT DIAGRAM (VARIABLE GAUGE TYPE)...258
HYDRAULIC CIRCUIT DIAGRAM (FIXED GAUGE TYPE)...259
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 10001-10634)...260
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 10635 AND UP)...261
COVER...1
FOREWORD...2
FOREWORD...3
SAFETY INFORMATION...6
INTRODUCTION...8
DIRECTIONS OF MACHINE...8
PRODUCT INFORMATION...9
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...9
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...9
EMISSION CONTROL INFORMATION LABEL...10
SERVICE METER LOCATION...10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...10
CONTENTS...11
SAFETY...15
SAFETY INFORMATION...16
POSITION FOR ATTACHING SAFETY LABELS...18
POSITION FOR ATTACHING SAFETY LABELS...19
SAFETY LABELS...20
SAFETY INFORMATION...24
SAFETY RULES...24
IF ABNORMALITIES 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
CRUSHING OR CUTTING PREVENTION...26
MOUNTING AND DISMOUNTING...27
NO PERSONS ON ATTACHMENTS...27
BURN PREVENTION...27
FIRE PREVENTION AND EXPLOSION PREVENTION...28
ACTION IF FIRE OCCURS...29
WINDSHIELD WASHER FLUID...29
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...29
ATTACHMENT INSTALLATION...29
ATTACHMENT COMBINATIONS...30
CAB WIDOW 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...32
SIGNALMAN'S SIGNAL AND SIGNS...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 AFTER STARTING ENGINE...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...42
BATTERY...43
BATTERY HAZARD PREVENTION...43
STARTING ENGINE WITH BOOSTER CABLES...44
TOWING...45
SAFETY RULES FOR TOWING...45
LIFTING OBJECTS WITH BUCKET...46
