Komatsu Hydraulic Excavator PC12R, PC15R Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC12R-8, PC15R-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC12R-8, PC15R-8 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: 2,030 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
WEBM000100 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
WEBM000101 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
WEBM002800 - Hydraulic Excavator PC15R-8 Shop Manual.pdf
SEBM013103 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
SEAM015102T - Hydraulic Excavator PC12R-8, PC15R-8 Operation & Maintenance Manual.pdf
WEAM002702 - Hydraulic Excavator PC12R-8, PC12R-8 HS, PC15R-8, PC15R-8 HS Operation & Maintenance Manual.pdf
WEAM003000 - Hydraulic Excavator PC15R-8 Operation & Maintenance Manual.pdf
WEAM003001 - Hydraulic Excavator PC15R-8 Deluxe Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...5
00 FOREWORD...7
01 GENERAL...25
General assembly drawing...26
Specifications...30
List of lubricant and water...34
10 STRUCTURE AND FUNCTION...35
Power Train...36
Swing circle...37
Track frame and recoil spring...38
Hydraulic piping...39
Hydraulic tank...40
Hydraulic pump...41
Control valve (PC12R-8)...45
CLSS (PC12R-8)...53
Control valve (PC15R-8)...76
CLSS (PC15R-8)...84
Center swivel joint...105
Swing motor...107
Travel motor...109
Valve control...112
PPC valve...113
Work equipment...117
Machine monitor system...118
20 TESTING AND ADJUSTING...121
STANDARD VALUE TABLE...122
Standard value table for engine related parts...122
Standard value table for chassis related parts...124
Standard value table for electrical parts...138
TESTING AND ADJUSTING...140
Tools for testing, adjusting, and troubleshooting...141
Measuring engine speed...142
Measuring exhaust color...143
Adjusting valve clearance...144
Measuring compression pressure...145
Testing and adjusting fuel injection timing...146
Measuring engine oil pressure...147
Testing and adjusting fan belt tension...148
Testing and adjusting fuel control lever...149
Measuring sprocket wear...150
Testing and adjusting track shoe tension...151
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ...152
Testing and adjusting LS differential pressure...158
Adjusting PC valve spring...160
Testing and adjusting control circut pressure...161
Measuring output pressure of PPC lock valve and travel boost valve...163
Testing PPC valve output pressure and swing holding brake inlet port pressure...164
Adjusting work equipment, swing PPC valve ...166
Testing and adjusting travel deviation...167
Measuring oil leakage inside work equipment cylinder...168
Releasing remaining pressure from hydraulic circuit...169
Releasing remaining pressure from hydraulic tank ...169
Pressurizing hydraulic tank...169
Bleeding air...170
TROUBLESHOOTING...172
Type of connector and position of installation...173
Connection table for connector pin numbers ...176
Troubleshooting of engine electrical system (E mode)...186
E-Mode related electrical circuit diagram...187
E-1 Engine does not start...188
a) When starting motor does not turn (starting system)...188
b) When starting motor turns (engine stop solenoid system)...190
E-2 Engine does not stop...192
Troubleshooting of hydraulic, mechanical system (H mode)...193
Table of failure modes and causes...194
H- 1 Speeds of all work equipment, swing, travel are slow or lack power...198
H- 2 There is excessive drop in engine speed, or engine stalls...200
H- 3 No work equipment, travel, swing move...201
H- 4 Abnormal noise generated (from around pump)...202
H- 5 Fine control ability is poor or response is poor (PC15R)...202
H- 6 Boom is slow or lacks power...203
H- 7 Arm is slow or lacks power...203
H- 8 Bucket is slow or lacks power...204
H- 9 Boom swing is slow or lacks power...204
H-10 Blade is slow or lacks power...205
H-11 Boom, arm, bucket do not move (boom swing, blade, travel and swing are normal)...205
H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade)...206
a) Boom, bucket, boom swing, blade...206
b) Arm...206
H-13 Excessive time lag (engine at low idling)...206
a) Boom, arm...206
b) Bucket...206
H-14 In compound operations, work equipment with larger load is slow...207
H-15 Travel deviation...208
a) Deviation in normal travel...208
b) Deviation when starting...208
H-16 Travel speed is slow or lacks power...209
H-17 Steering does not turn easily...209
H-18 Travel speed does not switch...210
H-19 Travel does not move (one side only)...210
H-20 Swing speed is slow or lacks power...211
a) Speed is slow or lacks power in both directions...211
b) Speed is slow or lacks power in one direction only (left or right)...211
H-21 Does not swing...212
a) Does not swing in either direction...212
b) Does not swing in one direction (left or right)...212
H-22 Swing acceleration is poor...213
a) Acceleration is poor in both directions...213
b) Acceleration is poor in one direction only (left or right)...213
H-23 Excessive overrun when stopping swing...214
a) Overrun when stopping is excessive in both directions...214
b) Overrun when stopping is excessive in one direction only (left or right)...214
H-24 Excessive shock when stopping swing (in one direction only)...214
H-25 Excessive abnormal noise when stopping swing...215
H-26 Excessive hydraulic drift of swing...215
Troubleshooting of machine monitor system (M mode)...216
Electrical circuit diagram for M Mode related parts...217
M-1 Abnormality in engine oil pressure caution lamp system...218
a) Lamp does not light up when starting switch is turned ON...218
b) Lamp lights up when engine is running (engine oil pressure is normal)...218
M-2 Abnormality in charge caution lamp system...220
a) Lamp does not light up when starting switch is turned ON...220
b) Lamp lights up when engine is running (battery charge is normal)...220
M-3 Abnormality in engine water temperature caution lamp system...222
a) Lamp does not stay lighted up for 3 seconds when starting switch is turned ON...222
b) Lamp does not go out after starting switch has been at ON for 3 seconds...222
c) Lamp lights up when engine is running (engine water temperature is normal)...223
M-4 Abnormality in preheating pilot lamp...224
a) Lamp does not light up when starting switch is turned to HEAT...224
b) Lamp does not go out when starting switch is at HEAT and preheating time (approx. 18 sec.) is completed...224
c) Lamp lights up when starting switch is at position other than HEAT...225
M-5 Abnormality in fuel gauge system...226
a) Gauge does not go up from E when fuel is added to fuel tank...226
b) Gauge does not go down from F even when there is no fuel in fuel tank...226
c) Fuel level does not match gauge display...227
M-6 Abnormality in service meter system...228
a) Service meter does not advance when starting switch is at ON...228
b) Service meter advances when starting switch is at OFF...228
c) Pilot lamp does not flash when service meter is advancing...228
M-7 Abnormality in night lighting system...230
a) Night lighting does not light up when lamp switch is turned ON...230
b) Night lighting lights up when lamp switch is turned OFF ...230
30 DISASSEMBLY AND ASSEMBLY...232
Method of using manual...234
Precautions when carrying out operation...235
Special tool list...237
Starting motor...238
Removal and installation...238
Alternator ...239
Removal and installation...239
Fuel injection pump ...240
Removal and installation...240
Nozzle holder ...241
Removal and installation...241
Water pump ...242
Removal and installation...242
Thermostat ...243
Removal and installation...243
Engine front seal...244
Removal and installation...244
Engine rear seal...245
Removal...245
Installation...246
Cylinder head...247
Removal...247
Installation...248
Radiator...249
Removal...249
Installation...250
Engine, hydraulic pump...251
Removal...232
Installation...253
Fuel tank...254
Removal and installation...254
Damper...255
Removal and installation...255
Center swivel joint...256
Removal and installation...256
Disassembly and assembly...257
Travel motor...258
Removal and installation...258
Sprocket...259
Removal and installation...259
Swing motor...260
Removal and installation...260
Revolving frame...261
Removal...261
Installation...262
Swing circle...263
Removal and installation...263
Idler...264
Removal and installation...264
Disassembly...265
Assembly...266
Idler cushion (rubber shoe)...267
Removal and installation...267
Disassembly and assembly...268
Idler cushion (steel shoe)...269
Disassembly...232
Assembly...270
Track roller...271
Removal and installation...271
Disassembly and assembly...272
Rubber shoe...273
Removal and installation...273
Steel shoe...274
Removal and installation...274
Hydraulic tank...275
Removal...275
Installation...276
Hydraulic oil cooler...277
Removal and installation...277
Hydraulic pump...278
Removal and installation...278
Control valve...279
Removal...279
Installation...280
Disassembly...281
Assembly...286
PPC valve...293
Removal and installation...293
Disassembly...294
Assembly...295
Boom cylinder...296
Removal...296
Installation...297
Arm cylinder...298
Removal...298
Installation...299
Bucket cylinder...300
Removal...300
Installation...301
Swing cylinder...302
Removal...302
Installation...303
Blade cylinder...304
Removal and installation...304
Hydraulic cylinder...305
Disassembly...305
Assembly...308
Work equipment...312
Removal...312
Installation...313
Bucket...314
Removal and installation...314
Arm...315
Removal...315
Installation...316
Bucket, arm...317
Removal...317
Installation...318
Boom...319
Removal ...319
Installation...320
Swing bracket...321
Removal...321
Installation...322
Blade...323
Removal and installation...323
Canopy...324
Removal and installation...324
40 MAINTENANCE STANDARD...325
Swing circle...326
Track frame, recoil spring...327
Idler...328
Track roller...329
Track shoe...330
Hydraulic pump (PC15R-8)...332
Control valve (PC12R-8)...333
Control valve (PC15R-8)...339
Center swivel joint...345
Swing motor...346
PPC valve...347
Hydraulic cylinder...348
Work equipment...350
90 OTHERS...352
Hydraulic circuit diagram PC12R-8...353
Hydraulic circuit diagram PC15R-8...354
Electric circuit diagram PC12R,15R-8...355
1.1 FOREWORD...3
