Komatsu Hydraulic Excavator PC09 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC09-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC09-1 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: 1,027 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...25
GENERAL ASSEMBLY DRAWING...26
SPECIFICATIONS...27
WEIGHT TABLE...33
LIST OF LUBRICANT AND WATER...35
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...36
RADIATOR...37
ENGINE CONTROL...39
PTO...41
POWER TRAIN DIAGRAM...42
SWING CIRCLE...43
TRACK FRAME...44
IDLER CUSHION...46
IDLER...47
TRACK ROLLER...48
TRACK SHOE...49
HYDRAULIC EQUIPMENT LAYOUT...50
VALVE CONTROL...51
HYDRAULIC TANK...52
HYDRAULIC PUMP...53
10-SPOOL CONTROL VALVE...55
CENTER SWIVEL JOINT...57
SWING MOTOR...58
TRAVEL MOTOR...59
HYDRAULIC CYLINDER...65
WORK EQUIPMENT...67
DIMENSION OF WORK EQUIPMENT...69
MACHINE MONITOR SYSTEM...73
20 TESTING AND ADJUSTING...75
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...76
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...78
TESTING AND ADJUSTING...86
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...87
MEASUREMENT ENGINE SPEED...88
MASURING EXHAUST COLOR...90
ADJUSTMENT VALVE CLEARANCE...92
MEASURING COMPRESSION PRESSURE...93
MEASURING ENGINE OIL PRESSURE...94
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING...95
ADJUSTMENT OF FUEL CONTROL CABLE...97
BLEEDING AIR FROM FUEL CIRCUIT...99
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION...100
TESTING AND ADJUSTING TRACK SHOE TENSION...101
INSPECTION AND ADJUSTMENT OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS...102
IDENTIFICATION OF SPOT CAUSING WORK EQUIPMENT HYDRAULIC DRIFT...105
MEASUREMENT OF OIL LEAK AMOUNT INSIDE WORK EQUIPMENT CYLINDER...106
BLEEDING AIR FROM HYDRAULIC CIRCUITS...106
PRESSURIZING HYDRAULIC TANK...107
TROUBLESHOOTING...108
POINTS TO REMEMBER WHEN TROUBLESHOOTING...109
SEQUENCE OF EVENTS IN TROUBLESHOOTING...110
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...111
CHECKS BEFORE TROUBLESHOOTING...119
METHOD OF USING TROUBLESHOOTING...120
CONNECTOR MOUNTING LOCATIONS AND ELECTRICAL CIRCUITS...121
CONNECTOR PIN ALLOCATION DRAWING...122
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START, STOP, PREHEATING AND CHARGING SYSTEMS (E CIRCUIT)...124
ELECTRICAL CIRCUIT DIAGRAM FOR PANEL SYSTEMS (P CIRCUIT)...125
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS...126
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...128
INFORMATION IN TROUBLESHOOTING TABLE...129
E-1 ENGINE DOES NOT START...130
E-2 ENGINE DOES NOT STOP...134
E-3 ENGINE OIL PRESSURE LAMP DOES NOT WORK PROPERLY...135
E-4 ENGINE COOLING WATER TEMPERATURE LAMP DOES NOT WORK PROPERLY...137
E-5 ENGINE PREHEATING SYSTEM DOES NOT WORK...139
E-6 SERVICE METER DOES NOT ADVANCE...141
E-7 HORN DOES NOT SOUND, OR DOES NOT STOP SOUNDING...142
E-8 WORKING LAMP DOES NOT LIGHT UP, OR DOES NOT GO OFF...144
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)...146
METHOD OF USING TROUBLESHOOTING CHARTS...147
H-1 ALL WORK EQUIPMENT, TRAVEL AND SWING SHOW SLOW SPEED OR LACK IN POWER...149
H-2 ENGINE RUNNING SPEED DROPS SHARPLY OR ENGINE STAALS.MOREOVER, ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE AT ALL OR MOVE EXTREMELY SLOWLY...149
H-3 THERE IS NOISE FROM AROUND HYDRAULIC PUMP...150
H-4 CONTROL LEVERS AND PEDALS ARE HARD TO OPERATE...150
H-5 BOOM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT...151
H-6 ARM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT...151
H-7 BUCKET MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT...152
H-8 SWING IS SLOW, LACKS IN POWER AND HAS BIG HYDRAULIC DRIFT...152
H-9 BLADE MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT...152
H-10 MACHINE DEVIATES FROM TRAVEL PATH IN TRAVELING...153
a) THE MACHINE DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND IN REVERSE DIRECTIONS ...153
b) THE DEVIATION DIRECTION CHANGES DEPENDING ON FORWARD OR REVERSE TRAVEL...153
H-11 NO POWER OR SLOW IN TRAVELING...155
H-12 UNDERCARRIAGE DOES NOT MOVE (ONE SIDE ONLY)...155
H-13 TRAVEL SPEED CANNOT BE CHANGED...156
H-14 UPPER STRUCTURE DOES NOT SWING...156
H-15 SWING SPEED IS SLOW OR ACCELERATION IS POOR...157
H-16 OVERRUN WHEN STOPPING WING IS BIG...157
H-17 THERE IS BIG SHOCK WHEN STOPPING SWING...158
H-18 THERE IS BIG NOISE WHEN STOPPING SWING...158
H-19 HYDRAULIC DRIFT OF SWING IS BIG...159
H-20 TROUBLESHOOTING OF HYDRAULIC BREAKER...160
30 DISASSEMBLY AND ASSEMBLY...161
METHOD OF USING MANUAL...162
PRECAUTIONS WHEN CARRYING OUT OPERATION...163
SPECIAL TOOL LIST...165
SWING MOTOR...166
REMOVAL AND INSTALLATION...166
CENTER SWIVEL JOINT...167
REMOVAL AND INSTALLATION...166
DISASSEMBLY AND ASSEMBLY...168
ENGINE AND HYDRAULIC PUMP...169
REMOVAL...169
INSTALLATION...172
REVOLVING FRAME...173
REMOVAL ...173
INSTALLATION...174
SWING CIRCLE...175
REMOVAL AND INSTALLATION...175
IDLER...176
ASSEMBLY...176
TRACK ROLLER...177
ASSEMBLY...177
RUBBER SHOE...177
REMOVAL AND INSTALLATION...177
CONTROL VALVE...178
ASSEMBLY...178
HYDRAULIC CYLINDER...179
ASSEMBLY...179
HYDRAULIC BREAKER...182
DISASSEMBLY...183
ASSEMBLY...186
90 OTHERS...190
HYDRAULIC CIRCUIT DIAGRAM...191
FIXED GAUGE TYPE (STD)...191
VARIABLE GAUGE TYPE (IF EQUIPPED)...192
ELECTRICAL CIRCUIT DIAGRAM...193
STANDERD SPECIFICATION...193
TRAVEL ALREM SPECIFICATION (IF EQUIPPED)...194
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
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION...10
SERVICE METER LOCATION...10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...11
CONTENTS...12
SAFETY...16
SAFETY...17
SAFETY LABELS...19
LOCATION OF SAFETY LABELS...19
SAFETY LABELS...20
GENERAL PRECAUTIONS...23
SAFETY MACHINE OPERATION...31
STARTING ENGINE...31
OPERATION...32
TRANSPORTATION...39
BATTERY...40
TOWING...42
LIFTING OBJECTS WITH BUCKET...43
SAFETY MAINTENANCE INFORMATION...44
OPERATION...50
MACHINE VIEW ILLUSTRATIONS...51
OVERALL MACHINE VIEW...51
CONTROLS AND GAUGES...52
DETAILED CONTROLS AND GAUGES...53
METERS, LAMPS...53
SWITCHES...55
CONTROL LEVERS AND PEDALS...57
VARIABLE BLADE...64
ENGINE HOOD...64
FUSE...65
BLOCK FUSE...65
OPERATION MANUAL STORAGE...66
MACHINE OPERATIONS AND CONTROLS...67
BEFORE STARTING ENGINE...67
STARTING ENGINE...78
AFTER STARTING ENGINE...81
STOPPING THE ENGINE...84
CHECK AFTER SHUT OFF ENGINE...84
MACHINE OPERATION...85
STEERING THE MACHINE...89
SWINGING...91
WORK EQUIPMENT CONTROLS AND OPERATIONS...92
PROHIBITED OPERATIONS...94
GENERAL OPERATION INFORMATION...97
TRAVELING ON SLOPES...98
ESCAPE FROM MUD...100
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR...101
BUCKET REPLACEMENT...103
PARKING MACHINE...105
MACHINE INSPECTION AFTER DAILY WORK...106
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)...107
TRANSPORTATION...112
TRANSPORTATION PROCEDURE...112
LOADING AND UNLOADING WITH TRAILER...112
LIFTING MACHINE...114
SHIPPING MACHINE INFORMATION...116
COLD WEATHER OPERATION...117
COLD WEATHER OPERATION INFORMATION...117
AFTER DAILY WORK COMPLETION...119
AFTER COLD WEATHER SEASON...119
LONG TERM STORAGE...120
BEFORE STORAGE...120
DURING STORAGE...120
AFTER STORAGE...120
STARTING MACHINE AFTER LONG-TERM STORAGE...120
TROUBLES AND ACTIONS...121
RUNNING OUT OF FUEL...121
PHENOMENA THAT ARE NOT FAILURES...121
TOWING THE MACHINE...122
SEVERE JOB CONDITION...122
DISCHARGED BATTERY...123
OTHER TROUBLE...127
MAINTENANCE...132
MAINTENANCE INFORMATION...133
OUTLINE OF SERVICE...135
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...135
ELECTRIC SYSTEM MAINTENANCE...138
WEAR PARTS...139
WEAR PARTS LIST...139
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS...140
PROPER SELECTION...140
TIGHTENING TORQUE SPECIFICATIONS...144
TIGHTENING TORQUE LIST...144
SAFETY CRITICAL PARTS...145
SAFETY CRITICAL PARTS LIST...145
MAINTENANCE SCHEDULE...146
MAINTENANCE SCHEDULE CHART...146
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...147
MAINTENANCE PROCEDURE...148
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...148
WHEN REQUIRED...149
CHECK BEFORE STARTING...164
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE...164
EVERY 100 HOURS MAINTENANCE...165
EVERY 250 HOURS MAINTENANCE...166
EVERY 500 HOURS MAINTENANCE...171
EVERY 1000 HOURS MAINTENANCE...178
EVERY 2000 HOURS MAINTENANCE...179
SPECIFICATIONS...182
SPECIFICATIONS...183
ATTACHMENTS, OPTIONS...186
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION...187
SAFETY FIRST...187
ATTACHMENT INSTALLATION...188
BUCKET WITH HOOK...189
HOOK CONDITION...189
PROHIBITED OPERATIONS...189
ATTACHMENT GUIDE...190
ATTACHMENT COMBINATIONS...190
HANDLING ARM WITH BUILT-IN BREAKER...191
BUCKET POSTURE...191
REMOVING AND INSTALLING CHISEL...191
PROCEDURE FOR BREAKER OPERATIONS...192
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS...193
STOWING CHISEL, DUMMY CHISEL...194
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS...194
HANDLING DUMMY LINK...195
CHECK BEFORE STARTING...196
SPECIFICATIONS...197
HANDLING BUCKET COUPLER...198
PROCEDURE FOR REMOVING BUCKET...198
PROCEDURE FOR INSTALLING BUCKET...200
HANDLING FOLDING TOPS CANOPY...202
RECOMMENDED ATTACHMENT OPERATIONS...204
HYDRAULIC BREAKER...204
INDEX...208
