Komatsu Excavator PC05, PC07, PC10, PC15, PC20 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Excavator PC05-6, PC07-1, PC10-6, PC10-7, PC15-2, PC15-3, PC20-7, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Excavator PC05-6, PC07-1, PC10-6, PC10-7, PC15-2, PC15-3, PC20-7 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
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MAIN SECTIONS
COVER...1
CONTENTS...2
10 STRUCTURE AND FUNCTION...17
POWER TRAIN...18
SWING CIRCLE...20
SWING MACHINERY...22
TRACK FRAME AND RECOIL SPRING...23
HYDRAULIC PIPING...27
HYDRAULIC CIRCUIT DIAGRAM...29
HYDRAULIC TANK AND FUEL TANK...32
HYDRAULIC PUMP...33
7-SPOOL CONTROL VALVE...34
2-SPOOL CONTROL VALVE...36
SWING MOTOR...38
CENTER SWIVEL JOINT...41
TRAVEL MOTOR ...42
HYDRAULIC CYLINDER...43
VALVE CONTROL...49
WORK EQUIPMENT...50
ELECTRICAL CIRCUIT DIAGRAM...51
MONITOR SYSTEM...53
20 TESTING AND ADJUSTING...58
TABLE OF JUDGEMENT STANDARD VALUE...59
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...75
TOOL FOR TESTING, ADJUSTING AND TROUBLESHOOTING...77
ADJUSTING VALVE CLEARANCE...78
MEASURING COMPRESSION PRESSURE...79
ADJUSTING FUEL INJECTION TIMING...80
ADJUSTING FUEL CONTROL LEVER...81
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...82
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...85
BLEEDING AIR...86
TROUBLESHOOTING...87
POINTS TO REMEMBER WHEN TROUBLESHOOTING...88
SEQUENCE OF EVENTS IN TROUBLESHOOTING...89
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...90
CHECKS BEFORE TROUBLESHOOTING...97
ELECTRICAL CIRCUIT DIAGRAM...98
POSITION OF CONNECTORS FOR TROUBLESHOOTING...100
CONNECTION TABLE FOR CONNECTOR...102
HANDLING CONNECTORS...109
METHOD OF USING TROUBLESHOOTING CHARTS...110
TROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE)...112
C-1. THIS ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF...113
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...114
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER...115
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IN EXTREMELY SLOW...115
H-3 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...116
H-4 CONTROL LEVER IS HEAVY...116
H-5 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW EXCESSIVE HYDRAULIC DRIFT...117
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER ...117
H-7 EXCESSIVE TIME LAG...117
H-8 WHEN MACHINE IS TRAVELING . IT DEVIATES NATURALLY TO ONE SIDE...118
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE...118
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE...118
H-9 TRAVEL LACKS POWER (OR SPEED IS SLOW)...120
H-10 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...120
H-11 DOES NOT SWING...121
H-12 SWING SPEED IS SLOW OR ACCELERATION IS POOR...123
H-13 EXCESSIVE OVERRUN WHEN STOPPING SWING...123
H-14 EXCESSIVE SHOCK WHEN STOPPING SWING...124
H-15 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...125
H-16 EXCESSIVE HYDRAULIC DRIFT OF SWING...126
H-17 EXCESSIVE HYDRAULIC OF BOOM SWING...127
TABLE OF FAILURE MODES AND CAUSES...128
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...130
P-1 MONITOR PANEL DOES NOT WORK...131
P-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCHES TURNED ON, OR ALL LAMPS STAY LIGHTED UP...132
a) DO NOT LIGHT UP FOR 3 SECONDS...132
b) ALL LAMPS STAY LIGHTED UP...132
P-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...133
P-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...134
P-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING...135
P-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)...135
P-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...136
P-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING...137
P-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY...138
a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE...138
b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY ENTERS TED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING...138
P-10 ABNORMALITY IN FUEL GAUGE DISPLAY...139
a) ALL SEGMENTS OF FUEL GAUGE GO OUT...139
b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN...139
c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED...140
P-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND...140
P-12 ABNORMALITY IN SERVICE METER DISPLAY...141
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING...141
b) SERVICE METER PILOT LAMP DOES NOT FLASH...141
P-13 NIGHT LIGHTING DOES NOT LIGHT UP ...142
a) WHEN LAMP SWITCH IS AT POSITION 1OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP...142
b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP DOES NOT LIGHT UP...142
P-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)...143
30 DISASSEMBLY AND ASSEMBLY...144
METHOD OF USING MANUAL...146
PRECAUTIONS WHEN CARRYING OUT OPERATION...147
SPECIAL TOOL LIST...149
STARTING MOTOR...150
REMOVAL...150
INSTALLATION...150
ALTERNATOR...151
REMOVAL...151
INSTALLATION...151
FUEL INJECTION PUMP...152
REMOVAL...152
INSTALLATION...152
NOZZLE HOLDER...153
REMOVAL...153
INSTALLATION...153
WATER PUMP...154
REMOVAL...154
INSTALLATION...154
THERMOSTAT...156
REMOVAL...156
INSTALLATION...156
ENGINE FRONT SEAL...157
REMOVAL...157
INSTALLATION...157
ENGINE REAR SEAL...158
REMOVAL...158
INSTALLATION...158
CYLINDER HEAD...159
REMOVAL...159
INSTALLATION...160
RADIATOR AND OIL COOLER...163
REMOVAL...163
INSTALLATION...163
ENGINE AND HYDRAULIC PUMP...165
REMOVAL...165
INSTALLATION...166
DAMPER...167
REMOVAL...167
INSTALLATION...167
CENTER SWIVEL JOINT...168
REMOVAL...168
INSTALLATION...168
DISASSEMBLY...170
ASSEMBLY...170
TRAVEL MOTOR...171
REMOVAL...171
INSTALLATION...171
DISASSEMBLY...172
ASSEMBLY...177
SPROCKET...183
REMOVAL...183
INSTALLATION...183
SWING MOTOR AND SWING MACHINERY...184
REMOVAL...184
INSTALLATION...184
SWING MOTOR ...186
DISASSEMBLY...186
ASSEMBLY...188
SWING MACHINERY...192
DISASSEMBLY...192
ASSEMBLY...194
REVOLVING FRAME...196
REMOVAL...196
INSTALLATION...197
SWING CIRCLE...200
REMOVAL...200
INSTALLATION...200
IDLER AND RECOIL SPRING...201
REMOVAL...201
INSTALLATION...201
RECOIL SPRING...202
DISASSEMBLY...202
ASSEMBLY...203
TRACK ROLLER...204
REMOVAL...204
INSTALLATION...204
CARRIER ROLLER...205
REMOVAL...205
INSTALLATION...205
RUBBER SHOE...206
REMOVAL...206
INSTALLATION...206
HYDRAULIC PUMP...207
REMOVAL...207
INSTALLATION...207
7-SPOOL CONTROL VALVE...208
REMOVAL...208
INSTALLATION...208
2-SPOOL CONTROL VALVE...210
REMOVAL...210
INSTALLATION...210
7-SPOOL CONTROL VALVE...212
DISASSEMBLY...212
ASSEMBLY...214
2-SPOOL CONTROL VALVE...216
DISASSEMBLY...216
ASSEMBLY...217
BOOM CYLINDER...218
REMOVAL...218
INSTALLATION...218
ARM CYLINDER...219
REMOVAL...219
INSTALLATION...219
BUCKET CYLINDER...220
REMOVAL...220
INSTALLATION...220
SWING CYLINDER ...221
REMOVAL...221
INSTALLATION...221
BLADE CYLINDER...222
REMOVAL...222
INSTALLATION...222
HYDRAULIC CYLINDER...223
DISASSEMBLY...223
ASSEMBLY...225
WORK EQUIPMENT...227
REMOVAL...227
INSTALLATION...227
BUCKET...228
REMOVAL...228
INSTALLATION...228
ARM...229
REMOVAL...229
INSTALLATION...229
BOOM...230
REMOVAL...230
INSTALLATION...230
BLADE...231
REMOVAL...231
INSTALLATION...231
40 MAINTENANCE STANDARD...233
SWING CIRCLE...234
SWING MACHINERY...236
TRACK FRAME AND RECOIL SPRING...237
IDLER...239
CARRIER ROLLER...240
TRACK ROLLER...242
TRACK SHOE...244
HYDRAULIC PUMP...245
7-SPOOL CONTROL VALVE...246
2-SPOOL CONTROL VALVE...249
SWING MOTOR...251
TRAVEL MOTOR...252
CENTER SWIVEL JOINT...253
HYDRAULIC CYLINDER...254
WORK EQUIPMENT...257
1.1 FOREWORD...3
1.2 INFORMATION ON SAFETY...4
1.3 INTRODUCTION...6
1.3.1 INTENDED USE OF THE MACHINE...6
1.3.2 IMPROPER OR UNAUTHORIZED USES...6
1.3.3 MAIN CHARACTERISTICS...6
1.3.4 RUNNING-IN...7
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE...7
1.4 PRODUCT IDENTIFICATION...8
1.4.1 MACHINE SERIAL NUMBER...8
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...8
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...9
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...9
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...10
1.4.6 SERIAL NUMBERS AND DEALER?S ADDRESS...11
TABLE OF CONTENTS...12
2.1 SAFETY, NOISE AND VIBRATION PLATES...20
2.1.1 POSITION OF THE SAFETY PLATES...20
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...21
2.1.3 POSITION OF THE NOISE PLATES...26
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...26
2.2 GENERAL PRECAUTIONS...27
2.2.1 GENERAL SAFETY RULES...27
2.2.2 SAFETY DEVICES AND GUARDS...27
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...27
2.2.4 UNAUTHORIZED MODIFICATIONS...28
2.2.5 LEAVING THE OPERATOR SEAT...28
2.2.6 GETTING ON AND OFF THE MACHINE...29
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...30
2.2.8 PREVENTING BURNS...30
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...31
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...31
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...32
2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE...32
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...32
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...33
2.3.1 SAFETY AT THE WORK SITE...33
2.3.2 FIRE PREVENTION...33
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT...33
2.3.4 ROOM VENTILATION...34
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...34
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...35
2.4.1 STARTING THE ENGINE...35
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE...35
2.4.3 HAND SIGNALS...36
2.4.4 CHECKS FOR TRAVELLING IN REVERSE...41
