Komatsu Hydraulic Excavator PC03 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC03-2, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC03-2 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: 469 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM025000 - Hydraulic Excavator PC03-2 Shop Manual.pdf
SEAM040601 - Hydraulic Excavator PC03-2 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
FOREWORD...3
SAFETY...3
FOREWORD...5
HOW TO READ THE SHOP MANUAL...6
HOISTING INSTRUCTIONS...7
STANDARD TIGHTENING TORQUE...8
COATING MATERIALS...9
ELECTRIC WIRE CODE...10
COVERSION TABLE...11
01 GENERAL...17
GENERAL ASSEMBLY DRAWING...18
SPECIFICATIONS...19
WEIGHT TABLE...21
LIST OF LUBRICANT AND WATER...22
10 STRUCTURE...23
ENGINE MOUNT...24
POWER TRAIN...25
SWING CIRCLE...26
TRACK FRAME...27
IDLER...29
TRACK ROLLER...29
HYDRAULIC PIPING...32
HYDRAULIC DIAGRAM...34
HYDRAULIC TANK...38
HYDRAULIC PUMP...40
9-SPOOL CONTROL VALVE...41
SWING MOTOR...43
CENTER SWIVEL JOINT...44
TRAVEL MOTOR...45
VALVE CONTROL...46
HYDRAULIC CYLINDER...47
WORK EQUIPMENT...49
ELECTRICAL CIRCUIT DIAGRAM...51
20 TESTING AND ADJUSTING...53
STANDARD VALVE TABLE FOR ENGINE-RELATED PARTS...54
STANDARD VALVE TABLE FOR CHASSIS-RELATED PARTS...55
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...62
MEASURING ENGINE SPEED...63
MEASURING ENGINE OIL PRESSURE...63
ADJUSTING VALVE CLEARANCE...64
MEASURING COMPRESSION PRESSURE...65
TESTING AND ADJUSTING FUEL INJECTION TIMING...66
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...67
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...68
BLEEDING AIR FROM HYDRAULIC CYLINDERS...69
TROUBLESHOOTING...70
POINTS TO REMEMBER WHEN TROUBLESHOOTING...71
SEQUENCE OF EVENTS IN TROUBLESHOOTING...72
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...73
CHECKS BEFORE TROUBLESHOOTING CHARTS...81
METHOD OF USING TROUBLESHOOTING CHARTS...82
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...84
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVELING, SWINGING ARE SLOW OR LACK POWER...85
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS WORK EQUIPMENT TRAVELING, SWINGING DO NOT FUNCTION OR ARE...85
H-3 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...86
H-4 CONTROL LEVER IS HEAVY...86
H-5 WORK EQUIPMENT (BOOM, ARM, BUCKET ) IS SLOW EXCESSIVE HYDRAULIC DRIFT...87
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET ) LACKS POWER...87
H-7 EXCESSIVE TIME LAG...87
H-8 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE...88
A) DEVIATES IN SAME DIRECTION IN BOTH FORWARD AND REVERSE...88
B) DEVIATES IN DIFFERENT DIRECTIONS IN BOTH FORWARD AND REVERSE...88
H-9 TRAVEL LACKS POWER (OR SPEED IS SLOW...90
H-10 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...90
H-11 DOES NOT SWING...91
H-12 SWING SPEED IS SLOW OR ACCELERATION IS POOR...92
H-13 EXCESSIVE OVERRUN WHEN STOPPING SWING...92
H-14 EXCESSIVE SHOCK WHEN STOPPING SWING...93
H-15 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING ...93
H-16 EXCESSIVE HYDRAULIC DRIFT OF SWING...94
H-17 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING...94
TABLE OD FAILURE MODES AND CAUSES...95
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...96
M-1 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...97
M-2 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)...98
M-3 THE ENGINE COOLING WATER TEMPERATURE CASUTION LAMP WILL LIGHT ON, WHEN TURNING THE ENGINE STARTING SWITCH ON...99
M-4 THE WORKING LAMP DOES NOT LIGHT ON, EVEN THOUGH THE LAMP SWITCH IS TURNED ON...100
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...101
E-1 THE ENGINE DOES NOT START, EVEN THOUGH THE ENGINE STARTING SWITCH IS TURNED ON...102
A) WHEN THE ENGINE STARTING MOTOR DOES NOT ROTATE NORMALLY...102
B) WHEN THE ENGINE STARTING MOTOR ROTATES NORMALLY ...104
E-2 THE ENGINE DOES NOT STOP, EVEN THOUGH THE ENGINE STARTING SWITCH IS TURNED OFF...106
30 DISASSEMBLY AND ASSEMBLY...107
METHOD OF USING MANUAL...108
PRECAUTIONS WHEN CARRYING OUT OPERATION...110
SPECIAL TOOL LIST...112
RADIATOR...113
REMOVAL AND INSTALLATION ...113
CENTER SWIVEL JOINT...114
DISASSEMBLY AND ASSEMBLY...114
BATTERY...115
REMOVAL AND INSTALLATION ...115
ENGINE, MAIN PUMP...116
REMOVAL AND INSTALLATION ...117
TRAVEL MOTOR...119
REMOVAL AND INSTALLATION ...119
SPROCKET...120
REMOVAL AND INSTALLATION ...120
SWING MOTOR...121
REMOVAL AND INSTALLATION ...121
REVOLVING FRAME...122
REMOVAL AND INSTALLATION ...122
SWING CIRCLE...123
REMOVAL AND INSTALLATION ...123
IDLER...124
REMOVAL AND INSTALLATION ...124
IDLER...124
DISASSEMBLY AND ASSEMBLY...124
TRACK ROLLER...125
REMOVAL AND INSTALLATION ...125
TRACK ROLLER...126
DISASSEMBLY AND ASSEMBLY...126
RUBBER SHOE...127
REMOVAL AND INSTALLATION ...127
MAIN PUMP...127
REMOVAL AND INSTALLATION ...127
9-SPOOL CONTROL VALVE...128
REMOVAL AND INSTALLATION ...128
9-SPOOL CONTROL VALVE...130
DISASSEMBLY...130
ARM CYLINDER...132
REMOVAL AND INSTALLATION ...132
BUCKET CYLINDER...133
REMOVAL AND INSTALLATION ...133
BOOM CYLINDER...134
REMOVAL AND INSTALLATION ...134
BOOM SWING CYLINDER...135
REMOVAL AND INSTALLATION ...135
BLADE CYLINDER...136
REMOVAL AND INSTALLATION ...136
WORK EQIPMENT...137
REMOVAL AND INSTALLATION ...137
BUCKET...138
REMOVAL AND INSTALLATION ...138
ARM...139
REMOVAL AND INSTALLATION ...139
BOOM...140
REMOVAL...140
INSTALLATION...141
BLADE...142
REMOVAL AND INSTALLATION ...142
FUEL TANK...143
REMOVAL AND INSTALLATION ...143
MACHINE COVER...144
REMOVAL...144
INSTALLATION...145
HYDRAULIC TANK...146
REMOVAL AND INSTALLATION ...146
MONITOR PANEL...147
REMOVAL AND INSTALLATION...147
COUNTERWEIGHT...147
REMOVAL AND INSTALLATION...147
40 MAINTENANCE STANDARD...148
SWING CIRCLE...149
TRACK FRAME...150
IDLER...151
TRACK ROLLER...152
HYDRAULIC PUMP...153
CENTER SWIVEL JOINT...154
9-SPOOL CONTROL VALVE...155
TRAVEL MOTOR...157
HYDRAULIC CYLINDER...158
WORK EQUIPMENT...160
91 ENGINE ...164
CONTENTS...166
1. SPECIFICATIONS AND PERFORMANCE...168
1-1 2D68E-3B...168
2. CROSS SECTIONAL VIEWS...169
2-1 SPECIAL SWIRL PRE-COMBUSTION CHAMBER SYSTEM...169
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL...170
3-1 COOLING WATER...170
3-2 LUBRICATING OIL...170
3-3 FUEL OIL...172
4. TROUBLESHOOTING...173
4-1 TROUBLE CAUSES AND REMEDIES...173
4-2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE...175
5. SPECIAL SERVICE TOOLS...176
5-1 SPECIAL SERVICE TOOLS...176
5-2 MEASURING INSTRUMENTS...178
6. MEASUREMENT, INSPECTION AND ADJUSTMENT...181
6-1 MEASURING THE COMPRESSION PRESSURE...181
6-2 ADJUSTING THE VALVE HEAD...183
6-3 CHECKING THE V-BELT TENSION...184
6-4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE...184
6-5 CHECKING AND ADJUSTIONG THE FUEL INJECTION TIMING...188
6-6 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS...189
6-7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR LEAKAGE...189
6-8 CHECKING THE BATTERY...190
6-9 CHECKING SENSORS...192
6-10 CHECKING THE OIL COOLER...193
6-11 CHECKING THE PISTON COOLING NOZZLE...194
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION...195
7-1 CYLINDER HEAD...195
7-2 CYLINDER BLOCK...201
7-3 VALVE ROCKER ARM...204
7-4 PISTON AND PISTON RING...206
7-5 CONNECTING ROD...211
7-6 CAMSHAFT...214
7-7 CRANKSHAFT...216
7-8 GEARS...219
7-9 TROCHOID PUMP...221
8. DISASSEMBLY AND REASSEMBLY...222
8-1 DISASSEMBLY...222
8-2 PRECAUTIONS BEFORE AND DURING REASSEMBLY...227
9. SERVICE DATA...231
9-1 CYLINDER HEAD...231
9-2 CYLINDER BLOCK...232
9-3 VALVE ROCKER ARM...232
9-4 PISTON...233
9-5 PISTON RING...234
9-6 CONNECTING ROD...235
9-7 CAMSHAFT...235
9-8 CRANKSHAFT...235
9-9 SIDE GAP AND BACKLASH...236
9-10 OTHERS...236
10. TIGHENING TORQUJE...237
10-1 MAIN BOLT/NUT...237
10-2 STANDARD BOLT AND NUT...237
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM...238
11-1 EXPLODED VIEWS (YPFR TYPE)...238
11.2 DISASSEMBLY...239
11.3 INSPECTION...240
11-4 REASSEMBLY...242
13. GOVERNOR...243
13-1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM...243
13.3 DISASSEMBLY...244
13.4 INSPECTION...248
13-5 REASSEMBLY...250
ATTACHED DRAWING 1. EXPLODED VIEWS OF ENGINE COMPONENTS...254
ATTACHED DRAWING 2. EXPLODED VIEWS OF ENGINE COMPONENTS...255
COVER...1
1. FOREWORD...2
2. SAFETY INFORMATION...3
3. INTRODUCTION...4
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...5
5. CONTENTS...6
SAFETY...11
6. GENERAL PRECAUTIONS...12
7. PRECAUTIONS DURING OPERATION...18
7.1 BEFORE STARTING ENGINE...18
7.2 OPERATING MACHINE...21
7.3 TRANSPORTATION...27
7.4 BATTERY...28
7.5 TOWING...30
7.6 BUCKET WITH HOOK...31
8. PRECAUTIONS FOR MAINTENANCE...35
8.1 BEFORE CARRYING OUT MAINTENANCE...35
8.2 DURING MAINTENANCE...38
9. POSITION FOR ATTACHING SAFETY LABELS...43
OPERATION...45
10. GENERAL VIEW...46
10.1 GENERAL VIEW OF MACHINE...46
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...47
11. EXPLANATION OF COMPONENTS...48
11.1 METERS,LAMPS...48
11.2 SWITCHES...50
11.3 CONTROL LEVERS,PEDALS...52
11.4 ENGINE HOOD (WITH LOCK)...58
11.5 FUSE BOX...59
11.6 FUSIBLE LINK...60
11.7 OPERATION MANUAL STORAGE...60
12. OPERATION...61
12.1 CHECK BEFORE STARTING ENGINE...61
12.2 STARTING ENGINE...72
12.3 OPERATION AND CHECK AFTER STARTING ENGINE...75
12.4 MOVING MACHINE OFF...78
12.5 STEERING MACHINE...82
12.6 STOPPING MACHINE...84
12.7 SWINGING...85
12.8 OPERATION OF WORK EQUIPMENT...86
12.9 PROHIBITIONS FOR OPERATION...89
12.10 PRECAUTIONS FOR OPERATION...92
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...93
12.12 HOW TO ESCAPE FROM MUD...95
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...96
12.14 REPLACEMENT OF BUCKET...98
12.15 HANDLING RUBBER SHOES...100
12.16 PARKING MACHINE...105
12.17 CHECKS AFTER FINISHING WORK...106
12.18 STOPPING ENGINE...107
12.19 CHECKS AFTER STOPPING ENGINE...107
12.20 LOCKING...108
13. TRANSPORTATION...109
13.1 LOADING,UNLOADING WORK...109
13.2 METHOD OF LIFTING MACHINE...111
13.3 PRECAUTIONS FOR LOADING...113
13.4 PRECAUTIONS FOR TRANSPORTATION...114
14. COLD WEATHER OPERATION...115
14.1 PRECAUTIONS FOR LOW TEMPERATURE...115
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...118
14.3 AFTER COLD WEATHER...119
15. LONG-TERM STORAGE...120
15.1 BEFORE STORAGE...120
15.2 DURING STORAGE...121
15.3 AFTER STORAGE...121
16. TROUBLESHOOTING...122
16.1 PHENOMENA THAT ARE NOT FAILURES...122
16.2 METHOD OF TOWING MACHINE...123
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...123
16.3 IF BATTERY IS DISCHARGED...124
16.4 OTHER TROUBLE...129
MAINTENANCE...133
17. GUIDES TO MAINTENANCE...134
18. OUTLINES OF SERVICE...138
18.1 OUTLINE OF OIL,FUEL...139
18.2 OUTLINE OF ELECTRIC SYSTEM...144
18.3 OUTLINE OF HYDRAULIC SYSTEM...144
19. WEAR PARTS LIST...145
20. USE OF FUEL AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...146
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...150
21.1 INTRODUCTION OF NECESSARY TOOLS...150
21.2 TORQUE LIST...151
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...152
23. MAINTENANCE SCHEDULE CHART...154
23.1 MAINTENANCE SCHEDULE CHART...154
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...156
24. SERVICE PROCEDURE...157
24.1 INITIAL 100 HOURS SERVICE...157
24.2 INITIAL 250 HOURS SERVICE...157
24.3 INITIAL 500 HOURS SERVICE...157
24.4 WHEN REQUIRED...158
24.5 CHECK BEFORE STARTING...173
24.6 EVERY 100 HOURS SERVICE...178
24.7 EVERY 250 HOURS SERVICE...179
24.8 EVERY 500 HOURS SERVICE...183
24.9 EVERY 2000 HOURS SERVICE...187
SPECIFICATIONS...192
25. SPECIFICATIONS...193
OPTIONS,ATTACHMENTS...196
26. GENERAL PRECAUTIONS...197
26.1 PRECAUTIONS RELATED TO SAFETY...197
27. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS...198
27.1 SPECIFICATIONS,USES...198
27.2 ATTACHMENTS INSTALLATION COMBINATION...199
28. HANDLING BUCKET WITH HOOK...200
28.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...200
28.2 PROHIBITED OPERATIONS...200
28.3 PRECAUTIONS DURING OPERATIONS...201
29. HANDLING 2-WAY PIPING...202
29.1 SWITCHING BETWEEN 1-WAY AND 2-WAY...202
29.2 OPERATING PEDAL...202
29.3 METHOD OF USING PEDAL LOCK...203
VARIABLE GAUGE...204
30. HANDLING VARIABLE GAUGE SPECIFICATION MACHINE...205
31. PRECAUTIONS DURING OPERATION...206
31.1 TOWING...206
32. POSITION FOR ATTACHING SAFETY LABELS...207
32.1 POSITION FOR ATTACHING SAFETY LABELS...207
33. OPERATIONS...209
33.1 METHOD OF OPERATING VARIABLE GAUGE...209
33.2 PRECAUTIONS WHEN DIGGING...210
33.3 METHOD OF OPERATING VARIABLE BLADE...210
34. SPECIFICATION...211
