Komatsu Hydraulic Excavator PC20MR-2 Shop Manual SEBM037001 PDF

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Komatsu Hydraulic Excavator PC20MR-2 Shop Manual SEBM037001 – PDF  DOWNLOAD

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Komatsu Hydraulic Excavator PC20MR-2 Shop Manual SEBM037001 – PDF  DOWNLOAD

Language : English
Pages :408
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu Hydraulic Excavator PC20MR-2 Shop Manual SEBM037001 – PDF  DOWNLOAD

Machine model Serial number
PC20MR-2 15001 and up

Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
Testing and adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC20MR-2 Shop Manual SEBM037001 – PDF  DOWNLOAD

Machine model Serial number
PC20MR-2 15001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWORD 8
GENERAL 8
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
SPECIFICATION DIMENSION DRAWING 27
WORKING RANGE DRAWING 28
SPECIFICATIONS 29
WEIGHT TABLE 32
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 34
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 36
PTO 37
COOLING SYSTEM 39
POWER TRAIN 41
SWING CIRCLE 42
TRACK FRAME 43
IDLER CUSHION 44
IDLER 45
TRACK ROLLER 47
CARRIER ROLLER 48
SPROCKET 49
TRACK SHOE 50
HYDRAULIC COMPONENTS LAYOUT DRAWING 51
HYDRAULIC TANK 52
CENTER SWIVEL JOINT 53
TRAVEL MOTOR 54
HYDRAULIC CYLINDER 63
SOLENOID VALVE 66
MULTI-CONTROL VALVE (IF EQUIPPED) 69
HYDRAULIC PUMP 71
CONTROL VALVE 77
CLSS 90
OPERATION FOR EACH FUNCTION AND VALVE 93
SWING MOTOR113
PPC VALVE123
WORK EQUIPMENT132
DIMENSIONS OF EACH PART OF WORK EQUIPMENT135
FLOOR138
ENGINE CONTROL139
ELECTRIC CONTROL SYSTEM141
COMPONENT PART OF SYSTEM146
MONITOR SYSTEM147
MONITOR PANEL148
SENSORS150
20 TESTING AND ADJUSTING152
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS153
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS154
TESTING AND ADJUSTING164
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS165
MEASURING ENGINE SPEED167
MEASUREMENT OF EXHAUST GAS COLOR168
ADJUSTING VALVE CLEARANCE169
MEASURING COMPRESSION PRESSURE170
MEASURING ENGINE OIL PRESSURE171
TESTING AND ADJUSTING FUEL INJECTION TIMING172
BLEEDING AIR FROM FUEL CIRCUIT174
TESTING AND ADJUSTING FAN BELT TENSION175
ADJUSTING FUEL CONTROL LEVER LINKAGE176
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS177
TESTING AND ADJUSTING TRACK SHOE TENSION178
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, SWING, AND BLADE CIRCUITS180
MEASURING CONTROL CIRCUIT BASIC PRESSURE183
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE184
MEASURING SOLENOID VALVE OUTPUT PRESSURE186
MEASURING PPC VALVE OUTPUT PRESSURE188
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES190
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE190
MEASURING OF OIL LEAKAGE FROM CYLINDER192
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT194
BLEEDING AIR FROM CYLINDER194
PRESSURIZING HYDRAULIC TANK195
HOW TO OPEN AND CLOSE (TILT) FLOOR196
INSPECTION PROCEDURES FOR DIODE198
TROUBLESHOOTING200
POINTS TO REMEMBER WHEN TROUBLESHOOTING201
SEQUENCE OF EVENTS IN TROUBLESHOOTING202
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE203
CHECKS BEFORE TROUBLESHOOTING211
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING212
CONNECTORS LIST AND STEREOGRAM215
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS223
T-ADAPTER-BOXES AND T-ADAPTER TABLE246
TROUBLESHOOTING OF ELECTRICAL SYSTEM (EXCEPT MONITOR PANEL E-MODE)250
BEFORE STARTING E-MODE TROUBLESHOOTING251
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE253
E-1 ENGINE DOES NOT START254
E-2 ENGINE DOES NOT STOP260
E-3 WHEN SAFETY LOCK LEVER IS IN FREE POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE SYSTEMS DO NOT WORK262
E-4 WHEN SAFETY LOCK LEVER IS IN LOCK POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING AND BLADE SYSTEMS WORK265
E-5 WHEN MACHINE STARTS TRAVELING, TRAVEL ALARM DOES NOT SOUND267
E-6 WHEN MACHINE STOPS TRAVELING, TRAVEL ALARM DOES NOT STOP SOUNDING269
E-7 WINDSHIELD WIPER DOES NOT OPERATE [CAB SPECIFICATION]271
E-8 WINDSHIELD WASHER DOES NOT OPERATE [CAB SPECIFICATION]273
E-9 HEATER DOES NOT OPERATE275
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)278
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE279
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW280
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS283
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK 284
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP287
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW287
H-6 SPEED OR POWER OF BOOM IS LOW288
H-7 SPEED OR POWER OF ARM IS LOW289
H-8 SPEED OR POWER OF BUCKET IS LOW290
H-9 SPEED OR POWER OF BOOM SWING IS LOW291
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY291
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE292
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE293
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW293
H-14 MACHINE DEVIATES DURING TRAVEL294
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW296
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW296
H-17 TRAVEL SPEED DOES NOT CHANGE297
H-18 TRAVEL MOTOR DOES NOT WORK (ONE SIDE ONLY)297
H-19 SPEED OR POWER OF SWING IS LOW298
H-20 MACHINE DOES NOT SWING300
H-21 SWING ACCELERATION PERFORMANCE IS LOW302
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING303
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING304
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND304
H-25 HYDRAULIC DRIFT OF SWING IS LARGE305
H-26 SPEED OR POWER OF BLADE IS LOW306
H-27 BLADE DOES NOT MOVE307
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE307
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)308
BEFORE STARTING M-MODE TROUBLESHOOTING309
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE311
M-1 WHEN STARTING SWITCH IS TURNED ON, NO MONITOR/GAUGE OPERATES313
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME MONITORS/GAUGES DO NO OPERATE315
M-3 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING317
M-4 WHILE ENGINE IS RUNNING, ENGINE OIL PRESSURE MONITOR FLASHES319
M-5 WHILE ENGINE IS RUNNING, CHARGE LEVEL MONITOR FLASHES321
M-6 PREHEATING SYSTEM DOES NOT OPERATE323
M-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY326
M-8 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY329
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING331
M-10 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY332
M-11 MONITOR PANEL NIGHT LAMP AND WORKING LAMP DO NOT LIGHT UP335
TROUBLESHOOTING OF ENGINE (S MODE)340
TROUBLESHOOTING OF ENGINE (S-MODE)341
30 DISASSEMBLY AND ASSEMBLY348
HOW TO READ THIS MANUAL349
PRECAUTIONS WHEN PERFORMING OPERATION351
SPECIAL TOOL LIST353
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY355
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY357
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY362
REMOVAL AND INSTALLATION TRACK SHOE ASSEMBLY364
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY365
DISASSEMBLY AND ASSEMBLYOF RECOIL SPRING ASSEMBLY367
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY370
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY371
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY373
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY375
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY380
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY381
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY383
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY385
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY386
DISASSEMBLY AND ASSEMBLY OF HDYRAULIC CYLINDER ASSEMBLY390
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY394
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)395
90 OTHERS404
HYDRAULIC CIRCUIT DIAGRAM406
ELECTRICAL CIRCUIT DIAGRAM (1/2)407
ELECTRICAL CIRCUIT DIAGRAM (2/2)408

S.M 28/12/24