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Komatsu PC03-2 Hydraulic Excavator Shop Manual SN 21587 and up – PDF DOWNLOAD
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Komatsu PC03-2 Hydraulic Excavator Shop Manual
Serial Number: 21587 and up
Book Code: SEBM025000
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Description
Komatsu PC03-2 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC03-2 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC03-2
Serial Number: 21587 and up
Book Code: SEBM025000
Language: English
Pages: 255
File Format: Portable Document Format (PDF)
KOMATSU PC03-2 HYDRAULIC EXCAVATOR SHOP MANUAL SN 21587 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC03-2 Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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.
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” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC03-2 Hydraulic Excavator Shop Manual
MAIN MENU.............................................................................................................................. 0 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
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