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KOMATSU PC09-1 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC09 1 – PDF DOWNLOAD
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- KOMATSU PC09-1 SERVICE REPAIR MANUAL
- Serial Number:10001 & UP
- Publication Number:SEBM026105
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Description
KOMATSU PC09-1 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC09 1
KOMATSU PC09-1 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC09 1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC09-1 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC09 1
- 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 PC09-1 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC09 1
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
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