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Komatsu PC10-7, PC15-3, PC20-7 Excavator Shop Manual SN 25001, 5001, 35001 and up – PDF DOWNLOAD
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Komatsu PC10-7, PC15-3, PC20-7 Excavator Shop Manual
Book Code: SEBM020P0703
Models Covers:
PC10-7 SN 25001 AND UP
PC15-3 SN 5001 AND UP
PC20-7 SN 35001 AND UP
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Description
Komatsu PC10-7, PC15-3, PC20-7 Excavator Shop Manual
FILE DETAILS:
Komatsu PC10-7, PC15-3, PC20-7 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC10-7, PC15-3, PC20-7
Serial Number: 25001 and up, 5001 and up, 35001 and up
Book Code: SEBM020P0703
Language: English
Pages: 264
File Format: Portable Document Format (PDF)
KOMATSU PC10-7, PC15-3, PC20-7 EXCAVATOR SHOP MANUAL SN 25001, 5001, 35001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC10-7, PC15-3, PC20-7 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 PC10-7, PC15-3, PC20-7 Excavator Shop Manual
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
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