Komatsu PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual – PDF Download

Description

Komatsu PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual

Description:

Komatsu PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac- curate 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.The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections 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 this section.
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 PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual

COVER............................................................................................  1
	CONTENTS.....................................................................................  3
	LIST OF REVISED PAGES........................................................................  5
	SAFETY.......................................................................................  7
	FOREWORD.....................................................................................  9
	HOW TO READ THE SHOP MANUAL.................................................................. 10
	HOISTING INSTRUCTIONS........................................................................ 11
	STANDARD TIGHTENING TORQUE................................................................... 12
	COATING MATERIALS............................................................................ 13
	ELECTRIC WIRE CODE........................................................................... 14
	WEIGHT TABLE................................................................................. 15
	TABLE OF OIL AND COOLANT QUANTITIES.......................................................... 16
	10.STRUCTURE AND FUNCTION.................................................................... 19
		POWER TRAIN.............................................................................. 20
		SWING CIRCLE............................................................................. 22
		SWING MOTOR.............................................................................. 23
		FINAL DRIVE.............................................................................. 24
		TRACK FRAME AND RECOIL SPRING............................................................ 25
		VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING............................................. 27
		CARRIER ROLLER........................................................................... 28
		STEEL SHOE............................................................................... 29
		HYDRAULIC SYSTEM PC12R-8................................................................. 31
		HYDRAULIC SYSTEM PC15R-8................................................................. 33
		HYDRAULIC CIRCUIT DIAGRAM PC12R-8........................................................ 35
		HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL................................................ 37
		HYDRAULIC CIRCUIT DIAGRAM PC12R-8 HS..................................................... 39
		HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL HS............................................. 41
		HYDRAULIC CIRCUIT DIAGRAM PC15R-8........................................................ 43
		HYDRAULIC CIRCUIT DIAGRAM PC15R-8 HS..................................................... 45
		HYDRAULIC CIRCUIT DIAGRAM................................................................ 46
		HYDRAULIC PUMP........................................................................... 47
		CONTROL VALVE PC12R-8 PC12R-8 MISTRAL.................................................... 52
		CONTROL VALVE PC12R-8 HS PC12R-8 MISTRAL HS.............................................. 54
		CLSS..................................................................................... 62
		CONTROL VALVE PC15R-8.................................................................... 80
		CLSS..................................................................................... 90
		SWIVEL JOINT.............................................................................107
		TRAVEL MOTOR.............................................................................110
		CYLINDERS................................................................................113
		VALVE CONTROL............................................................................117
		ACCUMULATOR..............................................................................118
		PPC VALVE................................................................................119
		PPC VALVE................................................................................121
		SOLENOID VALVE...........................................................................124
		VARIABLE GAUGE UNDERCARRIAGE SERVOCONTROL................................................127
		SAFETY VALVE.............................................................................128
		CUTTING SHOVEL CONTROL VALVE.............................................................129
		ELECTRICAL CIRCUIT DIAGRAM...............................................................131
	20.TESTING AND ADJUSTMENTS...................................................................135
		NORMAL OR STANDARD TECHNICAL DATA........................................................136
		SPECIAL TOOLS............................................................................157
		CHECKING THE ENGINE SPEED................................................................159
		ADJUSTMENT OF VALVE CLEARANCE............................................................160
		MEASUREMENT OF THE COMPRESSION PRESSURE..................................................161
		CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....................................162
		CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...........................................163
		CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE.........................................165
		ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER......................................166
		CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER.................................167
		CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL.....................................168
		ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT.........169
		CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION.........................................170
		CONTROL AND REGULATION OF THE PRESSURE IN THE HYDRAULIC CIRCUITS (PC12R).................171
		CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS (PC15R)................174
		CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....177
		REGULATION OF THE PC VALVE...............................................................179
		CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC12R).........................180
		CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC15R).........................181
		ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...........................182
		BLEEDING AIR FROM THE HYDRAULIC CIRCUITS.................................................183
		CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT..........................185
		CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS.........................191
		CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR.........................................192
		METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT.................................193
	30.REMOVAL AND INSTALLATION..................................................................201
		HOW TO READ THE MANUAL...................................................................203
		PRECAUTIONS TO BE TAKEN WHILE WORKING....................................................204
		SPECIAL TOOLS............................................................................205
		STARTER MOTOR............................................................................207
		ALTERNATOR...............................................................................208
		PUMP GROUP...............................................................................209
		INJECTION NOZZLES........................................................................210
		CYLINDER HEAD............................................................................211
		OIL COOLER...............................................................................215
		RADIATOR.................................................................................216
		ENGINE HOOD..............................................................................217
		CAB AND CANOPY...........................................................................218
		HEATING FAN..............................................................................220
		REAR COUNTERWEIGHT.......................................................................221
		TOP COVER AND SIDE PANELS................................................................222
		HYDRAULIC OIL TANK.......................................................................224
		FUEL TANK................................................................................227
		ENGINE-PUMP GROUP........................................................................228
		PUMP.....................................................................................231
		ENGINE-PUMP COUPLING.....................................................................232
		CONTROL VALVE............................................................................233
		RIGHT-HAND PPC VALVE (BOOM-BUCKET).......................................................235
		LEFT-HAND PPC VALVE (ARM-BUCKET).........................................................236
		SERVOCONTROL SOLENOID GROUP (PC12 WITHOUT TRAVEL INCREMENT)..............................237
		SERVOCONTROL SOLENOID GROUP (PC12 WITH TRAVEL INCREMENT - PC15R).........................238
		SWIVEL JOINT.............................................................................239
		SWING MOTOR..............................................................................240
		REVOLVING FRAME..........................................................................241
		SWING CIRCLE.............................................................................243
		TRAVEL MOTOR.............................................................................244
		RUBBER TRACK SHOES.......................................................................245
		TRACK-SHOES..............................................................................246
		SPROCKET WHEEL...........................................................................247
		COMPLETE FINAL DRIVE.....................................................................248
		FINAL DRIVE..............................................................................249
		IDLER AND RECOIL SPRING ASSEMBLY.........................................................259
		IDLER....................................................................................260
		SPRING RECOIL AND THRUST CYLINDER GROUPS.................................................261
		TRACK ROLLERS............................................................................262
		BOOM CYLINDER............................................................................263
		ARM CYLINDER.............................................................................264
		BUCKET CYLINDER..........................................................................265
		BOOM SWING CYLINDER......................................................................266
		BLADE CYLINDER...........................................................................267
		WORKING EQUIPMENT CYLINDER...............................................................268
		UPPER WORKING EQUIPMENT..................................................................274
		BUCKET...................................................................................276
		ARM......................................................................................277
		BOOM.....................................................................................279
		BOOM SWING SUPPORT.......................................................................281
		BLADE....................................................................................282
	40.STANDARD MAINTENANCE......................................................................285
		SWING CIRCLE.............................................................................286
		TRACK FRAME AND RECOIL SPRING............................................................287
		VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING.............................................288
		IDLER....................................................................................289
		FINAL DRIVE..............................................................................290
		SPROCKET.................................................................................291
		TRACK ROLLER.............................................................................292
		TRACK SHOE...............................................................................293
		HYDRAULIC PUMP...........................................................................295
		CONTROL VALVE............................................................................297
		SWIVEL JOINT.............................................................................309
		SWING MOTOR..............................................................................311
		TRAVEL MOTOR.............................................................................312
		CYLINDERS PC12R-8........................................................................318
		CYLINDERS PC15R-8........................................................................319
		WORK EQUIPMENT PC12R-8...................................................................320
		WORK EQUIPMENT PC15R-8...................................................................322

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KOMATSU PC12R-8 PC15R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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