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KOMATSU PC12R-8 PC15R-8 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC12R-8 PC15R-8 – PDF DOWNLOAD
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- KOMATSU PC12R-8 PC15R-8 SERVICE REPAIR MANUAL
- SERIAL NUMBER:PC12R-8-10001 & UP,PC15R-8-10001 & UP
- PUBLICATION NUMBER:SEBM013103
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Description
KOMATSU PC12R-8 PC15R-8 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC12R-8 PC15R-8
KOMATSU PC12R-8 PC15R-8 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC12R-8 PC15R-8 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC12R-8 PC15R-8 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC12R-8 PC15R-8
- 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. - 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 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 SERVICE REPAIR MANUAL (SN:10001 & UP) KOMATSU PC12R-8 PC15R-8
MAIN MENU..................................................................................................................... 0 COVER......................................................................................................................... 1 CONTENTS...................................................................................................................... 2 SAFETY........................................................................................................................ 5 00 FOREWORD................................................................................................................... 7 01 GENERAL.................................................................................................................... 25 General assembly drawing.................................................................................................. 26 Specifications............................................................................................................ 30 List of lubricant and water............................................................................................... 34 10 STRUCTURE AND FUNCTION..................................................................................................... 35 Power Train............................................................................................................... 36 Swing circle.............................................................................................................. 37 Track frame and recoil spring............................................................................................. 38 Hydraulic piping.......................................................................................................... 39 Hydraulic tank............................................................................................................ 40 Hydraulic pump............................................................................................................ 41 Control valve (PC12R-8)................................................................................................... 45 CLSS (PC12R-8)............................................................................................................ 53 Control valve (PC15R-8)................................................................................................... 76 CLSS (PC15R-8)............................................................................................................ 84 Center swivel joint.......................................................................................................105 Swing motor...............................................................................................................107 Travel motor..............................................................................................................109 Valve control.............................................................................................................112 PPC valve.................................................................................................................113 Work equipment............................................................................................................117 Machine monitor system....................................................................................................118 20 TESTING AND ADJUSTING......................................................................................................121 STANDARD VALUE TABLE......................................................................................................122 Standard value table for engine related parts.............................................................................122 Standard value table for chassis related parts............................................................................124 Standard value table for electrical parts.................................................................................138 TESTING AND ADJUSTING.....................................................................................................140 Tools for testing, adjusting, and troubleshooting.....................................................................141 Measuring engine speed................................................................................................142 Measuring exhaust color...............................................................................................143 Adjusting valve clearance.............................................................................................144 Measuring compression pressure........................................................................................145 Testing and adjusting fuel injection timing...........................................................................146 Measuring engine oil pressure.........................................................................................147 Testing and adjusting fan belt tension................................................................................148 Testing and adjusting fuel control lever..............................................................................149 Measuring sprocket wear...............................................................................................150 Testing and adjusting track shoe tension..............................................................................151 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ....................................152 Testing and adjusting LS differential pressure........................................................................158 Adjusting PC valve spring.............................................................................................160 Testing and adjusting control circut pressure.........................................................................161 Measuring output pressure of PPC lock valve and travel boost valve....................................................163 Testing PPC valve output pressure and swing holding brake inlet port pressure.........................................164 Adjusting work equipment, swing PPC valve ............................................................................166 Testing and adjusting travel deviation................................................................................167 Measuring oil leakage inside work equipment cylinder..................................................................168 Releasing remaining pressure from hydraulic circuit...................................................................169 Releasing remaining pressure from hydraulic tank .....................................................................169 Pressurizing hydraulic tank...........................................................................................169 Bleeding air..........................................................................................................170 TROUBLESHOOTING...........................................................................................................172 Type of connector and position of installation........................................................................173 Connection table for connector pin numbers ...........................................................................176 Troubleshooting of engine electrical system (E mode)..................................................................186 E-Mode related electrical circuit diagram.........................................................................187 E-1 Engine does not start.........................................................................................188 a) When starting motor does not turn (starting system)........................................................188 b) When starting motor turns (engine stop solenoid system)....................................................190 E-2 Engine does not stop..........................................................................................192 Troubleshooting of hydraulic, mechanical system (H mode)..............................................................193 Table of failure modes and causes.................................................................................194 H- 1 Speeds of all work equipment, swing, travel are slow or lack power...........................................198 H- 2 There is excessive drop in engine speed, or engine stalls....................................................200 H- 3 No work equipment, travel, swing move........................................................................201 H- 4 Abnormal noise generated (from around pump)..................................................................202 H- 5 Fine control ability is poor or response is poor (PC15R).....................................................202 H- 6 Boom is slow or lacks power..................................................................................203 H- 7 Arm is slow or lacks power...................................................................................203 H- 8 Bucket is slow or lacks power................................................................................204 H- 9 Boom swing is slow or lacks power............................................................................204 H-10 Blade is slow or lacks power.................................................................................205 H-11 Boom, arm, bucket do not move (boom swing, blade, travel and swing are normal)...............................205 H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade).............................................206 a) Boom, bucket, boom swing, blade............................................................................206 b) Arm........................................................................................................206 H-13 Excessive time lag (engine at low idling)....................................................................206 a) Boom, arm..................................................................................................206 b) Bucket.....................................................................................................206 H-14 In compound operations, work equipment with larger load is slow..............................................207 H-15 Travel deviation.............................................................................................208 a) Deviation in normal travel.................................................................................208 b) Deviation when starting....................................................................................208 H-16 Travel speed is slow or lacks power..........................................................................209 H-17 Steering does not turn easily................................................................................209 H-18 Travel speed does not switch.................................................................................210 H-19 Travel does not move (one side only).........................................................................210 H-20 Swing speed is slow or lacks power...........................................................................211 a) Speed is slow or lacks power in both directions............................................................211 b) Speed is slow or lacks power in one direction only (left or right).........................................211 H-21 Does not swing...............................................................................................212 a) Does not swing in either direction.........................................................................212 b) Does not swing in one direction (left or right)............................................................212 H-22 Swing acceleration is poor...................................................................................213 a) Acceleration is poor in both directions....................................................................213 b) Acceleration is poor in one direction only (left or right).................................................213 H-23 Excessive overrun when stopping swing........................................................................214 a) Overrun when stopping is excessive in both directions......................................................214 b) Overrun when stopping is excessive in one direction only (left or right)...................................214 H-24 Excessive shock when stopping swing (in one direction only)..................................................214 H-25 Excessive abnormal noise when stopping swing.................................................................215 H-26 Excessive hydraulic drift of swing...........................................................................215 Troubleshooting of machine monitor system (M mode)....................................................................216 Electrical circuit diagram for M Mode related parts...............................................................217 M-1 Abnormality in engine oil pressure caution lamp system........................................................218 a) Lamp does not light up when starting switch is turned ON...................................................218 b) Lamp lights up when engine is running (engine oil pressure is normal)......................................218 M-2 Abnormality in charge caution lamp system.....................................................................220 a) Lamp does not light up when starting switch is turned ON...................................................220 b) Lamp lights up when engine is running (battery charge is normal)...........................................220 M-3 Abnormality in engine water temperature caution lamp system...................................................222 a) Lamp does not stay lighted up for 3 seconds when starting switch is turned ON..............................222 b) Lamp does not go out after starting switch has been at ON for 3 seconds....................................222 c) Lamp lights up when engine is running (engine water temperature is normal).................................223 M-4 Abnormality in preheating pilot lamp..........................................................................224 a) Lamp does not light up when starting switch is turned to HEAT..............................................224 b) Lamp does not go out when starting switch is at HEAT and preheating time (approx. 18 sec.) is completed....224 c) Lamp lights up when starting switch is at position other than HEAT.........................................225 M-5 Abnormality in fuel gauge system..............................................................................226 a) Gauge does not go up from E when fuel is added to fuel tank................................................226 b) Gauge does not go down from F even when there is no fuel in fuel tank......................................226 c) Fuel level does not match gauge display....................................................................227 M-6 Abnormality in service meter system...........................................................................228 a) Service meter does not advance when starting switch is at ON...............................................228 b) Service meter advances when starting switch is at OFF......................................................228 c) Pilot lamp does not flash when service meter is advancing..................................................228 M-7 Abnormality in night lighting system..........................................................................230 a) Night lighting does not light up when lamp switch is turned ON.............................................230 b) Night lighting lights up when lamp switch is turned OFF ...................................................230 30 DISASSEMBLY AND ASSEMBLY...................................................................................................232 Method of using manual....................................................................................................234 Precautions when carrying out operation...................................................................................235 Special tool list.........................................................................................................237 Starting motor............................................................................................................238 Removal and installation..............................................................................................238 Alternator ...............................................................................................................239 Removal and installation..............................................................................................239 Fuel injection pump ......................................................................................................240 Removal and installation..............................................................................................240 Nozzle holder ............................................................................................................241 Removal and installation..............................................................................................241 Water pump ...............................................................................................................242 Removal and installation..............................................................................................242 Thermostat ...............................................................................................................243 Removal and installation..............................................................................................243 Engine front seal.........................................................................................................244 Removal and installation..............................................................................................244 Engine rear seal..........................................................................................................245 Removal...............................................................................................................245 Installation..........................................................................................................246 Cylinder head.............................................................................................................247 Removal...............................................................................................................247 Installation..........................................................................................................248 Radiator..................................................................................................................249 Removal...............................................................................................................249 Installation..........................................................................................................250 Engine, hydraulic pump....................................................................................................251 Removal...............................................................................................................232 Installation..........................................................................................................253 Fuel tank.................................................................................................................254 Removal and installation..............................................................................................254 Damper....................................................................................................................255 Removal and installation..............................................................................................255 Center swivel joint.......................................................................................................256 Removal and installation..............................................................................................256 Disassembly and assembly..............................................................................................257 Travel motor..............................................................................................................258 Removal and installation..............................................................................................258 Sprocket..................................................................................................................259 Removal and installation..............................................................................................259 Swing motor...............................................................................................................260 Removal and installation..............................................................................................260 Revolving frame...........................................................................................................261 Removal...............................................................................................................261 Installation..........................................................................................................262 Swing circle..............................................................................................................263 Removal and installation..............................................................................................263 Idler.....................................................................................................................264 Removal and installation..............................................................................................264 Disassembly...........................................................................................................265 Assembly..............................................................................................................266 Idler cushion (rubber shoe)...............................................................................................267 Removal and installation..............................................................................................267 Disassembly and assembly..............................................................................................268 Idler cushion (steel shoe)................................................................................................269 Disassembly...........................................................................................................232 Assembly..............................................................................................................270 Track roller..............................................................................................................271 Removal and installation..............................................................................................271 Disassembly and assembly..............................................................................................272 Rubber shoe...............................................................................................................273 Removal and installation..............................................................................................273 Steel shoe................................................................................................................274 Removal and installation..............................................................................................274 Hydraulic tank............................................................................................................275 Removal...............................................................................................................275 Installation..........................................................................................................276 Hydraulic oil cooler......................................................................................................277 Removal and installation..............................................................................................277 Hydraulic pump............................................................................................................278 Removal and installation..............................................................................................278 Control valve.............................................................................................................279 Removal...............................................................................................................279 Installation..........................................................................................................280 Disassembly...........................................................................................................281 Assembly..............................................................................................................286 PPC valve.................................................................................................................293 Removal and installation..............................................................................................293 Disassembly...........................................................................................................294 Assembly..............................................................................................................295 Boom cylinder.............................................................................................................296 Removal...............................................................................................................296 Installation..........................................................................................................297 Arm cylinder..............................................................................................................298 Removal...............................................................................................................298 Installation..........................................................................................................299 Bucket cylinder...........................................................................................................300 Removal...............................................................................................................300 Installation..........................................................................................................301 Swing cylinder............................................................................................................302 Removal...............................................................................................................302 Installation..........................................................................................................303 Blade cylinder............................................................................................................304 Removal and installation..............................................................................................304 Hydraulic cylinder........................................................................................................305 Disassembly...........................................................................................................305 Assembly..............................................................................................................308 Work equipment............................................................................................................312 Removal...............................................................................................................312 Installation..........................................................................................................313 Bucket....................................................................................................................314 Removal and installation..............................................................................................314 Arm.......................................................................................................................315 Removal...............................................................................................................315 Installation..........................................................................................................316 Bucket, arm...............................................................................................................317 Removal...............................................................................................................317 Installation..........................................................................................................318 Boom......................................................................................................................319 Removal ..............................................................................................................319 Installation..........................................................................................................320 Swing bracket.............................................................................................................321 Removal...............................................................................................................321 Installation..........................................................................................................322 Blade.....................................................................................................................323 Removal and installation..............................................................................................323 Canopy....................................................................................................................324 Removal and installation..............................................................................................324 40 MAINTENANCE STANDARD.......................................................................................................325 Swing circle..............................................................................................................326 Track frame, recoil spring................................................................................................327 Idler.....................................................................................................................328 Track roller..............................................................................................................329 Track shoe................................................................................................................330 Hydraulic pump (PC15R-8)..................................................................................................332 Control valve (PC12R-8)...................................................................................................333 Control valve (PC15R-8)...................................................................................................339 Center swivel joint.......................................................................................................345 Swing motor...............................................................................................................346 PPC valve.................................................................................................................347 Hydraulic cylinder........................................................................................................348 Work equipment............................................................................................................350 90 OTHERS.....................................................................................................................352 Hydraulic circuit diagram PC12R-8.........................................................................................353 Hydraulic circuit diagram PC15R-8.........................................................................................354 Electric circuit diagram PC12R,15R-8......................................................................................355
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Elian Reese –
It was nice.