Komatsu PC15MR-1 Hydraulic Excavator Shop Manual SEBM019002 – PDF DOWNLOAD

Description

Komatsu PC15MR-1 Hydraulic Excavator Shop Manual SEBM019002 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC15MR-1 Hydraulic Excavator Shop Manual SEBM019002 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
PC15MR-1               10001 and up

FOREWORD:
GENERAL:

This shop manual has been prepared as an aid to improve the quality of repairs Ьу giving the serviceman an
accurate understanding of the product and Ьу 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 а service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters аге further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. lt serves not only to give an understanding
of the structure, but also serves as reference material for trouЫeshooting.
ln addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to Ье made before and after performing repairs, as well as adjustments to
Ье made at completion of the checks and repairs.
TrouЫeshooting charts correlating “ProЫems” with “Causes” аге also included in this section.
DISASSEMBL У AND ASSEMBL У
This section explains the procedures for removing, installing, disassemЫing and assemЫing each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassemЫed parts.
The contents of this section may Ье described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
ln addition, this section may give the specifications of attachments and options together.

Questions? Email us: [email protected]

https://vimeo.com/743677918

TABLE OF CONTENTS:

Komatsu PC15MR-1 Hydraulic Excavator Shop Manual SEBM019002 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 25
GENERAL ASSEMBLY DRAWING 26
SPECIFICATIONS 27
WEIGHT TABLE 30
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
SWING CIRCLE 35
TRACK FRAME, RECOIL SPRING 36
HYDRAULIC EQUIPMENT LAYOUT 37
HYDRAULIC TANK 38
HYDRAULIC PUMP 39
CONTROL VALVE 43
CLSS 51
CENTER SWIVEL JOINT 68
SWING MOTOR 70
TRAVEL MOTOR 72
VALVE CONTROL 78
PPC VALVE 79
PPC LOCK SOLENOID VALVE 83
TRAVEL 2-SPEED SELECTER VALVE 85
ELECTRIC WIRING DIAGRAM 86
MONITOR SYSTEM 88
20 TESTING AND ADJUSTING 91
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 92
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 93
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 101
TESTING AND ADJUSTING 103
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 104
MEASURING ENGINE SPEED 105
MEASURING EXHAUST COLOR 106
ADJUSTING VALVE CLEARANCE 107
MEASURING COMPRESSION PRESSURE 108
TESTING AND ADJUSTING FUEL INJECTION TIMING 109
MEASURING ENGINE OIL PRESSURE 110
TESTING AND ADJUSTING FAN BELT TENSION 111
ADJUSTING FUEL CONTROL LEVER 112
MEASURING SPROCKET WEAR 113
TESTING AND ADJUSTING TRACK SHOE TENSION 114
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 115
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE 117
ADJUSTING PC VALVE SPRING 119
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE 120
TESTING PPC LOCK VALVE 121
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE 122
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 124
TESTING AND ADJUSTING TRAVEL DEVIATION 125
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER 126
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 127
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 128
PRESSURIZING HYDRAULIC TANK 128
BLEEDING AIR 129
TROUBLESHOOTING 131
POINTS TO REMEMBER WHEN TROUBLESHOOTING 132
SEQUENCE OF EVENTS IN TROUBLESHOOTING 133
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 134
CHECKS BEFORE TROUBLESHOOTING 142
CONNECTOR TYPES AND MOUNTING LOCATIONS 143
CONNECTOR PIN ALLOCATION DRAWING 144
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 146
METHOD OF USING TROUBLESHOOTING CHARTS 156
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 158
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 159
E-1 ENGINE DOES NOT START 161
a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM) 161
b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM) 163
E-2 ENGINE DOES NOT STOP 165
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED 166
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED 168
E-5 TRAVEL ALARM DOES NOT SOUND 169
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 170
TABLE OF FAILURE MODES AND CAUSES 171
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 173
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 174
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 174
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 175
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 175
H-6 BOOM IS SLOW OR LACKS POWER 176
H-7 ARM IS SLOW OR LACKS POWER 176
H-8 BUCKET IS SLOW OR LACKS POWER 177
H-9 BOOM SWING IS SLOW OR LACKS POWER 177
H-10 BLADE IS SLOW OR LACKS POWER 178
H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL) 178
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE) 179
a) BOOM, BUCKET, BOOM SWING, BLADE 179
b) ARM 179
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 179
a) BOOM, ARM 179
b) BUCKET 179
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 180
H-15 TRAVEL DEVIATION 181
a) DEVIATION IN NORMAL TRAVEL 181
b) DEVIATION WHEN STARTING 181
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER 182
H-17 STEERING DOES NOT TURN EASILY 182
H-18 TRAVEL SPEED DOES NOT SWITCH 182
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 183
H-20 SWING SPEED IS SLOW OR LACKS POWER 183
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS 183
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY 183
H-21 DOES NOT SWING 184
a) DOES NOT SWING IN EITHER DIRECTION 184
b) DOES NOT SWING IN ONE DIRECTION ONLY 184
H-22 SWING ACCELERATION IS POOR 185
a) ACCELERATION IS POOR IN BOTH DIRECTIONS 185
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY 185
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING 186
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS 186
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY 186
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY) 186
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 187
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING 187
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 188
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS 189
M-1 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP SYSTEM 190
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON 190
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL) 190
M-2 ABNORMALITY IN CHARGE CAUTION LAMP SYSTEM 192
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON 192
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (BATTERY CHARGE IS NORMAL) 192
M-3 ABNORMALITY IN ENGINE WATER TEMPERATURE CAUTION LAMP SYSTEM 194
a) LAMP DOES NOT STAY LIGHTED UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON 194
b) LAMP DOES NOT GO OUT AFTER STARTING SWITCH HAS BEEN AN ON FOR 3 SECONDS 194
c) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE WATER TEMPERATURE IS NORMAL) 195
M-4 ABNORMALITY IN PREHEATING PILOT LAMP 196
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO HEAT 196
b) LAMP DOES NOT GO OUT WHEN STARTING SWITCH IS AT HEAT AND PREHEATING TIME (APPROX 18 SEC ) IS COMPLETED 196
c) LAMP LIGHTS UP WHEN STARTING SWITCH IS AT POSITION OTHER THAN HEAT 197
M-5 ABNORMALITY IN FUEL GAUGE SYSTEM 198
a) GAUGE DOES NOT GO UP FROM E WHEN FUEL IS ADDED TO FUEL TANK 198
b) GAUGE DOES NOT GO DOWN FROM F EVEN WHEN THERE IS NO FUEL IN FUEL TANK 198
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY 199
M-6 ABNORMALITY IN SERVICE METER SYSTEM 200
a) SERVICE METER DOES NOT ADVANCE WHEN STARTING SWITCH IS AT ON 200
b) SERVICE METER ADVANCES WHEN STARTING SWITCH IS AT OFF 200
c) PILOT LAMP DOES NOT FLASH WHEN SERVICE METER IS ADVANCING 200
M-7 ABNORMALITY IN NIGHT LIGHTING SYSTEM 202
a) NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON 202
b) NIGHT LIGHTING LIGHTS UP WHEN LAMP SWITCH IS TURNED OFF 202
30 DISASSEMBLY AND ASSEMBLY 204
METHOD OF USING MANUAL 205
PRECAUTIONS WHEN CARRYING OUT OPERATION 206
SPECIAL TOOL LIST 208
ENGINE AND HYDRAULIC PUMP 209
REMOVAL 209
INSTALLATION 213
CENTER SWIVEL JOINT 214
REMOVAL 214
INSTALLATION 214
DISASSEMBLY 215
ASSEMBLY 215
SWING MOTOR 216
REMOVAL 216
INSTALLATION 216
REVOLVING FRAME 217
REMOVAL 217
INSTALLATION 218
SWING CIRCLE 219
REMOVAL 219
INSTALLATION 219
IDLER 220
ASSEMBLY 220
TRACK ROLLER 221
ASSEMBLY 221
RUBBER SHOE 222
REMOVAL 222
INSTALLATION 222
CONTROL VALVE 223
DISASSEMBLY 223
ASSEMBLY 228
HYDRAULIC CYLINDER 235
ASSEMBLY 235
40 MAINTENANCE STANDARD 238
SWING CIRCLE 239
TRACK FRAME, RECOIL SPRING 240
IDLER 241
TRACK ROLLER 242
TRACK SHOE 243
HYDRAULIC PUMP 245
CONTROL VALVE 246
CENTER SWIVEL JOINT 250
SWING MOTOR 251
TRAVEL MOTOR 252
PPC VALVE 253
HYDRAULIC CYLINDER 254
WORK EQUIPMENT 255
90 OTHERS 257
HYDRAULIC CIRCUIT DIAGRAM (VARIABLE GAUGE TYPE) 258
HYDRAULIC CIRCUIT DIAGRAM (FIXED GAUGE TYPE) 259
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO : 10001-10634) 260
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO : 10635 AND UP) 261

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V