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Komatsu PC15MR-1 Hydraulic Excavator Shop Manual SEBM019002 – PDF DOWNLOAD
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Komatsu PC15MR-1 Hydraulic Excavator Shop Manual
MACHINE MODEL SERIAL NUMBER
PC15MR-1 10001 and up
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Description
Komatsu PC15MR-1 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC15MR-1 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC15MR-1
Serial Number: 10001 and up
Book Code: SEBM019002
Language: English
Pages: 261
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC15MR-1 Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
Testing and adjusting:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu PC15MR-1 Hydraulic Excavator Shop Manual
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
KOMATSU PC15MR-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEBM019002 – PDF DOWNLOAD:
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