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KOMATSU PC20MR-2 SERVICE REPAIR MANUAL (SEBM037001) – PDF DOWNLOAD
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- KOMATSU PC20MR-2 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM037001
- Serial number:PC20MR-2 15001 and up
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Description
KOMATSU PC20MR-2 SERVICE REPAIR MANUAL (SEBM037001)
KOMATSU PC20MR-2 SERVICE REPAIR MANUAL (SEBM037001) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC20MR-2 SERVICE REPAIR MANUAL (SEBM037001)
- 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 PC20MR-2 SERVICE REPAIR MANUAL (SEBM037001)
MAIN MENU......................................................................................................................... 0 COVER............................................................................................................................. 1 CONTENTS.......................................................................................................................... 2 SAFETY............................................................................................................................ 6 SAFETY NOTICE................................................................................................................. 6 FOREWORD.......................................................................................................................... 8 GENERAL....................................................................................................................... 8 HOISTING INSTRUCTIONS......................................................................................................... 10 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................................... 11 COATING MATERIALS............................................................................................................. 13 STANDARD TIGHTENING TORQUE.................................................................................................... 15 ELECTRIC WIRE CODE............................................................................................................ 18 CONVERSION TABLE.............................................................................................................. 19 UNITS......................................................................................................................... 25 01 GENERAL........................................................................................................................ 26 SPECIFICATION DIMENSION DRAWING............................................................................................... 27 WORKING RANGE DRAWING......................................................................................................... 28 SPECIFICATIONS................................................................................................................ 29 WEIGHT TABLE.................................................................................................................. 32 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS................................................................................... 34 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................... 36 PTO........................................................................................................................... 37 COOLING SYSTEM................................................................................................................ 39 POWER TRAIN................................................................................................................... 41 SWING CIRCLE.................................................................................................................. 42 TRACK FRAME................................................................................................................... 43 IDLER CUSHION................................................................................................................. 44 IDLER......................................................................................................................... 45 TRACK ROLLER.................................................................................................................. 47 CARRIER ROLLER................................................................................................................ 48 SPROCKET...................................................................................................................... 49 TRACK SHOE.................................................................................................................... 50 HYDRAULIC COMPONENTS LAYOUT DRAWING........................................................................................... 51 HYDRAULIC TANK................................................................................................................ 52 CENTER SWIVEL JOINT........................................................................................................... 53 TRAVEL MOTOR.................................................................................................................. 54 HYDRAULIC CYLINDER............................................................................................................ 63 SOLENOID VALVE................................................................................................................ 66 MULTI-CONTROL VALVE (IF EQUIPPED)............................................................................................. 69 HYDRAULIC PUMP................................................................................................................ 71 CONTROL VALVE................................................................................................................. 77 CLSS.......................................................................................................................... 90 OPERATION FOR EACH FUNCTION AND VALVE......................................................................................... 93 SWING MOTOR...................................................................................................................113 PPC VALVE.....................................................................................................................123 WORK EQUIPMENT................................................................................................................132 DIMENSIONS OF EACH PART OF WORK EQUIPMENT.....................................................................................135 FLOOR.........................................................................................................................138 ENGINE CONTROL................................................................................................................139 ELECTRIC CONTROL SYSTEM.......................................................................................................141 COMPONENT PART OF SYSTEM......................................................................................................146 MONITOR SYSTEM................................................................................................................147 MONITOR PANEL.................................................................................................................148 SENSORS.......................................................................................................................150 20 TESTING AND ADJUSTING..........................................................................................................152 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.................................................................................153 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................................154 TESTING AND ADJUSTING.........................................................................................................164 LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS.....................................................................165 MEASURING ENGINE SPEED....................................................................................................167 MEASUREMENT OF EXHAUST GAS COLOR..........................................................................................168 ADJUSTING VALVE CLEARANCE.................................................................................................169 MEASURING COMPRESSION PRESSURE............................................................................................170 MEASURING ENGINE OIL PRESSURE.............................................................................................171 TESTING AND ADJUSTING FUEL INJECTION TIMING...............................................................................172 BLEEDING AIR FROM FUEL CIRCUIT............................................................................................174 TESTING AND ADJUSTING FAN BELT TENSION....................................................................................175 ADJUSTING FUEL CONTROL LEVER LINKAGE......................................................................................176 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS.........................................................................177 TESTING AND ADJUSTING TRACK SHOE TENSION..................................................................................178 TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, SWING, AND BLADE CIRCUITS..................................180 MEASURING CONTROL CIRCUIT BASIC PRESSURE..................................................................................183 TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE.......................................................................184 MEASURING SOLENOID VALVE OUTPUT PRESSURE..................................................................................186 MEASURING PPC VALVE OUTPUT PRESSURE.......................................................................................188 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES.....................................................................190 MEASURING SWING HOLDING BRAKE RELEASE PRESSURE............................................................................190 MEASURING OF OIL LEAKAGE FROM CYLINDER....................................................................................192 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT........................................................................194 BLEEDING AIR FROM CYLINDER................................................................................................194 PRESSURIZING HYDRAULIC TANK...............................................................................................195 HOW TO OPEN AND CLOSE (TILT) FLOOR........................................................................................196 INSPECTION PROCEDURES FOR DIODE...........................................................................................198 TROUBLESHOOTING...............................................................................................................200 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................201 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................202 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................................203 CHECKS BEFORE TROUBLESHOOTING.............................................................................................211 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING..........................................................................212 CONNECTORS LIST AND STEREOGRAM............................................................................................215 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................223 T-ADAPTER-BOXES AND T-ADAPTER TABLE.......................................................................................246 TROUBLESHOOTING OF ELECTRICAL SYSTEM (EXCEPT MONITOR PANEL E-MODE)........................................................250 BEFORE STARTING E-MODE TROUBLESHOOTING................................................................................251 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................253 E-1 ENGINE DOES NOT START.............................................................................................254 E-2 ENGINE DOES NOT STOP..............................................................................................260 E-3 WHEN SAFETY LOCK LEVER IS IN FREE POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE SYSTEMS DO NOT WORK....262 E-4 WHEN SAFETY LOCK LEVER IS IN LOCK POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING AND BLADE SYSTEMS WORK............265 E-5 WHEN MACHINE STARTS TRAVELING, TRAVEL ALARM DOES NOT SOUND........................................................267 E-6 WHEN MACHINE STOPS TRAVELING, TRAVEL ALARM DOES NOT STOP SOUNDING.................................................269 E-7 WINDSHIELD WIPER DOES NOT OPERATE [CAB SPECIFICATION].............................................................271 E-8 WINDSHIELD WASHER DOES NOT OPERATE [CAB SPECIFICATION]............................................................273 E-9 HEATER DOES NOT OPERATE...........................................................................................275 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)..............................................................278 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................279 H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW...........................................280 H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS....................................................................283 H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK .........................................284 H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP...............................................................287 H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW.......................................................................287 H-6 SPEED OR POWER OF BOOM IS LOW.....................................................................................288 H-7 SPEED OR POWER OF ARM IS LOW......................................................................................289 H-8 SPEED OR POWER OF BUCKET IS LOW...................................................................................290 H-9 SPEED OR POWER OF BOOM SWING IS LOW...............................................................................291 H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY..............................................................................291 H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE..........................................................................292 H-12 TIME LAG OF WORK EQUIPMENT IS LARGE..............................................................................293 H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW........................................293 H-14 MACHINE DEVIATES DURING TRAVEL...................................................................................294 H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW..............................................................................296 H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................................................296 H-17 TRAVEL SPEED DOES NOT CHANGE.....................................................................................297 H-18 TRAVEL MOTOR DOES NOT WORK (ONE SIDE ONLY).......................................................................297 H-19 SPEED OR POWER OF SWING IS LOW...................................................................................298 H-20 MACHINE DOES NOT SWING...........................................................................................300 H-21 SWING ACCELERATION PERFORMANCE IS LOW............................................................................302 H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING..........................................................................303 H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING..................................................................304 H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND........................................................304 H-25 HYDRAULIC DRIFT OF SWING IS LARGE................................................................................305 H-26 SPEED OR POWER OF BLADE IS LOW...................................................................................306 H-27 BLADE DOES NOT MOVE..............................................................................................307 H-28 HYDRAULIC DRIFT OF BLADE IS LARGE................................................................................307 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)..........................................................................308 BEFORE STARTING M-MODE TROUBLESHOOTING................................................................................309 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................311 M-1 WHEN STARTING SWITCH IS TURNED ON, NO MONITOR/GAUGE OPERATES......................................................313 M-2 WHEN STARTING SWITCH IS TURNED ON, SOME MONITORS/GAUGES DO NO OPERATE.............................................315 M-3 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING...........................................................317 M-4 WHILE ENGINE IS RUNNING, ENGINE OIL PRESSURE MONITOR FLASHES......................................................319 M-5 WHILE ENGINE IS RUNNING, CHARGE LEVEL MONITOR FLASHES.............................................................321 M-6 PREHEATING SYSTEM DOES NOT OPERATE................................................................................323 M-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY..............................................................326 M-8 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY.......................................................................329 M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING............................................................331 M-10 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY...........................................................332 M-11 MONITOR PANEL NIGHT LAMP AND WORKING LAMP DO NOT LIGHT UP........................................................335 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................................340 TROUBLESHOOTING OF ENGINE (S-MODE)....................................................................................341 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................348 HOW TO READ THIS MANUAL.......................................................................................................349 PRECAUTIONS WHEN PERFORMING OPERATION.........................................................................................351 SPECIAL TOOL LIST.............................................................................................................353 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY......................................................................355 REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY........................................................357 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY................................................................362 REMOVAL AND INSTALLATION TRACK SHOE ASSEMBLY..................................................................................364 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY....................................................................................365 DISASSEMBLY AND ASSEMBLYOF RECOIL SPRING ASSEMBLY.............................................................................367 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.............................................................................370 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY......................................................................371 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY......................................................................373 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY..............................................................................375 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..........................................................380 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...........................................................................381 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY..........................................................................383 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY.............................................................................385 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY............................................................................386 DISASSEMBLY AND ASSEMBLY OF HDYRAULIC CYLINDER ASSEMBLY.......................................................................390 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.............................................................................394 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)................................................................395 90 OTHERS.........................................................................................................................404 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................406 ELECTRICAL CIRCUIT DIAGRAM (1/2)..............................................................................................407 ELECTRICAL CIRCUIT DIAGRAM (2/2)..............................................................................................408
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
