Komatsu PC20MR-3 Hydraulic Excavator Shop Manual SEN04767-03 PDF

Description

Komatsu PC20MR-3 Hydraulic Excavator Shop Manual SEN04767-03 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC20MR-3 Hydraulic Excavator Shop Manual SEN04767-03 – PDF DOWNLOAD 

Language : English
Pages : 504
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC20MR-3 Hydraulic Excavator Shop Manual SEN04767-03 – PDF DOWNLOAD 

SERIAL NUMBERS 20001 and up

Cover 1
00 Index and foreword 3
100 Index 3
Composition of shop manual 4
Table of contents 6
200 Foreword and general information 11
Safety notice 12
How to read the shop manual 17
Explanation of terms for maintenance standard 19
Handling of electric equipment and hydraulic component 21
Handling of connectors newly used for engines 30
How to read electric wire code 33
Precautions when carrying out operation 36
Method of disassembling and connecting push-pull type coupler 39
Standard tightening torque table 42
01 Specification 53
100 Specification and technical data 53
Specification dimension drawing 54
Working range drawing 55
Specifications 56
Weight table 59
Table of fuel, coolant and lubricants 61
10 Structure, function and maintenance standard 63
100 Engine and cooling system 63
PTO 64
Cooling system 66
200 Power train 69
Power train 70
Swing circle 71
300 Undercarriage and frame 73
Track frame 74
Idler cushion 75
Idler 76
Track roller 78
Sprocket 79
Track shoe 80
401 Hydraulic system, Part 1 83
Hydraulic components layout drawing 84
Hydraulic tank and filter 85
Center swivel joint 86
Travel motor 87
Hydraulic cylinder 96
Solenoid valve 99
402 Hydraulic system, Part 2 103
Hydraulic pump 104
Control valve 110
403 Hydraulic system, Part 3 123
CLSS 124
Operation for each function and valve 128
Swing motor 148
PPC valve 159
500 Work equipment 169
Work equipment 171
Dimensions of each part of work equipment 174
600 Cab and its attachments 179
Floor 180
700 Electrical system 183
Engine control system 184
Electric control system 186
KOMTRAX system 191
Component parts of system 194
Monitor system 195
Sensors 198
20 Standard value table 201
100 Standard service value table 201
Standard value table for engine related parts 202
Standard value table for chassis related parts 203
30 Testing and adjusting 215
100 Testing and adjusting 215
List of testing, adjusting, and troubleshooting tools 217
Measuring engine speed 220
Adjusting valve clearance 221
Measuring compression pressure 222
Measuring engine oil pressure 223
Testing and adjusting fuel injection timing 224
Bleeding air from fuel circuit 226
Testing and adjusting fan belt tension 227
Adjusting fuel control lever linkage 228
Measurement of clearance in swing circle bearings 229
Testing and adjusting track shoe tension 230
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits 232
Measuring control circuit basic pressure 235
Testing and adjusting pump LS differential pressure 236
Measuring solenoid valve output pressure 238
Measuring PPC valve output pressure 240
Adjusting play of work equipment and swing PPC valves 242
Measuring swing holding brake release pressure 242
Measurement of oil leakage from cylinder 244
Releasing residual pressure from hydraulic circuit 246
Bleeding air from cylinder 246
Pressurizing hydraulic tank 247
How to open and close (tilt) floor 248
Inspection procedures for diode 252
How to start operation of KOMTRAX terminal 253
Lamp display of KOMTRAX terminal 257
Preparation work for troubleshooting of electrical system 260
40 Troubleshooting 263
100 General Information on troubleshooting 263
Points to remember when troubleshooting 264
Sequence of events in troubleshooting 265
Check before troubleshooting 266
Classification and troubleshooting steps 267
Probable problems and troubleshooting No 268
Connection table for connector pin numbers 271
T- branch box and T- branch adapter table 307
200 Troubleshooting of electrical system (E-mode) 311
Before starting E-mode troubleshooting 312
Information contained in troubleshooting table 314
E- 1 Engine does not start 315
E- 2 Engine does not stop 321
E- 3 When lock lever is in FREE position, whole work equipment, travel, swing, and blade systems do not work 323
E- 4 When lock lever is in LOCK position, whole work equipment, travel, swing, and blade systems work 326
E- 5 When machine starts traveling, travel alarm does not sound 328
E- 6 When machine stops traveling, travel alarm does not stop sounding 331
E- 7 Windshield wiper does not operate [Cab specification] 333
E- 8 Windshield washer does not operate [Cab specification] 335
E- 9 Heater does not operate 337
300 Troubleshooting of hydraulic and mechanical system (H-mode) 343
Information contained in troubleshooting table 345
H- 1 Speed or power of whole work equipment, travel, swing, and blade is low 346
H- 2 Engine speed lowers extremely or engine stalls 349
H- 3 Whole work equipment, travel system, swing system, and blade do not work 350
H- 4 Abnormal sound comes out from around hydraulic pump 353
H- 5 Fine control performance or response is low 353
H- 6 Speed or power of boom is low 354
H- 7 Speed or power of arm is low 355
H- 8 Speed or power of bucket is low 356
H- 9 Speed or power of boom swing is low 357
H-10 Work equipment does not move in its single operation 358
H-11 Work equipment hydraulic drift is large 358
H-12 Time lag of work equipment is large 359
H-13 In compound operation of work equipment, speed of part loaded more is low 359
H-14 Machine deviates during travel 360
H-15 Travel speed or travel power is low 362
H-16 Machine is not steered well or steering power is low 362
H-17 Travel speed does not change 363
H-18 Travel motor does not work (one side only) 363
H-19 Speed or power of swing is low 364
H-20 Machine does not swing 366
H-21 Swing acceleration performance is low 368
H-22 Machine overruns when it stops swinging 369
H-23 Large shock is made when machine stops swinging 370
H-24 When upper structure stops swinging, it makes large sound 370
H-25 Hydraulic drift of swing is large 371
H-26 Speed or power of blade is low 372
H-27 Blade does not move 373
H-28 Hydraulic drift of blade is large 373
400 Troubleshooting of engine (S-mode) 375
Troubleshooting charts 376
500 Troubleshooting of Machine monitor System(M-mode) 383
Before starting M-mode troubleshooting 384
Information contained in troubleshooting table 386
M- 1 When starting switch is turned ON, no monitor/gauge operates 387
M- 2 When starting switch is turned ON, some monitors/gauges do not operate 389
M- 3 Caution buzzer does not sound or does not stop sounding 390
M- 4 While engine is running, engine oil pressure monitor flashes 392
M- 5 While engine is running, charge level monitor flashes 393
M- 6 Preheating system does not operate 395
M- 7 Coolant temperature gauge does not indicate normally 397
M- 8 Fuel level gauge does not indicate normally 400
M- 9 Service meter does not operate while engine is running 402
M-10Travel speed shifting system does not operate normally 403
M-11 Machine monitor night lamp and working lamp do not right up 406
50 Disassembly and assembly 411
100 General information on disassembly and assembly 411
How to read this manual 412
Coating materials list 414
Special tool list 417
200 Engine and cooling system 421
Removal and installation of fuel injection pump assembly 422
Removal and installation of radiator and hydraulic oil cooler assembly 424
Removal and installation of engine and hydraulic pump assembly 428
300 Power train 433
Removal and installation of swing circle assembly 434
400 Undercarriage and frame 437
Removal and installation of track shoe assembly 438
Disassembly and assembly of idler assembly 439
Disassembly and assembly of recoil spring 441
Disassembly and assembly of track roller assembly 444
Removal and installation of floor frame assembly 445
Removal and installation of revolving frame assembly 449
500 Hydraulic system 453
Disassembly and assembly of control valve assembly 454
Removal and installation of center swivel joint assembly 458
Disassembly and assembly of center swivel joint assembly 460
Removal and installation of swing motor and swing machinery assembly 462
Disassembly and assembly of hydraulic cylinder assembly 463
600 Work equipment 469
Removal and installation of work equipment assembly 470
700 Cab and its attachments 473
Removal and installation of front window assembly 474
Removal and installation of operator’s cab glass (stuck glass) 475
800 Electric system 485
Removal and installation of KOMTRAX terminal 486
90 Diagrams and drawings 489
100 Hydraulic diagrams and drawings 489
Hydraulic circuit diagram 491
200 Electrical diagrams and drawings 495
Electrical circuit diagram (1/2) 497
Electrical circuit diagram (2/2) 499
Connector list and stereogram 501

DESCRIPTION:

Komatsu PC20MR-3 Hydraulic Excavator Shop Manual SEN04767-03 – PDF DOWNLOAD 

SERIAL NUMBERS 20001 and up

How to read the shop manual :
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 24/12/24