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Komatsu PC20MRX-1 Hydraulic Excavator Shop Manual 10001 and up – PDF DOWNLOAD
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Komatsu PC20MRX-1 Hydraulic Excavator Shop Manual
MACHINE MODEL SERIAL NUMBER
PC20MRX-1 10001 and up
Book Code: SEBM016602
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Description
Komatsu PC20MRX-1 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC20MRX-1 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC20MRX-1
Serial Number: 10001 and up
Book Code: SEBM016602
Language: English
Pages: 382
File Format: Portable Document Format (PDF)
KOMATSU PC20MRX-1 HYDRAULIC EXCAVATOR SHOP MANUAL 10001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC20MRX-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 servicemen 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 thissection.
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 PC20MRX-1 Hydraulic Excavator Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER PAGE................................................................................................................................... 1 CONTENTS..................................................................................................................................... 2 00 FOREWARD.................................................................................................................................. 2 SAFETY................................................................................................................................... 5 FOREWARD................................................................................................................................. 7 HOW TO READ THE SHOP MANUAL.............................................................................................................. 2 HOISTING INSTRUCTIONS.................................................................................................................... 9 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER............................................................................... 10 COATING MATERIALS........................................................................................................................ 12 STANDARD TIGHTENING TORQUE............................................................................................................... 14 ELECTRIC WIRE CODE....................................................................................................................... 17 CONVERSION TABLE......................................................................................................................... 18 01 GENERAL.................................................................................................................................. 24 GENERAL ASSEMBLY DRAWING................................................................................................................. 25 SPECIFICATIONS........................................................................................................................... 27 WEIGHT TABLE............................................................................................................................. 31 LIST OF LUBRICANT AND WATER.............................................................................................................. 33 10 STRUCTURE AND FUNCTION................................................................................................................... 34 RADIATOR, OIL COOLER..................................................................................................................... 35 ENGINE CONTROL........................................................................................................................... 36 PTO...................................................................................................................................... 37 POWER TRAIN DIAGRAM...................................................................................................................... 38 SWING CIRCLE............................................................................................................................. 39 SWING MACHINERY.......................................................................................................................... 40 TRACK FRAME.............................................................................................................................. 41 RECOIL SPRING............................................................................................................................ 42 TRACK SHOE............................................................................................................................... 43 HYDRAULIC PIPING DRAWING................................................................................................................. 44 HYDRAULIC TANK........................................................................................................................... 46 HYDRAULIC PUMP........................................................................................................................... 47 CONTROL VALVE............................................................................................................................ 67 CLSS..................................................................................................................................... 75 CENTER SWIVEL JOINT......................................................................................................................104 SWING MOTOR..............................................................................................................................105 TRAVEL MOTOR.............................................................................................................................106 VALVE CONTROL............................................................................................................................110 PPC VALVE................................................................................................................................111 SOLENOID VALVE...........................................................................................................................118 WORK EQUIPMENT...........................................................................................................................120 ELECTRICAL WIRING DIAGRAM................................................................................................................121 MACHINE MONITOR SYSTEM...................................................................................................................123 20 TESTING AND ADJUSTING....................................................................................................................128 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS............................................................................................129 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...........................................................................................130 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 ADJUSTING FUEL CONTROL LEVER.........................................................................................................149 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................................150 MEASURING SPROCKET WEAR..............................................................................................................151 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....................................................152 TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE.......................................................................................154 ADJUSTING TCC VALVE..................................................................................................................155 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE.......................................................................................156 MEASURING SWING HOLDING BRAKE INLET PORT PRESSURE....................................................................................157 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE............................................................................................157 TESTING AND ADJUSTING TRAVEL DEVIATION...............................................................................................158 MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER.................................................................................159 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT..................................................................................161 RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK.....................................................................................161 PRESSURIZING HYDRAULIC TANK..........................................................................................................161 BLEEDING AIR.........................................................................................................................162 TROUBLESHOOTING..........................................................................................................................164 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................165 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................166 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................167 CHECKS BEFORE TROUBLESHOOTING........................................................................................................175 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................176 CONNECTOR PIN ALLOCATION DRAWING.....................................................................................................177 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................179 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................186 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................188 E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM........................................................................................189 E-1 ENGINE DOES NOT START.......................................................................................................191 A) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)......................................................................191 B) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)..................................................................193 E-2 ENGINE DOES NOT STOP........................................................................................................195 E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK IS CANCELED......................................................196 E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED..........................................................197 E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED....................................................198 E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED.....................................................199 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).............................................................................200 TABLE OF FAILURE MODES AND CAUSES................................................................................................201 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER..........................................................203 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...................................................................204 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE.......................................................................................205 H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP).................................................................................205 H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR............................................................................206 H-6 BOOM IS SLOW OR LACKS POWER.................................................................................................207 H-7 ARM IS SLOW OR LACKS POWER..................................................................................................207 H-8 BUCKET IS SLOW OR LACKS POWER...............................................................................................208 H-9 BOOM SWING IS SLOW OR LACKS POWER...........................................................................................208 H-10 BLADE IS SLOW OR LACKS POWER...............................................................................................209 H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL).............................................209 H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE)...........................................................210 A) BOOM.....................................................................................................................210 B) ARM, BUCKET, BOOM SWING..................................................................................................210 C) BLADE....................................................................................................................210 H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)..................................................................................211 H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW............................................................211 H-15 TRAVEL DEVIATION...........................................................................................................212 A) DEVIATION IN NORMAL TRAVEL...............................................................................................212 B) DEVIATION WHEN STARTING..................................................................................................212 H-16 TRAVEL SPEED IS SLOW OR LACKS POWER.......................................................................................213 H-17 STEERING DOES NOT TURN EASILY..............................................................................................213 H-18 TRAVEL SPEED DOES NOT SWITCH...............................................................................................214 H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).......................................................................................214 H-20 SWING SPEED IS SLOW OR LACKS POWER.........................................................................................215 A) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS..........................................................................215 B) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY (LEFT OR RIGHT).......................................................215 H-21 DOES NOT SWING.............................................................................................................216 A) DOES NOT SWING IN EITHER DIRECTION.......................................................................................216 B) DOES NOT SWING IN ONE DIRECTION (LEFT OR RIGHT)..........................................................................216 H-22 SWING ACCELERATION IS POOR.................................................................................................217 A) ACCELERATION IS POOR IN BOTH DIRECTIONS..................................................................................217 B) ACCELERATION IS POOR IN ONE DIRECTION ONLY (LEFT OR RIGHT)...............................................................217 H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING......................................................................................218 A) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS....................................................................218 B) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY (LEFT OR RIGHT).................................................218 H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY)................................................................219 H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...............................................................................219 H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING.........................................................................................219 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...................................................................................220 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS..............................................................................221 M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN......................................................................222 M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECONDS), LAMPS DO NOT GO....222 M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS......................................223 A) NO GAUGE LAMPS LIGHT UP (FUEL, COOLANT TEMPERATURE)......................................................................223 B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE), PILOT LAMP (PREHEATING) DO NOT LIGHT UP.............................223 M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS), EVEN IF STARTING SWITCH IS TURNED TO START, SELF CHECK IS NOT COMP....223 M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP.............................224 M-6 WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE), CHARGE CAUTION LAMP DOES NOT LIGHT UP...........................225 M-7 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT................................................226 M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP..........................................................226 M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP.......................................................................227 M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE...................................................................................229 A) LEVEL DOES NOT RISE FROM SEGMENT C.......................................................................................229 B) LEVEL DOES NOT GO DOWN FROM SEGMENT H, OR ALL SEGMENTS GO OUT............................................................229 C) COOLANT TEMPERATURE DOES NOT MATCH GUAGE DISPLAY.........................................................................230 M-11 ABNORMALITY IN FUEL GAUGE..................................................................................................231 A) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT................................................................231 B) LEVEL DOES NOT GO DOWN FROM SEGMENT F....................................................................................231 C) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY..................................................................................232 M-12 DEFECTIVE OPERATION OF ALARM BUZZER........................................................................................233 A) BUZZER DOES NOT SOUND....................................................................................................233 B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP..............................................................................233 M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE.....................................................................234 A) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP...............................................................................234 B) WHEN CHARGE CAUTION LAMP LIGHTS UP.......................................................................................234 C) PILOT LAMP DOES NOT FLASH (SERVICE METER IS ACTUATED)....................................................................234 M-14 NIGHT LIGHTING DOES NOT LIGHT UP...........................................................................................235 A) GAUGE LIGHTING DOES NOT LIGHT UP.........................................................................................235 B) SERVICE METER LIGHTING DOES NOT LIGHT UP.................................................................................235 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................236 METHOD OF USING MANUAL...................................................................................................................238 PRECAUTION WHEN CARRYING OUT OPERATION...............................................................................................239 SPECIAL TOOL LIST....................................................................................................................241 STARTING MOTOR...........................................................................................................................242 REMOVAL AND INSTALLATION.............................................................................................................242 ALTERNATOR...............................................................................................................................243 REMOVAL AND INSTALLATION.............................................................................................................243 FUEL INJECTION PUMP......................................................................................................................244 REMOVAL..............................................................................................................................244 INSTALLATION.........................................................................................................................245 NOZZLE HOLDER............................................................................................................................246 REMOVAL AND INSTALLATION.............................................................................................................246 WATER PUMP...............................................................................................................................247 REMOVAL AND INSTALLATION.............................................................................................................247 THERMOSTAT...............................................................................................................................248 REMOVAL AND INSTALLATION.............................................................................................................248 ENGINE FRONT SEAL........................................................................................................................249 REMOVAL AND INSTALLATION.............................................................................................................249 ENGINE REAR SEAL.........................................................................................................................250 REMOVAL..............................................................................................................................250 INSTALLATION.........................................................................................................................251 CYLINDER HEAD............................................................................................................................252 REMOVAL..............................................................................................................................252 INSTALLATION.........................................................................................................................253 RADIATOR.................................................................................................................................254 REMOVAL AND INSTALLATION.............................................................................................................254 ENGINE AND HYDRAULIC PUMP ...............................................................................................................255 REMOVAL..............................................................................................................................255 INSTALLATION.........................................................................................................................258 FUEL TANK................................................................................................................................259 REMOVAL AND INSTALLATION.............................................................................................................259 DAMPER...................................................................................................................................260 REMOVAL AND INSTALLATION.............................................................................................................260 CENTER SWIVEL JOINT......................................................................................................................261 REMOVAL AND INSTALLATION.............................................................................................................261 DISASSEMBLY AND ASSEMBLY.............................................................................................................262 TRAVEL MOTOR.............................................................................................................................263 REMOVAL AND INSTALLATION.............................................................................................................263 DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR PHV190......................................................................................264 SPROCKET.................................................................................................................................275 REMOVAL AND INSTALLATION.............................................................................................................275 SWING MOTOR AND SWING MACHINERY..........................................................................................................276 REMOVAL AND INSTALLATION.............................................................................................................276 REVOLVING FRAME..........................................................................................................................277 REMOVAL..............................................................................................................................277 INSTALLATION.........................................................................................................................278 SWING CIRCLE.............................................................................................................................279 REMOVAL AND INSTALLATION.............................................................................................................279 IDLER ...................................................................................................................................280 REMOVAL AND INSTALLATION.............................................................................................................280 DISASSEMBLY..........................................................................................................................281 ASSEMBLY.............................................................................................................................282 RECOIL SPRING............................................................................................................................284 REMOVAL AND INSTALLATION.............................................................................................................284 DISASSEMBLY AND ASSEMBLY.............................................................................................................285 TRACK ROLLER.............................................................................................................................286 REMOVAL AND INSTALLATION.............................................................................................................286 DISASSEMBLY .........................................................................................................................287 ASSEMBLY.............................................................................................................................288 RUBBER SHOE..............................................................................................................................289 REMOVAL AND INSTALLATION.............................................................................................................289 HYDRAULIC TANK...........................................................................................................................290 REMOVAL AND INSTALLATION.............................................................................................................290 HYDRAULIC OIL COOLER.....................................................................................................................291 REMOVAL AND INSTALLATION.............................................................................................................291 HYDRAULIC PUMP...........................................................................................................................292 REMOVAL AND INSTALLATION.............................................................................................................292 CONTROL VALVE............................................................................................................................293 REMOVAL..............................................................................................................................293 INSTALLATION.........................................................................................................................295 DISASSEMBLY..........................................................................................................................296 ASSEMBLY.............................................................................................................................301 MAIN RELIEF VALVE........................................................................................................................306 REMOVAL AND INSTALLATION.............................................................................................................306 RIGHT/LEFT PPC VALVE.....................................................................................................................307 REMOVAL..............................................................................................................................307 INSTALLATION.........................................................................................................................308 PPC VALVE................................................................................................................................309 DISASSEMBLY..........................................................................................................................309 ASSEMBLY.............................................................................................................................310 BOOM CYLINDER............................................................................................................................311 REMOVAL..............................................................................................................................311 INSTALLATION.........................................................................................................................312 ARM CYLINDER.............................................................................................................................313 REMOVAL..............................................................................................................................313 INSTALLATION.........................................................................................................................314 BUCKET CYLINDER..........................................................................................................................315 REMOVAL..............................................................................................................................315 INSTALLATION.........................................................................................................................316 SWING CYLINDER...........................................................................................................................317 REMOVAL..............................................................................................................................317 INSTALLATION.........................................................................................................................318 BLADE CYLINDER...........................................................................................................................319 REMOVAL AND INSTALLATION.............................................................................................................319 HYDRAULIC CYLINDER.......................................................................................................................320 DISASSEMBLY..........................................................................................................................320 ASSEMBLY.............................................................................................................................323 WORK EQUIPMENT...........................................................................................................................326 REMOVAL..............................................................................................................................326 INSTALLATION.........................................................................................................................327 BUCKET...................................................................................................................................328 REMOVAL AND INSTALLATION.............................................................................................................328 QUICK BUCKET.............................................................................................................................329 REMOVAL AND INSTALLATION.............................................................................................................329 ARM......................................................................................................................................330 REMOVAL..............................................................................................................................330 INSTALLATION.........................................................................................................................331 BUCKET AND ARM...........................................................................................................................332 REMOVAL..............................................................................................................................332 INSTALLATION.........................................................................................................................333 BOOM.....................................................................................................................................334 REMOVAL..............................................................................................................................334 INSTALLATION.........................................................................................................................335 SWING BRACKET............................................................................................................................336 REMOVAL..............................................................................................................................336 INSTALLATION.........................................................................................................................337 BLADE....................................................................................................................................338 REMOVAL AND INSTALLATION.............................................................................................................338 SOLENOID VALVE...........................................................................................................................339 REMOVAL AND INSTALLATION.............................................................................................................339 COUNTERWEIGHT............................................................................................................................340 REMOVAL AND INSTALLATION.............................................................................................................340 SEAT AND BRACKET.........................................................................................................................341 REMOVAL AND INSTALLATION.............................................................................................................341 MONITOR..................................................................................................................................342 REMOVAL AND INSTALLATION.............................................................................................................342 40 MAINTENANCE STANDARD.....................................................................................................................343 SWING CIRCLE.............................................................................................................................344 TRACK FRAME, RECOIL SPRING...............................................................................................................345 IDLER....................................................................................................................................346 TRACK ROLLER.............................................................................................................................347 TRACK SHOE...............................................................................................................................348 HYDRAULIC PUMP...........................................................................................................................351 CONTROL PUMP.............................................................................................................................352 CONTROL VALVE............................................................................................................................353 CENTER SWIVEL JOINT......................................................................................................................359 TRAVEL MOTOR.............................................................................................................................360 PPC VALVE................................................................................................................................361 HYDRAULIC CYLINDER.......................................................................................................................363 WORK EQUIPMENT...........................................................................................................................365 DIMENSION OF WORK EQUIPMENT..............................................................................................................367 90 OTHERS...................................................................................................................................371 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................372 ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................377
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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