Komatsu PC20MRX-1 Shop Manual SEBM016602 – PDF DOWNLOAD
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Komatsu PC20MRX-1 Shop Manual SEBM016602 – PDF DOWNLOAD
Description
Komatsu PC20MRX-1 Shop Manual SEBM016602 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC20MRX-1 Shop Manual SEBM016602 – PDF DOWNLOAD
Language : English
Pages :382
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu PC20MRX-1 Shop Manual SEBM016602 – PDF DOWNLOAD
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
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 this section.
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 Shop Manual SEBM016602 – PDF DOWNLOAD
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 JOINT104
SWING MOTOR105
TRAVEL MOTOR106
VALVE CONTROL110
PPC VALVE111
SOLENOID VALVE118
WORK EQUIPMENT120
ELECTRICAL WIRING DIAGRAM121
MACHINE MONITOR SYSTEM123
20 TESTING AND ADJUSTING128
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS129
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS130
STANDARD VALUE TABLE FOR ELECTRICAL PARTS138
TESTING AND ADJUSTING140
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING141
MEASURING ENGINE SPEED142
MEASURING EXHAUST COLOR143
ADJUSTING VALVE CLEARANCE144
MEASURING COMPRESSION PRESSURE145
TESTING AND ADJUSTING FUEL INJECTION TIMING146
MEASURING ENGINE OIL PRESSURE147
TESTING AND ADJUSTING FAN BELT TENSION148
ADJUSTING FUEL CONTROL LEVER149
TESTING AND ADJUSTING TRACK SHOE TENSION150
MEASURING SPROCKET WEAR151
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT152
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE154
ADJUSTING TCC VALVE155
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE156
MEASURING SWING HOLDING BRAKE INLET PORT PRESSURE157
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE157
TESTING AND ADJUSTING TRAVEL DEVIATION158
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER159
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT161
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK161
PRESSURIZING HYDRAULIC TANK161
BLEEDING AIR162
TROUBLESHOOTING164
POINTS TO REMEMBER WHEN TROUBLESHOOTING165
SEQUENCE OF EVENTS IN TROUBLESHOOTING166
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE167
CHECKS BEFORE TROUBLESHOOTING175
CONNECTOR TYPES AND MOUNTING LOCATIONS176
CONNECTOR PIN ALLOCATION DRAWING177
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS179
METHOD OF USING TROUBLESHOOTING CHARTS186
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)188
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM189
E-1 ENGINE DOES NOT START191
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 STOP195
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK IS CANCELED196
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED197
E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED198
E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED199
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)200
TABLE OF FAILURE MODES AND CAUSES201
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER203
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS204
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE205
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)205
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR206
H-6 BOOM IS SLOW OR LACKS POWER207
H-7 ARM IS SLOW OR LACKS POWER207
H-8 BUCKET IS SLOW OR LACKS POWER208
H-9 BOOM SWING IS SLOW OR LACKS POWER208
H-10 BLADE IS SLOW OR LACKS POWER209
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) BOOM210
B) ARM, BUCKET, BOOM SWING210
C) BLADE210
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)211
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW211
H-15 TRAVEL DEVIATION212
A) DEVIATION IN NORMAL TRAVEL212
B) DEVIATION WHEN STARTING212
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER213
H-17 STEERING DOES NOT TURN EASILY213
H-18 TRAVEL SPEED DOES NOT SWITCH214
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)214
H-20 SWING SPEED IS SLOW OR LACKS POWER215
A) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS215
B) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY (LEFT OR RIGHT)215
H-21 DOES NOT SWING216
A) DOES NOT SWING IN EITHER DIRECTION216
B) DOES NOT SWING IN ONE DIRECTION (LEFT OR RIGHT)216
H-22 SWING ACCELERATION IS POOR217
A) ACCELERATION IS POOR IN BOTH DIRECTIONS217
B) ACCELERATION IS POOR IN ONE DIRECTION ONLY (LEFT OR RIGHT)217
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING218
A) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS218
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 SWING219
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING219
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)220
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS221
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN222
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECONDS), LAMPS DO NOT GO222
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS223
A) NO GAUGE LAMPS LIGHT UP (FUEL, COOLANT TEMPERATURE)223
B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE), PILOT LAMP (PREHEATING) DO NOT LIGHT UP223
M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS), EVEN IF STARTING SWITCH IS TURNED TO START, SELF CHECK IS NOT COMP223
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP224
M-6 WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE), CHARGE CAUTION LAMP DOES NOT LIGHT UP225
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT226
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP226
M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP227
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE229
A) LEVEL DOES NOT RISE FROM SEGMENT C229
B) LEVEL DOES NOT GO DOWN FROM SEGMENT H, OR ALL SEGMENTS GO OUT229
C) COOLANT TEMPERATURE DOES NOT MATCH GUAGE DISPLAY230
M-11 ABNORMALITY IN FUEL GAUGE231
A) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT231
B) LEVEL DOES NOT GO DOWN FROM SEGMENT F231
C) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY232
M-12 DEFECTIVE OPERATION OF ALARM BUZZER233
A) BUZZER DOES NOT SOUND233
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP233
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE234
A) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP234
B) WHEN CHARGE CAUTION LAMP LIGHTS UP234
C) PILOT LAMP DOES NOT FLASH (SERVICE METER IS ACTUATED)234
M-14 NIGHT LIGHTING DOES NOT LIGHT UP235
A) GAUGE LIGHTING DOES NOT LIGHT UP235
B) SERVICE METER LIGHTING DOES NOT LIGHT UP235
30 DISASSEMBLY AND ASSEMBLY236
METHOD OF USING MANUAL238
PRECAUTION WHEN CARRYING OUT OPERATION239
SPECIAL TOOL LIST241
STARTING MOTOR242
REMOVAL AND INSTALLATION242
ALTERNATOR243
REMOVAL AND INSTALLATION243
FUEL INJECTION PUMP244
REMOVAL244
INSTALLATION245
NOZZLE HOLDER246
REMOVAL AND INSTALLATION246
WATER PUMP247
REMOVAL AND INSTALLATION247
THERMOSTAT248
REMOVAL AND INSTALLATION248
ENGINE FRONT SEAL249
REMOVAL AND INSTALLATION249
ENGINE REAR SEAL250
REMOVAL250
INSTALLATION251
CYLINDER HEAD252
REMOVAL252
INSTALLATION253
RADIATOR254
REMOVAL AND INSTALLATION254
ENGINE AND HYDRAULIC PUMP 255
REMOVAL255
INSTALLATION258
FUEL TANK259
REMOVAL AND INSTALLATION259
DAMPER260
REMOVAL AND INSTALLATION260
CENTER SWIVEL JOINT261
REMOVAL AND INSTALLATION261
DISASSEMBLY AND ASSEMBLY262
TRAVEL MOTOR263
REMOVAL AND INSTALLATION263
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR PHV190264
SPROCKET275
REMOVAL AND INSTALLATION275
SWING MOTOR AND SWING MACHINERY276
REMOVAL AND INSTALLATION276
REVOLVING FRAME277
REMOVAL277
INSTALLATION278
SWING CIRCLE279
REMOVAL AND INSTALLATION279
IDLER 280
REMOVAL AND INSTALLATION280
DISASSEMBLY281
ASSEMBLY282
RECOIL SPRING284
REMOVAL AND INSTALLATION284
DISASSEMBLY AND ASSEMBLY285
TRACK ROLLER286
REMOVAL AND INSTALLATION286
DISASSEMBLY 287
ASSEMBLY288
RUBBER SHOE289
REMOVAL AND INSTALLATION289
HYDRAULIC TANK290
REMOVAL AND INSTALLATION290
HYDRAULIC OIL COOLER291
REMOVAL AND INSTALLATION291
HYDRAULIC PUMP292
REMOVAL AND INSTALLATION292
CONTROL VALVE293
REMOVAL293
INSTALLATION295
DISASSEMBLY296
ASSEMBLY301
MAIN RELIEF VALVE306
REMOVAL AND INSTALLATION306
RIGHT/LEFT PPC VALVE307
REMOVAL307
INSTALLATION308
PPC VALVE309
DISASSEMBLY309
ASSEMBLY310
BOOM CYLINDER311
REMOVAL311
INSTALLATION312
ARM CYLINDER313
REMOVAL313
INSTALLATION314
BUCKET CYLINDER315
REMOVAL315
INSTALLATION316
SWING CYLINDER317
REMOVAL317
INSTALLATION318
BLADE CYLINDER319
REMOVAL AND INSTALLATION319
HYDRAULIC CYLINDER320
DISASSEMBLY320
ASSEMBLY323
WORK EQUIPMENT326
REMOVAL326
INSTALLATION327
BUCKET328
REMOVAL AND INSTALLATION328
QUICK BUCKET329
REMOVAL AND INSTALLATION329
ARM330
REMOVAL330
INSTALLATION331
BUCKET AND ARM332
REMOVAL332
INSTALLATION333
BOOM334
REMOVAL334
INSTALLATION335
SWING BRACKET336
REMOVAL336
INSTALLATION337
BLADE338
REMOVAL AND INSTALLATION338
SOLENOID VALVE339
REMOVAL AND INSTALLATION339
COUNTERWEIGHT340
REMOVAL AND INSTALLATION340
SEAT AND BRACKET341
REMOVAL AND INSTALLATION341
MONITOR342
REMOVAL AND INSTALLATION342
40 MAINTENANCE STANDARD343
SWING CIRCLE344
TRACK FRAME, RECOIL SPRING345
IDLER346
TRACK ROLLER347
TRACK SHOE348
HYDRAULIC PUMP351
CONTROL PUMP352
CONTROL VALVE353
CENTER SWIVEL JOINT359
TRAVEL MOTOR360
PPC VALVE361
HYDRAULIC CYLINDER363
WORK EQUIPMENT365
DIMENSION OF WORK EQUIPMENT367
90 OTHERS371
HYDRAULIC CIRCUIT DIAGRAM372
ELECTRICAL CIRCUIT DIAGRAM377
IMAGES PREVIEW OF THE MANUAL:
S.M 13/12/24
