Komatsu PC25MR-5 Compact Hydraulic Excavator Shop Manual SEBN06967-00 – PDF

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Komatsu PC25MR-5 Compact Hydraulic Excavator Shop Manual SEBN06967-00 – PDF DOWNLOAD

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Komatsu PC25MR-5 Compact Hydraulic Excavator Shop Manual SEBN06967-00 – PDF DOWNLOAD

Language : English
Pages : 782
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC25MR-5 Compact Hydraulic Excavator Shop Manual SEBN06967-00 – PDF DOWNLOAD

• SERIAL NUMBERS   25001 and up 

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 10
How to Read the Shop Manual 10
Safety Notice for Operation 12
Precautions to Prevent Fire 20
Procedures If Fire Occurs 22
Precautions When You Discard Waste Materials 23
Precautions When You Handle Hydraulic Equipment 24
Precautions When You Disconnect and Connect Pipings 27
Precautions When You Handle Electrical Equipment 34
Precautions When You Handle Fuel System Equipment 36
Precautions When You Handle Intake System Equipment 37
Practical Use of KOMTRAX 38
Disconnect and Connect Push-Pull Type Coupler 39
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 39
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 40
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 41
Precautions for Disconnection and Connection of Connectors 43
Disconnect and Connect Deutsch Connector 47
How to Disconnect and Connect Slide Lock Type Connector 48
Disconnect and Connect Connector with Lock to Pull 50
Disconnect and Connect Connector with Lock to Push 51
Disconnect and Connect Connector with Housing to Rotate 53
Standard Tightening Torque Table 54
Abbreviation List 61
01 Specification 65
Table of Contents 66
Specifications 67
Specification Drawing 67
Specification Drawing: PC25MR-5 67
Working Range Drawings 68
Working Range Drawings: PC25MR-5 68
Specifications 69
Specifications: PC25MR-5 69
Weight Table 74
Weight Table: PC25MR-5 74
Fuel, Coolant, Lubricant 76
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 76
10 Structure and Function 79
Table of Contents 80
Boot-up System 82
Layout Drawing of Boot-up System 82
System Operating Lamp System 83
System Diagram of System Operating Lamp System 83
Function of Operation Lamp System 83
Operation of System Operating Lamp System 83
Battery Disconnect Switch 85
Function of Battery Disconnect Switch 85
Operation of Battery Disconnect Switch 85
Engine System 86
Layout Drawing of Engine System 86
Engine Control System 87
System Diagram of Engine Control 87
Operation of Engine Control System 88
Component Parts of Engine System 89
PTO 89
Cooling System 90
Layout Drawing of Cooling System 90
Specifications of Cooling System 91
Control System 92
Layout Drawing of Control System 92
Machine Monitor System 93
System Diagram of Machine Monitor System 93
Function of Machine Monitor System 93
KOMTRAX System 94
System Diagram of KOMTRAX System 94
Function of KOMTRAX System 94
Component Parts of Control System 95
Machine Monitor 95
KOMTRAX Terminal 98
Fuel Control Lever 100
Hydraulic System 102
Layout Drawing of Hydraulic System 102
CLSS 103
System Diagram of CLSS 103
Function of CLSS 104
Component Parts of Hydraulic System 106
Hydraulic Tank 106
Main Pump 109
Control Valve 115
Work Equipment System 144
Layout Drawing of Work Equipment System 144
Structure of Valve Control 146
PPC Lock System 148
System Diagram of PPC Lock 148
Function of PPC Lock System 149
Work Equipment Double Lock System 150
Function of Work Equipment Double Lock System 150
Operation of Work Equipment Double Lock System 150
Component Parts of Work Equipment System 151
Work Equipment and Swing PPC Valve 151
Attachment PPC Valve 156
Blade PPC Valve 158
Boom Swing PPC Valve 160
Bipartite Solenoid Valve 162
Pilot Circuit Accumulator 165
Swing System 166
Layout Drawing of Swing System 166
Component Parts of Swing System 167
Swing Motor 167
Swing Circle 178
Travel System 179
Layout Drawing of Travel System 179
System Diagram of Travel Control System 181
Function of Travel Control System 181
Component Parts of Travel System 183
Travel Motor 183
Travel PPC Valve 194
Center Swivel Joint 196
Undercarriage and Frame 197
Layout Drawing of Undercarriage 197
Specifications of Undercarriage 198
Idler Cushion 199
Structure of Idler Cushion 199
Specifications of Idler Cushion 199
Work Equipment 200
Structure of Work Equipment 200
Function of Work Equipment 201
Work Equipment Clearance Adjustment Shim 202
Function of Work Equipment Clearance Adjustment Shim 202
20 Standard Value Table 203
Table of Contents 204
Standard Value Table for Engine 205
Standard Value Table for Engine: PC25MR-5 205
Standard Value Table for Machine 207
Standard Value Table for Machine: PC25MR-5 207
Gear Pump: PC25MR-5 217
Piston Pump PC25MR-5 218
Machine Posture and Procedures to Measure Performance 219
30 Testing and Adjusting 223
Table of Contents 224
Related Information on Testing and Adjusting 226
Tools for Testing and Adjusting 226
Engine and Cooling System 230
Examine Engine Speed 230
How to Examine Engine Speed 230
Examine Exhaust Gas Color 235
How to Examine Exhaust Gas Color with the Handy Smoke Checker 235
How to Examine Exhaust Gas Color with Smoke Meter 236
Examine and Adjust Valve Clearance 238
How to Examine Valve Clearance 238
How to Adjust Valve Clearance 241
Examine Compression Pressure 242
How to Examine Compression Pressure 242
Examine Engine Oil Pressure 246
How to Examine Engine Oil Pressure 246
Examine and Adjust Fuel Injection Timing 248
How to Examine Fuel Injection Timing 248
Adjust Fuel Injection Timing 250
Bleed Air from Fuel System 251
How to Bleed Air from Fuel System 251
Examine Fuel Circuit for Leakage 252
How to Examine Fuel System for Leakage 252
Examine and Adjust Alternator Belt 253
Examine and Adjust Alternator Belt 253
Power Train 255
Examine Swing Circle Bearing Clearance 255
How to Examine Swing Circle Bearing Clearance 255
Undercarriage and Frame 257
Examine and Adjust Track Tension 257
How to Examine Track Tension 257
How to Adjust Track Tension 257
Hydraulic System 259
Release Remained Pressure in Hydraulic Circuit 259
How to Release Remained Pressure from Hydraulic Tank 259
How to Release Remained Pressure in Hydraulic Cylinder Circuit 259
How to Release Remained Pressure from Swing Motor Circuit 260
How to Release Remained Pressure from Travel Motor Circuit 260
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 262
How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 262
Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 268
Examine and Adjust Swing and Blade Circuit Oil Pressure 270
How to Examine Oil Pressure in Swing and Blade Circuits 270
Adjust Oil Pressure in Swing and Blade Circuits 273
Examine and Adjust Oil Pressure in Control Circuit 275
How to Examine Oil Pressure in Control Circuit 275
How to Adjust Oil Pressure in Control Circuit 276
Examine and Adjust Oil Pressure in Pump LS Control Circuit 277
Examine LS Differential Pressure 277
Adjust LS Valve 279
Examine Outlet Pressure of Solenoid Valve 280
How to Examine Outlet Pressure of Solenoid Valve 280
Examine PPC Valve Outlet Pressure 283
How to Examine PPC Valve Outlet Pressure 283
Adjust Play of Work Equipment and Swing PPC Valves 287
How to Adjust Play of Work Equipment and Swing PPC Valves 287
Examine Swing Parking Brake Release Pressure 288
How to Examine Swing Parking Brake Release Pressure 288
Examine Travel Deviation 291
How to Examine Travel Deviation 291
Examine Parts Which Cause Hydraulic Drift of Work Equipment 292
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 292
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 293
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 293
Examine Oil Leakage 294
How to Examine Oil Leakage from Boom Cylinder 294
How to Examine Oil Leakage from Arm Cylinder 295
How to Examine Oil Leakage from Bucket Cylinder 296
How to Examine Oil Leakage from Boom Swing Cylinder 297
How to Examine Oil Leakage from Blade Cylinder 298
Bleed Air from Hydraulic System 300
How to Bleed Air from Hydraulic System 300
Bleed Air from Work Equipment Cylinder 300
How to Bleed Air from Swing Motor 301
Bleed Air from Travel Motor 301
Pressurize Hydraulic Tank 302
How to Pressurize Hydraulic Tank 302
Electrical System 304
How to Start Up KOMTRAX Terminal 304
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 308
Display of KOMTRAX Terminal Lamps 310
Handle Battery Disconnect Switch 313
Examine Diodes 314
Examine Diodes by Digital Tester 314
How to Examine Diodes by Analog Tester 314
Pm Clinic 315
Pm Clinic Service 315
Pm Clinic Check Sheet: PC25MR-5 316
40 Troubleshooting 323
Table of Contents 324
Related Information to Troubleshooting 327
General Troubleshooting Points 327
Sequence of Events in Troubleshooting 328
Checks Before Troubleshooting 330
Inspection Procedure Before Troubleshooting 332
Walk-Around Check 332
Test in Accordance with Testing Procedure 333
Examine Fuel Level and Type 333
Examine Fuel Filter Element, Drain Water and Sediment 334
Examine Fuel Filter Element 335
Examine Engine Oil Level (Oil Quantity in Oil Pan) 336
Examine Coolant Level (Reservoir Tank) 337
Examine, Clean and Replace Air Cleaner 339
Examine Hydraulic Oil Level 343
Examine Hydraulic Oil Strainer 345
Examine Hydraulic Oil Filter 348
Examine Oil Level in Final Drive Case 349
Bleed Air from Fuel System 350
Bleed Air from Hydraulic System 350
How to Examine Electric Equipment 350
Preparation for Troubleshooting of Electrical System 360
Connect Adapter for Troubleshooting Machine Monitor 360
Connect Adapter to Troubleshoot KOMTRAX Terminal 361
Procedure for Troubleshooting 362
Symptom and Troubleshooting Numbers 363
Connector List and Layout 366
Connector Contact Connection Table 372
T-Branch Box and T-Branch Adapter Table 414
Fuse Location Table 420
Troubleshooting of Electrical System (E-Mode) 422
Engine Does Not Start (Engine Does Not Crank) 422
Engine Does Not Start (Fuel Feed Pump System) 429
Preheating System Does Not Operate 431
When You Turn Starting Switch to ON Position, All Items of Machine Monitor Do Not Work, or One of Items Does Not Work 433
Charge Level Caution Lamp Comes On While Engine is in Operation 436
Fuel Level Monitor Pilot Lamp Comes On While Engine is in Operation 438
Engine Coolant Temperature Monitor Pilot Lamp Comes On While Engine is in Operation 439
Engine Oil Pressure Caution Lamp Comes On While Engine is in Operation 440
Fuel Gauge Does Not Move from Minimum or Maximum 441
Display of Fuel Gauge is Different from Actual Fuel Level 443
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 444
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 446
Travel Speed Does Not Change Even When You Change Travel Speed 447
Travel Alarm Does Not Operate During Travel 450
Travel Alarm Does Not Stop When Machine Stops 454
Alarm Buzzer Does Not Operate 456
Alarm Buzzer Does Not Stop 458
Service Meter is Not Shown While Starting Switch is in OFF Position 459
Service Meter Does Not Operate While Engine is in Operation 460
All Work Equipment, Swing, Travel Do Not Operate 461
All Work Equipment, Swing, Travel Cannot be Locked 466
Horn Does Not Sound 469
Horn Does Not Stop 471
Working Lamp Does Not Come On 472
KOMTRAX System Does Not Operate Correctly 474
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 475
Information Shown in Troubleshooting Table (H-Mode) 475
All Work Equipment, Travel, Swing, Blade Do Not Operate 476
All Work Equipment or Travel Does Not Operate 477
Travel and Blade Do Not Operate 478
Swing and Blade Do Not Operate 479
All Work Equipment, Travel, Swing, Blade Speed is Low or Power is Low 480
All Work Equipment and Travel Speeds are Low or Power is Low 481
Travel and Blade Speed is Low or Power is Low 482
Swing and Blade Speed or Power is Low 483
Fine Control Performance or Response is Unsatisfactory 484
There is an Unusual Noise from Around Main Pump 485
Engine Speed Drops Largely or Engine Stops 486
All Work Equipment Speed or Power is Low 487
All Work Equipment and Blade Speeds are Low or Power is Low 488
Blade Does Not Operate 489
All Work Equipment Do Not Operate 490
All Work Equipment and Blade Do Not Operate 491
Boom Speed or Power is Low 492
Arm Speed or Power is Low 494
Bucket Speed or Power is Low 495
Blade Speed or Power is Low 496
Boom Swing Speed or Power is Low 498
Work Equipment Does Not Move in Single Operation 499
Hydraulic Drift of Boom is Large 501
Hydraulic Drift of Arm is Large 502
Hydraulic Drift of Bucket is Large 503
Hydraulic Drift of Blade is Large 504
Time Lag of Work Equipment is Large 505
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 506
Machine Does Not Travel Straight 507
Machine Does Not Move Off Straight 509
Machine is Not Steered Well or Steering Power is Low 510
Travel Speed is Low 512
One of Tracks Does Not Run 514
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 515
Upper Structure Does Not Swing in Two Directions of Right and Left 516
Machine Swings Only in One Direction 518
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 520
Swing Acceleration or Swing Speed is Low in Only One Direction 522
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 523
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 524
Shock is Large When Upper Structure Stops Swing Operation 525
Large Unusual Noise is Made When Upper Structure Stops Swing Operation 526
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 527
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 528
Troubleshooting of Engine (S-Mode) 529
Information Shown in Troubleshooting Table (S-Mode) 529
Engine Does Not Crank When Starting Switch is Turned to Start Position 530
Engine Cranks but No Exhaust Smoke Comes Out 531
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 532
Engine Startability is Unsatisfactory 533
Engine Does Not Pick Up Smoothly 535
Engine Stops During Operation 536
Engine Does Not Rotate Smoothly 538
Engine Lacks Output (or Lacks Power) 539
Engine Oil Consumption is Excessive 541
Engine Oil Becomes Dirty Quickly 542
Fuel Consumption is Excessive 543
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 544
Engine Oil Pressure Drops 545
Fuel Mixes Into Engine Oil 546
Water Mixes Into Engine Oil (Milky) 547
Coolant Temperature Increases Too High (Overheat) 548
Unusual Noise is Heard 549
Vibration is Excessive 550
Air Cannot be Bled from Fuel Circuit 551
50 Disassembly and Assembly 553
Table of Contents 554
Related Information on Disassembly and Assembly 556
How to Read This Manual 556
Coating Materials List 557
Special Tool List 562
Engine and Cooling System 564
Drain and Add Coolant 564
How to Drain Coolant 564
How to Add Coolant 566
Drain and Add Hydraulic Oil 567
How to Drain Hydraulic Oil 567
How to Add Hydraulic Oil 569
Remove and Install Radiator Assembly 570
How to Remove Radiator Assembly 570
How to Install Radiator Assembly 573
Remove and Install Hydraulic Oil Cooler Assembly 576
How to Remove Hydraulic Oil Cooler Assembly 576
How to Install Hydraulic Oil Cooler Assembly 581
Remove and Install Engine and Main Pump Assembly 586
How to Remove Engine and Main Pump Assembly 587
How to Install Engine and Main Pump Assembly 594
Remove and Install Fuel Tank Assembly 601
How to Remove Fuel Tank Assembly 601
How to Install Fuel Tank Assembly 604
Power Train 606
Remove and Install Travel Motor Assembly 606
How to Remove Travel Motor Assembly 606
How to Install Travel Motor Assembly 608
Remove and Install Swing Motor Assembly 610
How to Remove Swing Motor Assembly 610
How to Install Swing Motor Assembly 612
Remove and Install Swing Circle Assembly 613
How to Remove Swing Circle Assembly 613
How to Install Swing Circle Assembly 614
Undercarriage and Frame 615
Disassemble and Assemble Recoil Spring Assembly 615
How to Disassemble Recoil Spring Assembly 616
How to Assemble Recoil Spring Assembly 618
Remove and Install Track Assembly 620
How to Remove Track Assembly 620
How to Install Track Assembly 621
Disassemble and Assemble Idler Assembly 622
How to Disassemble Idler Assembly 622
How to Assemble Idler Assembly 624
Disassemble and Assemble Track Roller Assembly 626
How to Disassemble Track Roller Assembly 626
How to Assemble Track Roller Assembly 627
Remove and Install Revolving Frame Assembly 628
How to Remove Revolving Frame Assembly 628
How to Install Revolving Frame Assembly 631
Remove and Install Counterweight Assembly 633
How to Remove Counterweight Assembly 633
How to Install Counterweight Assembly 635
Hydraulic System 637
Remove and Install Center Swivel Joint Assembly 637
How to Remove Center Swivel Joint Assembly 637
How to Install Center Swivel Joint Assembly 640
Remove and Install Hydraulic Tank Assembly 643
How to Remove Hydraulic Tank Assembly 643
How to Install Hydraulic Tank Assembly 646
Remove and Install Main Pump Assembly 649
How to Remove Main Pump Assembly 649
How to Install Main Pump Assembly 651
Work Equipment 652
Remove and Install Blade Assembly 652
How to Remove Blade Assembly 652
How to Install Blade Assembly 654
Remove and Install Work Equipment Assembly 655
How to Remove Work Equipment Assembly 655
How to Install Work Equipment Assembly 658
Disassemble and Assemble Work Equipment Cylinder Assembly 660
How to Disassemble Work Equipment Cylinder Assembly 661
How to Assemble Work Equipment Cylinder Assembly 664
CAB Related Parts 668
Remove and Install Floor Frame Assembly 668
How to Remove Floor Frame Assembly 668
How to Install Floor Frame Assembly 675
Remove and Install Operator Seat 682
How to Remove Operator Seat 682
How to Install Operator Seat 683
Remove and Install Seat Belt 684
How to Remove Seat Belt 684
How to Install Seatbelt 685
Electrical System 686
Remove and Install Machine Monitor Assembly 686
How to Remove Machine Monitor Assembly 686
How to Install Machine Monitor Assembly 688
Remove and Install KOMTRAX Terminal Assembly 690
How to Remove KOMTRAX Terminal Assembly 690
How to Install KOMTRAX Terminal Assembly 692
60 Maintenance Standard 693
Table of Contents 694
Explanation of Terms for Maintenance Standard 695
Engine and Cooling System 697
Maintenance Standard for Engine Mount 697
Maintenance Standard for PTO 698
Maintenance Standard for Cooling System 699
Power Train 700
Maintenance Standard for Swing Circle 700
Maintenance Standard for Sprocket 701
Undercarriage and Frame 702
Maintenance Standard for Track Frame and Idler Cushion 702
Maintenance Standard for Idler 704
Maintenance Standard for Track Roller 706
Maintenance Standard for Rubber Shoe 707
Hydraulic System 708
Maintenance Standard for Hydraulic Tank 708
Maintenance Standard for Main Pump 709
Maintenance Standard for Swing Motor 710
Maintenance Standard for Travel Motor 711
Maintenance Standard for Control Valve 712
Maintenance Standard for Work Equipment and Swing PPC Valve 722
Maintenance Standard for Blade PPC Valve 725
Maintenance Standard for Boom Swing PPC Valve 727
Maintenance Standard for Travel PPC Valve 729
Maintenance Standard for Attachment PPC Valve 732
Maintenance Standard for Center Swivel Joint 734
Work Equipment 735
Maintenance Standard for Work Equipment Linkage 735
Dimensions for Arm 742
Dimensions for Bucket 743
Maintenance Standard for Boom Cylinder 744
Maintenance Standard for Arm Cylinder 745
Maintenance Standard for Bucket Cylinder 746
Maintenance Standard for Blade Cylinder 747
Maintenance Standard for Boom Swing Cylinder 748
90 Circuit Diagrams 749
Table of Contents 750
How to Read the Codes for Electric Cable 751
Hydraulic Circuit Diagram 755
Symbols Used in Hydraulic Circuit Diagram 755
Hydraulic Circuit Diagram 759
Hydraulic Circuit Diagram (at Boom Raise Operation) 761
Hydraulic Circuit Diagram (at Left Swing Operation) 763
Hydraulic Circuit Diagram (at Boom Raise and Left Swing Operation) 765
Electrical Circuit Diagram 767
Symbols Used in Electric Circuit Diagram 767
Electrical Circuit Diagram (1/2) 771
Electrical Circuit Diagram (2/2) 773
Index 775

DESCRIPTION:

Komatsu PC25MR-5 Compact Hydraulic Excavator Shop Manual SEBN06967-00 – PDF DOWNLOAD

• SERIAL NUMBERS   25001 and up 

G.B 18/12/24