Komatsu PC05-6 PC07-1 PC10-6 PC10-7 PC15-2 PC15-3 PC20-7 Excavator Workshop Repair Service Manual PDF - MKMTSPC05PC20.zip

A full-service repair manual featuring Electrical Wiring Diagrams for the Komatsu Excavator models PC05-6, PC07-1, PC10-6, PC10-7, PC15-2, PC15-3, and PC20-7, containing every technical detail needed to service, troubleshoot, overhaul, and rebuild these machines the way professional technicians do.

This workshop service repair manual for the Komatsu Excavator PC05-6, PC07-1, PC10-6, PC10-7, PC15-2, PC15-3, and PC20-7 contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 613 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

SEBM020M0604 - Hydraulic Excavator PC05-6, PC07-1, PC10-6, PC15-2 Shop Manual.pdf

SEBM020P0703 - Hydraulic Excavator PC10-7, PC15-3, PC20-7 Shop Manual.pdf

EEPB000800 - Hydraulic Excavator PC05-6F Parts Book.pdf

SEAM020MB600 - Hydraulic Excavator PC05-6, PC10-6, PC15-2 Operation & Maintenance Manual.pdf

WEAM007700 - Hydraulic Excavator GALEO PC14R-2 Operation & Maintenance Manual.pdf

WEAM007800 - Hydraulic Excavator GALEO PC16R-2 Operation & Maintenance Manual.pdf

MAIN SECTIONS

COVER...1

CONTENTS...2

10 STRUCTURE AND FUNCTION...17

POWER TRAIN...18

SWING CIRCLE...20

SWING MACHINERY...22

TRACK FRAME AND RECOIL SPRING...23

HYDRAULIC PIPING...27

HYDRAULIC CIRCUIT DIAGRAM...29

HYDRAULIC TANK AND FUEL TANK...32

HYDRAULIC PUMP...33

7-SPOOL CONTROL VALVE...34

2-SPOOL CONTROL VALVE...36

SWING MOTOR...38

CENTER SWIVEL JOINT...41

TRAVEL MOTOR ...42

HYDRAULIC CYLINDER...43

VALVE CONTROL...49

WORK EQUIPMENT...50

ELECTRICAL CIRCUIT DIAGRAM...51

MONITOR SYSTEM...53

20 TESTING AND ADJUSTING...58

TABLE OF JUDGEMENT STANDARD VALUE...59

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...75

TOOL FOR TESTING, ADJUSTING AND TROUBLESHOOTING...77

ADJUSTING VALVE CLEARANCE...78

MEASURING COMPRESSION PRESSURE...79

ADJUSTING FUEL INJECTION TIMING...80

ADJUSTING FUEL CONTROL LEVER...81

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...82

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...85

BLEEDING AIR...86

TROUBLESHOOTING...87

POINTS TO REMEMBER WHEN TROUBLESHOOTING...88

SEQUENCE OF EVENTS IN TROUBLESHOOTING...89

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...90

CHECKS BEFORE TROUBLESHOOTING...97

ELECTRICAL CIRCUIT DIAGRAM...98

POSITION OF CONNECTORS FOR TROUBLESHOOTING...100

CONNECTION TABLE FOR CONNECTOR...102

HANDLING CONNECTORS...109

METHOD OF USING TROUBLESHOOTING CHARTS...110

TROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE)...112

C-1. THIS ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF...113

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...114

H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER...115

H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IN EXTREMELY SLOW...115

H-3 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...116

H-4 CONTROL LEVER IS HEAVY...116

H-5 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW EXCESSIVE HYDRAULIC DRIFT...117

H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER ...117

H-7 EXCESSIVE TIME LAG...117

H-8 WHEN MACHINE IS TRAVELING . IT DEVIATES NATURALLY TO ONE SIDE...118

a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE...118

b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE...118

H-9 TRAVEL LACKS POWER (OR SPEED IS SLOW)...120

H-10 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...120

H-11 DOES NOT SWING...121

H-12 SWING SPEED IS SLOW OR ACCELERATION IS POOR...123

H-13 EXCESSIVE OVERRUN WHEN STOPPING SWING...123

H-14 EXCESSIVE SHOCK WHEN STOPPING SWING...124

H-15 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...125

H-16 EXCESSIVE HYDRAULIC DRIFT OF SWING...126

H-17 EXCESSIVE HYDRAULIC OF BOOM SWING...127

TABLE OF FAILURE MODES AND CAUSES...128

TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...130

P-1 MONITOR PANEL DOES NOT WORK...131

P-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCHES TURNED ON, OR ALL LAMPS STAY LIGHTED UP...132

a) DO NOT LIGHT UP FOR 3 SECONDS...132

b) ALL LAMPS STAY LIGHTED UP...132

P-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...133

P-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...134

P-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING...135

P-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)...135

P-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...136

P-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING...137

P-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY...138

a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE...138

b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY ENTERS TED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING...138

P-10 ABNORMALITY IN FUEL GAUGE DISPLAY...139

a) ALL SEGMENTS OF FUEL GAUGE GO OUT...139

b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN...139

c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED...140

P-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND...140

P-12 ABNORMALITY IN SERVICE METER DISPLAY...141

a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING...141

b) SERVICE METER PILOT LAMP DOES NOT FLASH...141

P-13 NIGHT LIGHTING DOES NOT LIGHT UP ...142

a) WHEN LAMP SWITCH IS AT POSITION 1OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP...142

b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP DOES NOT LIGHT UP...142

P-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)...143

30 DISASSEMBLY AND ASSEMBLY...144

METHOD OF USING MANUAL...146

PRECAUTIONS WHEN CARRYING OUT OPERATION...147

SPECIAL TOOL LIST...149

STARTING MOTOR...150

REMOVAL...150

INSTALLATION...150

ALTERNATOR...151

REMOVAL...151

INSTALLATION...151

FUEL INJECTION PUMP...152

REMOVAL...152

INSTALLATION...152

NOZZLE HOLDER...153

REMOVAL...153

INSTALLATION...153

WATER PUMP...154

REMOVAL...154

INSTALLATION...154

THERMOSTAT...156

REMOVAL...156

INSTALLATION...156

ENGINE FRONT SEAL...157

REMOVAL...157

INSTALLATION...157

ENGINE REAR SEAL...158

REMOVAL...158

INSTALLATION...158

CYLINDER HEAD...159

REMOVAL...159

INSTALLATION...160

RADIATOR AND OIL COOLER...163

REMOVAL...163

INSTALLATION...163

ENGINE AND HYDRAULIC PUMP...165

REMOVAL...165

INSTALLATION...166

DAMPER...167

REMOVAL...167

INSTALLATION...167

CENTER SWIVEL JOINT...168

REMOVAL...168

INSTALLATION...168

DISASSEMBLY...170

ASSEMBLY...170

TRAVEL MOTOR...171

REMOVAL...171

INSTALLATION...171

DISASSEMBLY...172

ASSEMBLY...177

SPROCKET...183

REMOVAL...183

INSTALLATION...183

SWING MOTOR AND SWING MACHINERY...184

REMOVAL...184

INSTALLATION...184

SWING MOTOR ...186

DISASSEMBLY...186

ASSEMBLY...188

SWING MACHINERY...192

DISASSEMBLY...192

ASSEMBLY...194

REVOLVING FRAME...196

REMOVAL...196

INSTALLATION...197

SWING CIRCLE...200

REMOVAL...200

INSTALLATION...200

IDLER AND RECOIL SPRING...201

REMOVAL...201

INSTALLATION...201

RECOIL SPRING...202

DISASSEMBLY...202

ASSEMBLY...203

TRACK ROLLER...204

REMOVAL...204

INSTALLATION...204

CARRIER ROLLER...205

REMOVAL...205

INSTALLATION...205

RUBBER SHOE...206

REMOVAL...206

INSTALLATION...206

HYDRAULIC PUMP...207

REMOVAL...207

INSTALLATION...207

7-SPOOL CONTROL VALVE...208

REMOVAL...208

INSTALLATION...208

2-SPOOL CONTROL VALVE...210

REMOVAL...210

INSTALLATION...210

7-SPOOL CONTROL VALVE...212

DISASSEMBLY...212

ASSEMBLY...214

2-SPOOL CONTROL VALVE...216

DISASSEMBLY...216

ASSEMBLY...217

BOOM CYLINDER...218

REMOVAL...218

INSTALLATION...218

ARM CYLINDER...219

REMOVAL...219

INSTALLATION...219

BUCKET CYLINDER...220

REMOVAL...220

INSTALLATION...220

SWING CYLINDER ...221

REMOVAL...221

INSTALLATION...221

BLADE CYLINDER...222

REMOVAL...222

INSTALLATION...222

HYDRAULIC CYLINDER...223

DISASSEMBLY...223

ASSEMBLY...225

WORK EQUIPMENT...227

REMOVAL...227

INSTALLATION...227

BUCKET...228

REMOVAL...228

INSTALLATION...228

ARM...229

REMOVAL...229

INSTALLATION...229

BOOM...230

REMOVAL...230

INSTALLATION...230

BLADE...231

REMOVAL...231

INSTALLATION...231

40 MAINTENANCE STANDARD...233

SWING CIRCLE...234

SWING MACHINERY...236

TRACK FRAME AND RECOIL SPRING...237

IDLER...239

CARRIER ROLLER...240

TRACK ROLLER...242

TRACK SHOE...244

HYDRAULIC PUMP...245

7-SPOOL CONTROL VALVE...246

2-SPOOL CONTROL VALVE...249

SWING MOTOR...251

TRAVEL MOTOR...252

CENTER SWIVEL JOINT...253

HYDRAULIC CYLINDER...254

WORK EQUIPMENT...257

1.1 FOREWORD...3

1.2 INFORMATION ON SAFETY...4

1.3 INTRODUCTION...6

1.3.1 INTENDED USE OF THE MACHINE...6

1.3.2 IMPROPER OR UNAUTHORIZED USES...6

1.3.3 MAIN CHARACTERISTICS...6

1.3.4 RUNNING-IN...7

1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE...7

1.4 PRODUCT IDENTIFICATION...8

1.4.1 MACHINE SERIAL NUMBER...8

1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...8

1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...9

1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...9

1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...10

1.4.6 SERIAL NUMBERS AND DEALER?S ADDRESS...11

TABLE OF CONTENTS...12

2.1 SAFETY, NOISE AND VIBRATION PLATES...20

2.1.1 POSITION OF THE SAFETY PLATES...20

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...21

2.1.3 POSITION OF THE NOISE PLATES...26

2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...26

2.2 GENERAL PRECAUTIONS...27

2.2.1 GENERAL SAFETY RULES...27

2.2.2 SAFETY DEVICES AND GUARDS...27

2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...27

2.2.4 UNAUTHORIZED MODIFICATIONS...28

2.2.5 LEAVING THE OPERATOR SEAT...28

2.2.6 GETTING ON AND OFF THE MACHINE...29

2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...30

2.2.8 PREVENTING BURNS...30

2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...31

2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...31

2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...32

2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE...32

2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...32

2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...33

2.3.1 SAFETY AT THE WORK SITE...33

2.3.2 FIRE PREVENTION...33

2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT...33

2.3.4 ROOM VENTILATION...34

2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...34