Komatsu PC10-7, PC15-3, PC20-7 Hydraulic Excavator Service Repair Shop Manual - SEBM020P0703

This Complete Service Repair Workshop Manual PDF Download for the PC10-7, PC15-3, PC20-7 Komatsu Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC10-7 - S/N: 25001 and up
Komatsu PC15-3 - S/N: 5001 and up
Komatsu PC20-7 - S/N: 35001 and up


TABLE OF CONTENTS :

10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM020P0703
Total Pages : 264


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

Instant download means no shipping cost or waiting for a CD to arrive in the mail…you will receive this manual today via instant download on completion of payment via our secure payment processor. We accept all major credit/debit cards/paypal.

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CONTENTS

10 STRUCTURE AND FUNCTION
POWER TRAIN
SWING CIRCLE
SWING MACHINERY
TRACK FRAME AND RECOIL SPRING
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK AND FUEL TANK
HYDRAULIC PUMP
7-SPOOL CONTROL VALVE
2-SPOOL CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
HYDRAULIC CYLINDER
VALVE CONTROL
WORK EQUIPMENT
ELECTRICAL CIRCUIT DIAGRAM
MONITOR SYSTEM

20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TOOL FOR TESTING, ADJUSTING AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
ADJUSTING FUEL INJECTION TIMING
ADJUSTING FUEL CONTROL LEVER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
BLEEDING AIR
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
POSITION OF CONNECTORS FOR TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR
HANDLING CONNECTORS
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE)
C-1. THIS ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IN EXTREMELY SLOW
H-3 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)
H-4 CONTROL LEVER IS HEAVY
H-5 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW EXCESSIVE HYDRAULIC DRIFT
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER
H-7 EXCESSIVE TIME LAG
H-8 WHEN MACHINE IS TRAVELING . IT DEVIATES NATURALLY TO ONE SIDE
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE
H-9 TRAVEL LACKS POWER (OR SPEED IS SLOW)
H-10 MACHINE DOES NOT MOVE (ONE SIDE ONLY)
H-11 DOES NOT SWING
H-12 SWING SPEED IS SLOW OR ACCELERATION IS POOR
H-13 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-14 EXCESSIVE SHOCK WHEN STOPPING SWING
H-15 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
H-16 EXCESSIVE HYDRAULIC DRIFT OF SWING
H-17 EXCESSIVE HYDRAULIC OF BOOM SWING
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)
P-1 MONITOR PANEL DOES NOT WORK
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
a) DO NOT LIGHT UP FOR 3 SECONDS
b) ALL LAMPS STAY LIGHTED UP
P-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)
P-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)
P-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING
P-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)
P-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)
P-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING
P-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY
a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE
b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY ENTERS TED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING
P-10 ABNORMALITY IN FUEL GAUGE DISPLAY
a) ALL SEGMENTS OF FUEL GAUGE GO OUT
b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN
c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED
P-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND
P-12 ABNORMALITY IN SERVICE METER DISPLAY
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING
b) SERVICE METER PILOT LAMP DOES NOT FLASH
P-13 NIGHT LIGHTING DOES NOT LIGHT UP
a) WHEN LAMP SWITCH IS AT POSITION 1OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP
b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP DOES NOT LIGHT UP
P-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL
INSTALLATION
ALTERNATOR
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL
INSTALLATION
ENGINE FRONT SEAL
REMOVAL
INSTALLATION
ENGINE REAR SEAL
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR AND OIL COOLER
REMOVAL
INSTALLATION
ENGINE AND HYDRAULIC PUMP
REMOVAL
INSTALLATION
DAMPER
REMOVAL
INSTALLATION
CENTER SWIVEL JOINT
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRAVEL MOTOR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SPROCKET
REMOVAL
INSTALLATION
SWING MOTOR AND SWING MACHINERY
REMOVAL
INSTALLATION
SWING MOTOR
DISASSEMBLY
ASSEMBLY
SWING MACHINERY
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING CIRCLE
REMOVAL
INSTALLATION
IDLER AND RECOIL SPRING
REMOVAL
INSTALLATION
RECOIL SPRING
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL
INSTALLATION
CARRIER ROLLER
REMOVAL
INSTALLATION
RUBBER SHOE
REMOVAL
INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
7-SPOOL CONTROL VALVE
REMOVAL
INSTALLATION
2-SPOOL CONTROL VALVE
REMOVAL
INSTALLATION
7-SPOOL CONTROL VALVE
DISASSEMBLY
ASSEMBLY
2-SPOOL CONTROL VALVE
DISASSEMBLY
ASSEMBLY
BOOM CYLINDER
REMOVAL
INSTALLATION
ARM CYLINDER
REMOVAL
INSTALLATION
BUCKET CYLINDER
REMOVAL
INSTALLATION
SWING CYLINDER
REMOVAL
INSTALLATION
BLADE CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
BUCKET
REMOVAL
INSTALLATION
ARM
REMOVAL
INSTALLATION
BOOM
REMOVAL
INSTALLATION
BLADE
REMOVAL
INSTALLATION

40 MAINTENANCE STANDARD
SWING CIRCLE
SWING MACHINERY
TRACK FRAME AND RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC PUMP
7-SPOOL CONTROL VALVE
2-SPOOL CONTROL VALVE
SWING MOTOR
TRAVEL MOTOR
CENTER SWIVEL JOINT
HYDRAULIC CYLINDER
WORK EQUIPMENT

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