Komatsu PC20MR-3 Hydraulic Excavator Service Repair Shop Manual (20001 and up) - SEN04767-02

This complete service repair workshop manual PDF download for the PC20MR-3 Komatsu Hydraulic Excavator (S/N: 20001 and up) 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 :

Machine Model : PC20MR-3
Serial Numbers : 20001 and up


TABLE OF CONTENTS :

00. Index and foreword
01. Specification
10. Structure and function
20. Standard value table
30. Testing and adjusting
40. Troubleshooting
50. Disassembly and assembly
90. Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN04767-02
Total Pages : 500


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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00 Index and foreword
100 Index
Composition of shop manual
Table of contents
200 Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
100 Specification and technical data
Specification dimension drawing
Working range drawing
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
100 Engine and cooling system
PTO
Cooling system
200 Power train
Power train
Swing circle
300 Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Sprocket
Track shoe
401 Hydraulic system, Part 1
Hydraulic components layout drawing
Hydraulic tank and filter
Center swivel joint
Travel motor
Hydraulic cylinder
Solenoid valve
402 Hydraulic system, Part 2
Hydraulic pump
Control valve
403 Hydraulic system, Part 3
CLSS
Operation for each function and valve
Swing motor
PPC valve
500 Work equipment
Work equipment
Dimensions of each part of work equipment
600 Cab and its attachments
Floor
700 Electrical system
Engine control system
Electric control system
KOMTRAX system
Component parts of system
Monitor system
Sensors

20 Standard value table
100 Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts

30 Testing and adjusting
100 Testing and adjusting
List of testing, adjusting, and troubleshooting tools
Measuring engine speed
Adjusting valve clearance
Measuring compression pressure
Measuring engine oil pressure
Testing and adjusting fuel injection timing
Bleeding air from fuel circuit
Testing and adjusting fan belt tension
Adjusting fuel control lever linkage
Measurement of clearance in swing circle bearings
Testing and adjusting track shoe tension
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits
Measuring control circuit basic pressure
Testing and adjusting pump LS differential pressure
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Measuring swing holding brake release pressure
Measurement of oil leakage from cylinder
Releasing residual pressure from hydraulic circuit
Bleeding air from cylinder
Pressurizing hydraulic tank
How to open and close (tilt) floor
Inspection procedures for diode
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Preparation work for troubleshooting of electrical system

40 Troubleshooting
100 General Information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and troubleshooting steps
Probable problems and troubleshooting No.
Connection table for connector pin numbers
T- branch box and T- branch adapter table
200 Troubleshooting of electrical system (E-mode)
Before starting E-mode troubleshooting
Information contained in troubleshooting table
E-1 Engine does not start
E- 2 Engine does not stop
E- 3 When lock lever is in FREE position, whole work equipment, travel, swing, and blade systems do not work
E- 4 When lock lever is in LOCK position, whole work equipment, travel, swing, and blade systems work
E- 5 When machine starts traveling, travel alarm does not sound
E- 6 When machine stops traveling, travel alarm does not stop sounding
E- 7 Windshield wiper does not operate [Cab specification]
E- 8 Windshield washer does not operate [Cab specification]
E- 9 Heater does not operate
300 Troubleshooting of hydraulic and mechanical system (H-mode)
Information contained in troubleshooting table
H- 1 Speed or power of whole work equipment, travel, swing, and blade is low
H- 2 Engine speed lowers extremely or engine stalls
H- 3 Whole work equipment, travel system, swing system, and blade do not work
H- 4 Abnormal sound comes out from around hydraulic pump
H- 5 Fine control performance or response is low
H- 6 Speed or power of boom is low
H- 7 Speed or power of arm is low
H- 8 Speed or power of bucket is low
H- 9 Speed or power of boom swing is low
H-10 Work equipment does not move in its single operation
H-11 Work equipment hydraulic drift is large
H-12 Time lag of work equipment is large
H-13 In compound operation of work equipment, speed of part loaded more is low
H-14 Machine deviates during travel
H-15 Travel speed or travel power is low
H-16 Machine is not steered well or steering power is low
H-17 Travel speed does not change
H-18 Travel motor does not work (one side only)
H-19 Speed or power of swing is low
H-20 Machine does not swing
H-21 Swing acceleration performance is low
H-22 Machine overruns when it stops swinging
H-23 Large shock is made when machine stops swinging
H-24 When upper structure stops swinging, it makes large sound
H-25 Hydraulic drift of swing is large
H-26 Speed or power of blade is low
H-27 Blade does not move
H-28 Hydraulic drift of blade is large
400 Troubleshooting of engine (S-mode)
Troubleshooting charts
500 Troubleshooting of Machine monitor System(M-mode)
Before starting M-mode troubleshooting
Information contained in troubleshooting table
M- 1 When starting switch is turned ON, no monitor/gauge operates
M- 2 When starting switch is turned ON, some monitors/gauges do not operate
M- 3 Caution buzzer does not sound or does not stop sounding
M- 4 While engine is running, engine oil pressure monitor flashes
M- 5 While engine is running, charge level monitor flashes
M- 6 Preheating system does not operate
M- 7 Coolant temperature gauge does not indicate normally
M- 8 Fuel level gauge does not indicate normally
M- 9 Service meter does not operate while engine is running
M-10Travel speed shifting system does not operate normally
M-11 Machine monitor night lamp and working lamp do not right up

50 Disassembly and assembly
100 General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
200 Engine and cooling system
Removal and installation of fuel injection pump assembly
Removal and installation of radiator and hydraulic oil cooler assembly
Removal and installation of engine and hydraulic pump assembly
300 Power train
Removal and installation of swing circle assembly
400 Undercarriage and frame
Removal and installation of track shoe assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Disassembly and assembly of track roller assembly
Removal and installation of floor frame assembly
Removal and installation of revolving frame assembly
500 Hydraulic system
Disassembly and assembly of control valve assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of hydraulic cylinder assembly
600 Work equipment
Removal and installation of work equipment assembly
700 Cab and its attachments
Removal and installation of front window assembly
Removal and installation of operator's cab glass (stuck glass)
800 Electric system
Removal and installation of KOMTRAX terminal

90 Diagrams and drawings
100 Hydraulic diagrams and drawings
Hydraulic circuit diagram
200 Electrical diagrams and drawings
Electrical circuit diagram (1/2)
Electrical circuit diagram (2/2)
Connector list and stereogram

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