Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC09-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC09-1 workshop service repair manual includes:
* 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.

SEBM026105 - Hydraulic Excavator PC09-1 Shop Manual.pdf
SEAM044501T - Hydraulic Excavator GALEO PC09-1 Operation & Maintenance Manual.pdf
SEAM044502 - Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
TEN00062-04 - Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
TEN00555-00 - Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf

Total Pages: 1,027 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
SEAM044501T - Hydraulic Excavator GALEO PC09-1 Operation & Maintenance Manual....2
  COVER....2
  FOREWORD....3
    FOREWORD....4
    SAFETY INFORMATION....7
    INTRODUCTION....9
      DIRECTIONS OF MACHINE....9
    PRODUCT INFORMATION....10
      MACHINE SERIAL NUMBER PLATE AND ITS LOCATION....10
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....10
      EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....11
      SERVICE METER LOCATION....11
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....12
  CONTENTS....13
  SAFETY....16
    SAFETY INFORMATION....17
    SAFETY LABELS....19
      LOCATION OF SAFETY LABELS....19
      SAFETY LABELS....20
    SAFETY INFORMATION....23
      SAFETY RULES....23
      IF ABNORMALITIES ARE FOUND....23
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....23
      FIRE EXTINGUISHER AND FIRST AID KIT....23
      SAFETY EQUIPMENT....23
      KEEP MACHINE CLEAN....24
      OPERATOR'S SEAT EQUIPMENT....24
      LEAVING OPERATOR'S SEAT WITH LOCK....24
      HANDRAILS AND STEPS....25
      MOUNTING AND DISMOUNTING....25
      NO PERSONS ON ATTACHMENTS....25
      BURN PREVENTION....26
      FIRE PREVENTION AND EXPLOSION PREVENTION....27
      ACTION IF FIRE OCCURS....27
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....28
      ATTACHMENT INSTALLATION....28
      ATTACHMENT COMBINATIONS....28
      UNAUTHORIZED MODIFICATIONS....28
      SAFETY AT JOBSITE....29
      WORKING ON LOOSE GROUND....29
      DISTANCE TO HIGH VOLTAGE CABLES....29
      ENSURE GOOD VISIBILITY....30
      VENTILATION FOR ENCLOSED AREA....30
      SIGNALMAN'S SIGNAL AND SIGNS....30
      ASBESTOS DUST HAZARD PREVENTION....30
    SAFETY MACHINE OPERATION....31
      STARTING ENGINE....31
        CHECKS BEFORE STARTING ENGINE....31
        SAFETY RULES FOR STARTING ENGINE....31
        SAFETY ENGINE IN COLD WEATHER....31
      OPERATION....32
        CHECKS BEFORE OPERATION....32
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....32
        SAFETY RULES FOR TRAVELING....33
        TRAVELING ON SLOPES....34
        OPERATIONS ON SLOPES....35
        PROHIBITED OPERATIONS....35
        OPERATIONS ON SNOW....37
        PARKING MACHINE....37
      TRANSPORTATION....39
        LOADING AND UNLOADING....39
        SHIPPING THE MACHINE....39
      BATTERY....40
        BATTERY HAZARD PREVENTION....40
        STARTING ENGINE WITH BOOSTER CABLES....41
      TOWING....42
        SAFETY RULES FOR TOWING....42
      LIFTING OBJECTS WITH BUCKET....43
        SAFETY RULES FOR LIFTING OBJECTS....43
    SAFETY MAINTENANCE INFORMATION....44
      WARNING TAG....44
      KEEP WORK PLACE CLEAN AND TIDY....44
      APPOINT LEADER WHEN WORKING WITH OTHERS....44
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....45
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....46
      PROPER TOOLS....46
      PERSONNEL....46
      ATTACHMENTS....47
      WORK UNDER THE MACHINE....47
      NOISE....47
      WHEN USING HAMMER....47
      WELDING WORKS....47
      REMOVING BATTERY TERMINALS....48
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....48
      SAFETY RULES FOR HIGH-PRESSURE OIL....48
      SAFETY HANDLING HIGH-PRESSURE HOSES....49
      WASTE MATERIALS....49
      COMPRESSED AIR....49
      PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....49
  OPERATION....50
    MACHINE VIEW ILLUSTRATIONS....51
      OVERALL MACHINE VIEW....51
      CONTROLS AND GAUGES....52
    DETAILED CONTROLS AND GAUGES....53
      METERS,LAMPS....53
      SWITCHES....55
      CONTROL LEVERS AND PEDALS....57
      VARIABLE BLADE....64
      ENGINE HOOD....64
      FUSE....65
      BLOCK FUSE....65
      OPERATION MANUAL STORAGE....66
    MACHINE OPERATIONS AND CONTROLS....67
      BEFORE STARTING ENGINE....67
      STARTING ENGINE....78
      AFTER STARTING ENGINE....81
      STOPPING THE ENGINE....84
      CHECK AFTER SHUT OFF ENGINE....84
      MACHINE OPERATION....85
      STEERING THE MACHINE....89
      SWINGING....91
      WORK EQUIPMENT CONTROLS AND OPERATIONS....92
      PROHIBITED OPERATIONS....94
      GENERAL OPERATION INFORMATION....97
      TRAVELING ON SLOPES....98
      ESCAPE FROM MUD....100
      WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR....101
      BUCKET REPLACEMENT....103
      PARKING MACHINE....105
      MACHINE INSPECTION AFTER DAILY WORK....106
      RUBBER SHOES(MACHINE WITH RUBBER SHOES ONLY)....107
    TRANSPORTATION....112
      TRANSPORTATION PROCEDURE....112
      LOADING AND UNLOADING WITH TRAILER....112
      LIFTING MACHINE....114
      SHIPPING MACHINE INFORMATION....116
    COLD WEATHER OPERATION....117
      COLD WEATHER OPERATION INFORMATION....117
      AFTER DAILY WORK COMPLETION....119
      AFTER COLD WEATHER SEASON....119
    LONG TERM STORAGE....120
      BEFORE STORAGE....120
      DURING STORAGE....120
      AFTER STORAGE....120
      STARTING MACHINE AFTER LONG-TERM STORAGE....120
    TROUBLES AND ACTIONS....121
      RUNNING OUT OF FUEL....121
      PHENOMENA THAT ARE NOT FAILURES....121
      TOWING THE MACHINE....122
      SEVERE JOB CONDITION....122
      DISCHARGED BATTERY....123
      OTHER TROUBLE....127
  MAINTENANCE....131
    MAINTENANCE INFORMATION....132
    LUBRICANTS, COOLANT AND FILTERS....134
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....134
      ELECTRIC SYSTEM MAINTENANCE....136
    WEAR PARTS....137
      WEAR PARTS LIST....137
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....138
      PROPER SELECTION....138
    TIGHTENING TORQUE SPECIFICATIONS....142
      TIGHTENING TORQUE LIST....142
    SAFETY CRITICAL PARTS....143
      SAFETY CRITICAL PARTS LIST....143
    MAINTENANCE SCHEDULE....144
      MAINTENANCE SCHEDULE CHART....144
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....145
    MAINTENANCE SCHEDULE....146
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....146
      WHEN REQUIRED....147
        CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT....147
        CLEAN INSIDE OF COOLING SYSTEM....149
        CHECK LEVEL OF BATTERY ELECTROLYTE....152
        CHECK RUBBER SHOES....155
        CHECK AND ADJUST RUBBER SHOE TENSION....157
        REPLACE RUBBER SHOES....159
        DRAIN WATER AND SEDIMENT FROM FUEL TANK....162
      CHECKS BEFORE STARTING....163
      EVERY 100 HOURS MAINTENANCE....164
        LUBRICATING....164
      EVERY 250 HOURS MAINTENANCE....165
        LUBRICATING....165
        REPLACE ENGINE OIL IN ENGINE OIL PAN....166
        CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL....167
        REPLACE HYDRAULIC OIL FILTER CARTRIDGE....168
        CHECK AND ADJUST COOLINE FAN BELT TENSION....169
      EVERY 500 HOURS MAINTENANCE....170
        LUBRICATING....170
        REPLACE ENGINE OIL FILTER CARTRIDGE....171
        REPLACE FUEL FILTER ELEMENT....172
        CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS....174
        REPLACE FUEL FEED PUMP PRE-FILTER....175
      EVERY 1000 HOURS MAINTENANCE....176
        CHANGE OIL IN FINAL DRIVE CASE....176
      EVERY 2000 HOURS MAINTENANCE....177
        CHANGE OIL IN HYDRAULIC TANK,CLEAN STRAINER....177
        CHECK ALTERNATOR,STARTING MOTOR....178
        CHECK ENGINE VALVE CLEARANCE,ADJUST....178
  SPECIFICATIONS....179
    SPECIFICATIONS....180
  ATTACHMENTS, OPTIONS....182
    ATTACHMENTS AND OPTIONS-GENERAL INFORAMTION....183
      SAFETY FIRST....183
      ATTACHMENT INSTALLATION....184
    BUCKET WITH HOOK....185
      HOOK CONDITION....185
      PROHIBITED OPERATIONS....185
    ATTACHMENT GUIDE....186
      ATTACHMENT COMBINATIONS....186
    HANDLING ARM WITH BUILT-IN BREAKER....187
      BUCKET POSTURE....187
      REMOVING AND INSTALLING CHISEL....187
      PROCEDURE FOR BREAKER OPERATIONS....188
      PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS....189
      STOWING CHISEL,DUMMY CHISEL....190
      PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS....190
      HANDLING DUMMY LINK....191
      CHECK BEFORE STARTING....192
      SPECIFICATIONS....193
    HANDLING BUCKET COUPLER....194
      PROCEDURE FOR REMOVING BUCKET....194
      PROCEDURE FOR INSTALLING BUCKET....196
    RECOMMENDED ATTACHMENT OPERATIONS....198
      HYDRAULIC BREAKER....198
  INDEX....202
SEAM044502 - Hydraulic Excavator PC09-1 Operation & Maintenance Manual....205
  COVER....205
  FOREWARD....206
    FOREWORD....207
    SAFETY INFORMATION....210
    INTRODUCTION....212
      DIRECTIONS OF MACHINE....212
    PRODUCT INFORMATION....213
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....213
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....213
      EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....214
      SERVICE METER LOCATION....214
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....215
  CONTENTS....216
  SAFETY....220
    SAFETY INFORMATION....221
    SAFETY LABELS....223
      LOCATION OF SAFETY LABELS....223
      SAFETY LABELS....224
    SAFETY INFORMATION....227
      SAFETY RULES....227
      IF ABNORMALITIES ARE FOUND....227
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....227
      FIRE EXTINGUISHER AND FIRST AID KIT....227
      SAFETY EQUIPMENT....227
      KEEP MACHINE CLEAN....228
      OPERATOR'S SEAT EQUIPMENT....228
      LEAVING OPERATOR'S SEAT WITH LOCK....228
      HANDRAILS AND STEPS....229
      MOUNTING AND DISMOUNTING....229
      NO PERSONS ON ATTACHMENTS....229
      BURN PREVENTION....230
      FIRE PREVENTION AND EXPLOSION PREVENTION....231
      ACTION IF FIRE OCCURS....231
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....232
      ATTACHMENT INSTALLATION....232
      ATTACHMENT COMBINATIONS....232
      UNAUTHORIZED MODIFICATIONS....232
      SAFETY AT JOBSITE....233
      WORKING ON LOOSE GROUND....233
      DISTANCE TO HIGH VOLTAGE CABLES....233
      ENSURE GOOD VISIBILITY....234
      VENTILATION FOR ENCLOSED AREA....234
      SIGNALMAN'S SIGNAL AND SIGNS....234
      ASBESTOS DUST HAZARD PREVENTION....234
    SAFETY MACHINE OPERATION....235
      STARTING ENGINE....235
        CHECKS BEFORE STARTING ENGINE....235
        SAFETY RULES FOR STARTING ENGINE....235
        STARTING ENGINE IN COLD WEATHER....235
      OPERATION....236
        CHECKS BEFORE OPERATION....236
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....236
        SAFETY RULES FOR TRAVELING....237
        TRAVELING ON SLOPES....238
        OPERATIONS ON SLOPES ....239
        PROHIBITED OPERATIONS....239
        OPERATIONS ON SNOW....241
        PARKING MACHINE....241
      TRANSPORTATION....243
        LOADING AND UNLOADING....243
        SHIPPING THE MACHINE....243
      BATTERY....244
        BATTERY HAZARD PREVENTION....244
        STARTING ENGINE WITH BOOSTER CABLES....245
      TOWING....246
        SAFETY RULES FOR TOWING....246
      LIFTING OBJECTS WITH BUCKET....247
        SAFETY RULES FOR LIFTING OBJECTS....247
    SAFETY MAINTENANCE INFORMATION....248
      WARNING TAG....248
      KEEP WORK PLACE CLEAN AND TIDY....248
      APPOINT LEADER WHEN WORKING WITH OTHERS....248
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....249
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....250
      PROPER TOOLS....250
      PERSONNEL....250
      ATTACHMENTS....251
      WORK UNDER THE MACHINE....251
      NOISE....251
      WHEN USING HAMMER....251
      WELDING WORKS....251
      REMOVING BATTERY TERMINALS....252
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....252
      SAFETY RULES FOR HIGH-PRESSURE OIL....252
      SAFETY HANDLING HIGH-PRESSURE HOSES....253
      WASTE MATERIALS....253
      COMPRESSED AIR....253
      PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....253
  OPERATION....254
    MACHINE VIEW ILLUSTRATIONS....255
      OVERALL MACHINE VIEW....255
      CONTROLS AND GAUGES....256
    DETAILED CONTROLS AND GAUGES....257
      METERS,LAMPS....257
      SWITCHES....259
      CONTROL LEVERS AND PEDALS....261
      VARIABLE BLADE....268
      ENGINE HOOD....268
      FUSE....269
      BLOCK FUSE....269
      OPERATION MANUAL STORAGE....270
    MACHINE OPERATIONS AND CONTROLS....271
      BEFORE STARTING ENGINE....271
      STARTING ENGINE....282
      AFTER STARTING ENGINE....285
      STOPPING THE ENGINE....288
      CHECK AFTER SHUT OFF ENGINE....288
      MACHINE OPERATION....289
      STEERING THE MACHINE....293
      SWINGING....295
      WORK EQUIPMENT CONTROLS AND OPERATIONS....296
      PROHIBITED OPERATIONS....298
      GENERAL OPERATION INFORMATION....301
      TRAVELING ON SLOPES....302
      ESCAPE FROM MUD....304
      WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR....305
      BUCKET REPLACEMENT....307
      PARKING MACHINE....309
      MACHINE INSPECTION AFTER DAILY WORK....310
      RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)....311
    TRANSPORTATION....316
      TRANSPORTATION PROCEDURE....316
      LOADING AND UNLOADING WITH TRAILER....316
      LIFTING MACHINE....318
      SHIPPING MACHINE INFORMATION....320
    COLD WEATHER OPERATION....321
      COLD WEATHER OPERATION INFORMATION....321
      AFTER DAILY WORK COMPLETION....323
      AFTER COLD WEATHER SEASON....323
    LONG TERM STORAGE....324
      BEFORE STORAGE....324
      DURING STORAGE....324
      AFTER STORAGE....324
      STARTING MACHINE AFTER LONG-TERM STORAGE....324
    TROUBLES AND ACTIONS....325
      RUNNING OUT OF FUEL....325
      PHENOMENA THAT ARE NOT FAILURES....325
      TOWING THE MACHINE....326
      SEVERE JOB CONDITION....326
      DISCHARGED BATTERY....327
      OTHER TROUBLE....331
  MAINTENANCE....336
    MAINTENANCE INFORMATION....337
    LUBRICANTS, COOLANT AND FILTERS....339
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....339
      ELECTRIC SYSTEM MAINTENANCE....341
    WEAR PARTS....342
      WEAR PARTS LIST....342
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....343
      PROPER SELECTION....343
    TIGHTENING TORQUE SPECIFICATIONS....347
      TIGHTENING TORQUE LIST....347
    SAFETY CRITICAL PARTS....348
      SAFETY CRITICAL PARTS LIST....348
    MAINTENANCE SCHEDULE....349
      MAINTENANCE SCHEDULE CHART....349
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....350
    MAINTENANCE PROCEDURE....351
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....351
        REPLACE FUEL FILTER ELEMENT....376
        REPLACE ENGINE OIL FILTER CARTRIDGE....375
        CHECK ENGINE VALVE CLEARANCE, ADJUST....382
      WHEN REQUIRED....352
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....352
        CLEAN INSIDE OF COOLING SYSTEM....354
        CHECK LEVEL OF BATTERY ELECTROLYTE....357
        CHECK RUBBER SHOES....360
        CHECK AND ADJUST RUBBER SHOE TENSION....362
        REPLACE RUBBER SHOES....364
        DRAIN WATER AND SEDIMENT FROM FUEL TANK....366
      CHECK BEFORE STARTING....367
      EVERY 100 HOURS MAINTENANCE....368
        LUBRICATING....368
      EVERY 250 HOURS MAINTENANCE....369
        LUBRICATING....369
        REPLACE ENGINE OIL IN ENGINE OIL PAN....370
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....371
        REPLACE HYDRAULIC OIL FILTER CARTRIDGE....372
        CHECK AND ADJUST COOLING FAN BELT TENSION....373
      EVERY 500 HOURS MAINTENANCE....374
        LUBRICATING....374
        REPLACE ENGINE OIL FILTER CARTRIDGE....375
        REPLACE FUEL FILTER ELEMENT....376
        CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS....378
        REPLACE FUEL FEED PUMP PRE-FILTER....379
      EVERY 1000 HOURS MAINTENANCE....380
        CHANGE OIL IN FINAL DRIVE CASE....380
      EVERY 2000 HOURS MAINTENANCE....381
        CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER....381
        CHECK ALTERNATOR, STARTING MOTOR....382
        CHECK ENGINE VALVE CLEARANCE, ADJUST....382
  SPECIFICATIONS....384
    SPECIFICATIONS....385
  ATTACHMENTS, OPTIONS....388
    ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....389
      SAFETY FIRST....389
      ATTACHMENT INSTALLATION....390
    BUCKET WITH HOOK....391
      HOOK CONDITION....391
      PROHIBITED OPERATIONS....391
    ATTACHMENT GUIDE....392
      ATTACHMENT COMBINATIONS....392
    HANDLING ARM WITH BUILT-IN BREAKER....393
      BUCKET POSTURE....393
      REMOVING AND INSTALLING CHISEL....393
      PROCEDURE FOR BREAKER OPERATIONS....394
      PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS....395
      STOWING CHISEL, DUMMY CHISEL....396
      PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS....396
      HANDLING DUMMY LINK....397
      CHECK BEFORE STARTING....398
      SPECIFICATIONS....399
    HANDLING BUCKET COUPLER....400
      PROCEDURE FOR REMOVING BUCKET....400
      PROCEDURE FOR INSTALLING BUCKET....402
    RECOMMENDED ATTACHMENT OPERATIONS....404
      HYDRAULIC BREAKER....404
  INDEX....408
SEBM026105 - Hydraulic Excavator PC09-1 Shop Manual....412
  COVER....412
  CONTENTS....413
  01 GENERAL....436
    GENERAL ASSEMBLY DRAWING....437
    SPECIFICATIONS....438
    WEIGHT TABLE....444
    LIST OF LUBRICANT AND WATER....446
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....447
    RADIATOR....448
    ENGINE CONTROL....450
    PTO....452
    POWER TRAIN DIAGRAM....453
    SWING CIRCLE....454
    TRACK FRAME....455
    IDLER CUSHION....457
    IDLER....458
    TRACK ROLLER....459
    TRACK SHOE....460
    HYDRAULIC EQUIPMENT LAYOUT....461
    VALVE CONTROL....462
    HYDRAULIC TANK....463
    HYDRAULIC PUMP....464
    10-SPOOL CONTROL VALVE....466
    CENTER SWIVEL JOINT....468
    SWING MOTOR....469
    TRAVEL MOTOR....470
    HYDRAULIC CYLINDER....476
    WORK EQUIPMENT....478
    DIMENSION OF WORK EQUIPMENT....480
    MACHINE MONITOR SYSTEM....484
  20 TESTING AND ADJUSTING....486
    STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....487
    STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....489
    TESTING AND ADJUSTING....497
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....498
      MEASUREMENT ENGINE SPEED....499
      MASURING EXHAUST COLOR....501
      ADJUSTMENT VALVE CLEARANCE....503
      MEASURING COMPRESSION PRESSURE....504
      MEASURING ENGINE OIL PRESSURE....505
      INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING....506
      ADJUSTMENT OF FUEL CONTROL CABLE....508
      BLEEDING AIR FROM FUEL CIRCUIT....510
      TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION....511
      TESTING AND ADJUSTING TRACK SHOE TENSION....512
      INSPECTION AND ADJUSTMENT OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS....513
      IDENTIFICATION OF SPOT CAUSING WORK EQUIPMENT HYDRAULIC DRIFT....516
      MEASUREMENT OF OIL LEAK AMOUNT INSIDE WORK EQUIPMENT CYLINDER....517
      BLEEDING AIR FROM HYDRAULIC CIRCUITS....517
      PRESSURIZING HYDRAULIC TANK....518
    TROUBLESHOOTING....519
      POINTS TO REMEMBER WHEN TROUBLESHOOTING....520
      SEQUENCE OF EVENTS IN TROUBLESHOOTING....521
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....522
      CHECKS BEFORE TROUBLESHOOTING....530
      METHOD OF USING TROUBLESHOOTING....531
      CONNECTOR MOUNTING LOCATIONS AND ELECTRICAL CIRCUITS....532
      CONNECTOR PIN ALLOCATION DRAWING....533
      ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START, STOP, PREHEATING AND CHARGING SYSTEMS (E CIRCUIT)....535
      ELECTRICAL CIRCUIT DIAGRAM FOR PANEL SYSTEMS (P CIRCUIT)....536
      CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS....537
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....539
        INFORMATION IN TROUBLESHOOTING TABLE....540
        E-1 ENGINE DOES NOT START....541
        E-2 ENGINE DOES NOT STOP....545
        E-3 ENGINE OIL PRESSURE LAMP DOES NOT WORK PROPERLY....546
        E-4 ENGINE COOLING WATER TEMPERATURE LAMP DOES NOT WORK PROPERLY....548
        E-5 ENGINE PREHEATING SYSTEM DOES NOT WORK....550
        E-6 SERVICE METER DOES NOT ADVANCE....552
        E-7 HORN DOES NOT SOUND, OR DOES NOT STOP SOUNDING....553
        E-8 WORKING LAMP DOES NOT LIGHT UP, OR DOES NOT GO OFF....555
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)....557
        METHOD OF USING TROUBLESHOOTING CHARTS....558
        H-1 ALL WORK EQUIPMENT, TRAVEL AND SWING SHOW SLOW SPEED OR LACK IN POWER....560
        H-2 ENGINE RUNNING SPEED DROPS SHARPLY OR ENGINE STAALS.MOREOVER, ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE AT ALL OR MOVE EXTREMELY SLOWLY.....560
        H-3 THERE IS NOISE FROM AROUND HYDRAULIC PUMP....561
        H-4 CONTROL LEVERS AND PEDALS ARE HARD TO OPERATE....561
        H-5 BOOM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT....562
        H-6 ARM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT....562
        H-7 BUCKET MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT....563
        H-8 SWING IS SLOW, LACKS IN POWER AND HAS BIG HYDRAULIC DRIFT....563
        H-9 BLADE MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT....563
        H-10 MACHINE DEVIATES FROM TRAVEL PATH IN TRAVELING....564
          a) THE MACHINE DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND IN REVERSE DIRECTIONS ....564
          b) THE DEVIATION DIRECTION CHANGES DEPENDING ON FORWARD OR REVERSE TRAVEL....564
        H-11 NO POWER OR SLOW IN TRAVELING....566
        H-12 UNDERCARRIAGE DOES NOT MOVE (ONE SIDE ONLY)....566
        H-13 TRAVEL SPEED CANNOT BE CHANGED....567
        H-14 UPPER STRUCTURE DOES NOT SWING....567
        H-15 SWING SPEED IS SLOW OR ACCELERATION IS POOR....568
        H-16 OVERRUN WHEN STOPPING WING IS BIG....568
        H-17 THERE IS BIG SHOCK WHEN STOPPING SWING....569
        H-18 THERE IS BIG NOISE WHEN STOPPING SWING....569
        H-19 HYDRAULIC DRIFT OF SWING IS BIG....570
        H-20 TROUBLESHOOTING OF HYDRAULIC BREAKER....571
  30 DISASSEMBLY AND ASSEMBLY....572
    METHOD OF USING MANUAL....573
    PRECAUTIONS WHEN CARRYING OUT OPERATION....574
    SPECIAL TOOL LIST....576
    SWING MOTOR....577
      REMOVAL AND INSTALLATION....577
    CENTER SWIVEL JOINT....578
      REMOVAL AND INSTALLATION....577
      DISASSEMBLY AND ASSEMBLY....579
    ENGINE AND HYDRAULIC PUMP....580
      REMOVAL....580
      INSTALLATION....583
    REVOLVING FRAME....584
      REMOVAL ....584
      INSTALLATION....585
    SWING CIRCLE....586
      REMOVAL AND INSTALLATION....586
    IDLER....587
      ASSEMBLY....587
    TRACK ROLLER....588
      ASSEMBLY....588
    RUBBER SHOE....588
      REMOVAL AND INSTALLATION....588
    CONTROL VALVE....589
      ASSEMBLY....589
    HYDRAULIC CYLINDER....590
      ASSEMBLY....590
    HYDRAULIC BREAKER....593
      DISASSEMBLY....594
      ASSEMBLY....597
  90 OTHERS....601
    HYDRAULIC CIRCUIT DIAGRAM....602
      FIXED GAUGE TYPE (STD)....602
      VARIABLE GAUGE TYPE (IF EQUIPPED)....603
    ELECTRICAL CIRCUIT DIAGRAM....604
      STANDERD SPECIFICATION....604
      TRAVEL ALREM SPECIFICATION (IF EQUIPPED)....605
TEN00062-04 - Hydraulic Excavator PC09-1 Operation & Maintenance Manual....606
  COVER....606
  FOREWORD....607
    FOREWORD....608
    SAFETY INFORMATION....611
    INTRODUCTION....613
      DIRECTIONS OF MACHINE....613
    PRODUCT INFORMATION....614
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....614
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....614
      EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....615
      SERVICE METER LOCATION....615
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....616
    CONTENTS....617
  SAFETY....621
    SAFETY....622
    SAFETY LABELS....624
      LOCATION OF SAFETY LABELS....624
      SAFETY LABELS....625
    GENERAL PRECAUTIONS....628
    SAFETY MACHINE OPERATION....636
      STARTING ENGINE....636
      OPERATION....637
      TRANSPORTATION....644
      BATTERY....645
      TOWING....647
      LIFTING OBJECTS WITH BUCKET....648
    SAFETY MAINTENANCE INFORMATION....649
  OPERATION....655
    MACHINE VIEW ILLUSTRATIONS....656
      OVERALL MACHINE VIEW....656
      CONTROLS AND GAUGES....657
    DETAILED CONTROLS AND GAUGES....658
      METERS, LAMPS....658
      SWITCHES....660
      CONTROL LEVERS AND PEDALS....662
      VARIABLE BLADE....669
      ENGINE HOOD....669
      FUSE....670
      BLOCK FUSE....670
      OPERATION MANUAL STORAGE....671
    MACHINE OPERATIONS AND CONTROLS....672
      BEFORE STARTING ENGINE....672
      STARTING ENGINE....683
      AFTER STARTING ENGINE....686
      STOPPING THE ENGINE....689
      CHECK AFTER SHUT OFF ENGINE....689
      MACHINE OPERATION....690
      STEERING THE MACHINE....694
      SWINGING....696
      WORK EQUIPMENT CONTROLS AND OPERATIONS....697
      PROHIBITED OPERATIONS....699
      GENERAL OPERATION INFORMATION....702
      TRAVELING ON SLOPES....703
      ESCAPE FROM MUD....705
      WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR....706
      BUCKET REPLACEMENT....708
      PARKING MACHINE....710
      MACHINE INSPECTION AFTER DAILY WORK....711
      RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)....712
    TRANSPORTATION....717
      TRANSPORTATION PROCEDURE....717
      LOADING AND UNLOADING WITH TRAILER....717
      LIFTING MACHINE....719
      SHIPPING MACHINE INFORMATION....721
    COLD WEATHER OPERATION....722
      COLD WEATHER OPERATION INFORMATION....722
      AFTER DAILY WORK COMPLETION....724
      AFTER COLD WEATHER SEASON....724
    LONG TERM STORAGE....725
      BEFORE STORAGE....725
      DURING STORAGE....725
      AFTER STORAGE....725
      STARTING MACHINE AFTER LONG-TERM STORAGE....725
    TROUBLES AND ACTIONS....726
      RUNNING OUT OF FUEL....726
      PHENOMENA THAT ARE NOT FAILURES....726
      TOWING THE MACHINE....727
      SEVERE JOB CONDITION....727
      DISCHARGED BATTERY....728
      OTHER TROUBLE....732
  MAINTENANCE....737
    MAINTENANCE INFORMATION....738
    OUTLINE OF SERVICE....740
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....740
      ELECTRIC SYSTEM MAINTENANCE....743
    WEAR PARTS....744
      WEAR PARTS LIST....744
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....745
      PROPER SELECTION....745
    TIGHTENING TORQUE SPECIFICATIONS....749
      TIGHTENING TORQUE LIST....749
    SAFETY CRITICAL PARTS....750
      SAFETY CRITICAL PARTS LIST....750
    MAINTENANCE SCHEDULE....751
      MAINTENANCE SCHEDULE CHART....751
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....752
    MAINTENANCE PROCEDURE....753
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....753
      WHEN REQUIRED....754
      CHECK BEFORE STARTING....769
      EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE....769
      EVERY 100 HOURS MAINTENANCE....770
      EVERY 250 HOURS MAINTENANCE....771
      EVERY 500 HOURS MAINTENANCE....776
      EVERY 1000 HOURS MAINTENANCE....783
      EVERY 2000 HOURS MAINTENANCE....784
  SPECIFICATIONS....787
    SPECIFICATIONS....788
  ATTACHMENTS, OPTIONS....791
    ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....792
      SAFETY FIRST....792
      ATTACHMENT INSTALLATION....793
    BUCKET WITH HOOK....794
      HOOK CONDITION....794
      PROHIBITED OPERATIONS....794
    ATTACHMENT GUIDE....795
      ATTACHMENT COMBINATIONS....795
    HANDLING ARM WITH BUILT-IN BREAKER....796
      BUCKET POSTURE....796
      REMOVING AND INSTALLING CHISEL....796
      PROCEDURE FOR BREAKER OPERATIONS....797
      PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS....798
      STOWING CHISEL, DUMMY CHISEL....799
      PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS....799
      HANDLING DUMMY LINK....800
      CHECK BEFORE STARTING....801
      SPECIFICATIONS....802
    HANDLING BUCKET COUPLER....803
      PROCEDURE FOR REMOVING BUCKET....803
      PROCEDURE FOR INSTALLING BUCKET....805
    HANDLING FOLDING TOPS CANOPY....807
    RECOMMENDED ATTACHMENT OPERATIONS....809
      HYDRAULIC BREAKER....809
  INDEX....813
TEN00555-00 - Hydraulic Excavator PC09-1 Operation & Maintenance Manual....817
  COVER....817
  FOREWORD....818
    FOREWORD....819
    SAFETY INFORMATION....822
    INTRODUCTION....824
      DIRECTIONS OF MACHINE....824
    PRODUCT INFORMATION....825
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....825
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....825
      EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....826
      SERVICE METER LOCATION....826
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....827
    CONTENTS....828
  SAFETY....832
    SAFETY....833
    SAFETY LABELS....835
      LOCATION OF SAFETY LABELS....835
      SAFETY LABELS....836
    GENERAL PRECAUTIONS....839
    SAFETY MACHINE OPERATION....847
      STARTING ENGINE....847
      OPERATION....848
      TRANSPORTATION....855
      BATTERY....856
      TOWING....858
      LIFTING OBJECTS WITH BUCKET....859
    SAFETY MAINTENANCE INFORMATION....860
  OPERATION....866
    MACHINE VIEW ILLUSTRATIONS....867
      OVERALL MACHINE VIEW....867
      CONTROLS AND GAUGES....868
    DETAILED CONTROLS AND GAUGES....869
      METERS, LAMPS....869
      SWITCHES....871
      CONTROL LEVERS AND PEDALS....873
      VARIABLE BLADE....880
      ENGINE HOOD....880
      FUSE....881
      BLOCK FUSE....881
      OPERATION MANUAL STORAGE....882
    MACHINE OPERATIONS AND CONTROLS....883
      BEFORE STARTING ENGINE....883
      STARTING ENGINE....894
      AFTER STARTING ENGINE....897
      STOPPING THE ENGINE....900
      CHECK AFTER SHUT OFF ENGINE....900
      MACHINE OPERATION....901
      STEERING THE MACHINE....905
      SWINGING....907
      WORK EQUIPMENT CONTROLS AND OPERATIONS....908
      PROHIBITED OPERATIONS....910
      GENERAL OPERATION INFORMATION....913
      TRAVELING ON SLOPES....914
      ESCAPE FROM MUD....916
      WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR....917
      BUCKET REPLACEMENT....919
      PARKING MACHINE....921
      MACHINE INSPECTION AFTER DAILY WORK....922
      RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)....923
    TRANSPORTATION....928
      TRANSPORTATION PROCEDURE....928
      LOADING AND UNLOADING WITH TRAILER....928
      LIFTING MACHINE....930
      SHIPPING MACHINE INFORMATION....932
    COLD WEATHER OPERATION....933
      COLD WEATHER OPERATION INFORMATION....933
      AFTER DAILY WORK COMPLETION....935
      AFTER COLD WEATHER SEASON....935
    LONG TERM STORAGE....936
      BEFORE STORAGE....936
      DURING STORAGE....936
      AFTER STORAGE....936
      STARTING MACHINE AFTER LONG-TERM STORAGE....936
    TROUBLES AND ACTIONS....937
      RUNNING OUT OF FUEL....937
      PHENOMENA THAT ARE NOT FAILURES....937
      TOWING THE MACHINE....938
      SEVERE JOB CONDITION....938
      DISCHARGED BATTERY....939
      OTHER TROUBLE....943
  MAINTENANCE....948
    MAINTENANCE INFORMATION....949
    OUTLINE OF SERVICE....951
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....951
      ELECTRIC SYSTEM MAINTENANCE....954
    WEAR PARTS....955
      WEAR PARTS LIST....955
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....956
      PROPER SELECTION....956
    TIGHTENING TORQUE SPECIFICATIONS....960
      TIGHTENING TORQUE LIST....960
    SAFETY CRITICAL PARTS....961
      SAFETY CRITICAL PARTS LIST....961
    MAINTENANCE SCHEDULE....962
      MAINTENANCE SCHEDULE CHART....962
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....963
    MAINTENANCE PROCEDURE....964
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....964
      WHEN REQUIRED....965
      CHECK BEFORE STARTING....980
      EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE....980
      EVERY 100 HOURS MAINTENANCE....981
      EVERY 250 HOURS MAINTENANCE....982
      EVERY 500 HOURS MAINTENANCE....987
      EVERY 1000 HOURS MAINTENANCE....994
      EVERY 2000 HOURS MAINTENANCE....995
  SPECIFICATIONS....998
    SPECIFICATIONS....999
  ATTACHMENTS, OPTIONS....1002
    ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....1003
      SAFETY FIRST....1003
      ATTACHMENT INSTALLATION....1004
    BUCKET WITH HOOK....1005
      HOOK CONDITION....1005
      PROHIBITED OPERATIONS....1005
    ATTACHMENT GUIDE....1006
      ATTACHMENT COMBINATIONS....1006
    HANDLING ARM WITH BUILT-IN BREAKER....1007
      BUCKET POSTURE....1007
      REMOVING AND INSTALLING CHISEL....1007
      PROCEDURE FOR BREAKER OPERATIONS....1008
      PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS....1009
      STOWING CHISEL, DUMMY CHISEL....1010
      PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS....1010
      HANDLING DUMMY LINK....1011
      CHECK BEFORE STARTING....1012
      SPECIFICATIONS....1013
    HANDLING BUCKET COUPLER....1014
      PROCEDURE FOR REMOVING BUCKET....1014
      PROCEDURE FOR INSTALLING BUCKET....1016
    HANDLING FOLDING TOPS CANOPY....1018
    RECOMMENDED ATTACHMENT OPERATIONS....1020
      HYDRAULIC BREAKER....1020
  INDEX....1024

Komatsu Hydraulic Excavator PC09 Repair Service Manuals