Komatsu Hydraulic Excavator PC20MRX Repair Service Manuals
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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC20MRX, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC20MRX-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.
SEBM016602 - Hydraulic Excavator PC20MRX-1 Shop Manual.pdf
SEAM035202T - Hydraulic Excavator PC20MRx-1Operation & Maintenance Manual.pdf
SEAM035203 - Hydraulic Excavator PC20MRx-1 Operation & Maintenance Manual.pdf
Total Pages: 805 pages
File Format: PDF
Language: English
SEAM035202T - Hydraulic Excavator PC20MRx-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
SERVICE METER LOCATION...11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...11
CONTENTS...12
SAFETY...15
SAFETY INFORMATION...16
WARNING LABELS AND PICTOGRAMS...18
WARNING LABELS AND PICTOGRAMS-LOCATION...18
WARNING LABELS AND PICTOGRAMS-ACTUAL...19
SAFETY INFORMATION...22
SAFETY RULES...22
IF ABNORMALITIES ARE FOUND...22
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...22
FIRE EXTINGUISHER AND FIRST AID KIT...22
SAFETY EQUIPMENT...22
KEEP MACHINE CLEAN...23
KEEP OPERATOR'S COMPARTMENT CLEAN...23
LEAVING OPERATOR'S SEAT WITH LOCK...23
HANDRAILS AND STEPS...24
MOUNTING AND DISMOUNTING...24
NO PERSONS ON ATTACHMENTS...24
BURN PREVENTION...25
FIRE PREVENTION AND EXPLOSION PREVENTION...25
ACTION IF FIRE OCCURS...26
WINDSHIELD WASHER FLUID...26
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...26
ATTACHMENT INSTALLATION...27
ATTACHMENT COMBINATIONS...27
CAB WIDOW GLASSES...27
UNAUTHORIZED MODIFICATIONS...27
SAFETY AT JOBSITE...27
WORKING ON LOOSE GROUND...27
DISTANCE TO HIGH VOLTAGE CABLES...28
ENSURE GOOD VISIBILITY...28
VENTILATION FOR ENCLOSED AREA...29
SIGNALMAN'S SIGNAL AND SIGNS...29
EMERGENCY EXIT FROM OPERATOR'S CAB...29
ASBESTOS DUST HAZARD PREVENTION...29
SAFETY MACHINE OPERATION...30
BEFORE STARTING ENGINE...30
CHECKS BEFORE STARTING ENGINE...30
SAFETY RULES FOR STARTING ENGINE...30
STARTING ENGINE IN COLD WEATHER...31
AFTER STARTING ENGINE...32
CHECKS AFTER STARTING ENGINE...32
SAFETY RULES FOR CHANGING MAHCINE DIRECTIONS...32
SAFETY RULES FOR TRAVELING...33
TRAVELING ON SLOPES...34
OPERATIONS ON SLOPES...35
PROHIBITED OPERATIONS...35
OPERATIONS ON SNOW...36
PARKING MACHINE...37
TRANSPORTATION...38
LOADING AND UNLOADING...38
SHIPPING THE MACHINE...38
BATTERY...39
BATTERY HAZARD PREVENTION...39
STARTING ENGINE WITH BOOSTER CABLES...40
TOWING...41
SAFETY RULES FOR TOWING...41
LIFTING OBJECTS WITH BUCKET...42
SAFETY RULES FOR LIFTING OBJECTS...42
SAFETY MAINTENANCE INFORMATION...43
WARING TAG...43
KEEP WORK PLACE CLEAN AND TIDY...43
APPOINT LEADER WHEN WORKING WITH OTHERS...43
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...44
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...45
PROPER TOOLS...45
PERSONNEL...45
ATTACHMENTS...46
WORK UNDER THE MACHINE...46
NOISE...46
WHEN USING HAMMER...46
WELDING WORKS...46
REMOVING BATTERY TERMINALS...47
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...47
DO NOT DISASSEMBLE RECOIL SPRINGS...47
SAFETY RULES FOR HIGH-PRESSURE OIL...48
SAFETY HANDLING HIGH-PRESSURE HOSES...48
WASTE MATERIALS...48
AIR CONDITIONER MAINTENANCE...48
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
MONITORING SYSTEM...53
SWITCHES...59
CONTROL LEVERS AND PEDALS...62
ENGINE HOOD...67
WINDSHIELD...69
SLIDING DOOR...72
EMERGENCY ESCAPE HAMMER...73
FUSE...74
BLOCK FUSE...74
COVER WITH LOCK...75
OPREATION MANUAL STORAGE...75
TOOL BOX...75
GREASE GUN HOLDER...76
MACHINE OPERATIONS AND CONTROLS...77
BEFORE STARTING ENGINE...77
STARTING ENGINE...89
AFTER STARTING ENGINE...92
STOPPING THE ENGINE...95
CHECK AFTER SHUT OFF ENGINE...95
MACHINE OPERATION...96
STEERING THE MACHINE...100
SWINGING...102
WORK EQUIPMENT CONTROLS AND OPERATIONS...103
PROHIBITED OPERATIONS...105
GENERAL OPERATION INFORMATION...108
TRAVELING ON SLOPES...109
ESCAPE FROM MUD...111
RECOMMENDED APPLICATIONS...111
BUCKET REPLACEMENT ...114
PARKING MACHINE...115
MACHINE INSPECTION AFTER DAILY WORK...116
LOCKING...117
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)...118
TRANSPORTATION...122
TRANSPORTATION PROCEDURE...122
LOADING AND UNLOADING WITH TRAILER...122
LIFTING MACHINE...123
SHIPPING MACHINE INFORMATION...125
COLD WEATHER OPERATION...126
COLD WEATHER OPERATION INFORMATION...126
AFTER DAILY WORK COMPLETION...128
CAB HEATER IN COLD WEATHER...128
AFTER COLD WEATHER SEASON...128
LONG TERM STORAGE...129
BEFORE STORAGE...129
DURING STORAGE...129
AFTER STORAGE...129
STARTING MACHINE AFTER LONG-TERM STORAGE...130
TROUBLES AND ACTIONS...131
RUNNING OUT OF FUEL...131
PHENOMENA THAT ARE NOT FAILURES...131
TOWING THE MACHINE...132
SEVERE JOB CONDITION...132
DISCHARGED BATTERY...133
OTHER TROUBLE...137
MAINTENANCE...141
MAINTENANCE INFORMATION...142
LUBRICANTS, COOLANT AND FILTERS...144
OIL...144
ELECTRIC SYSTEM MAINTENANCE...145
WEAR PARTS...146
WEAR PARTS LIST...146
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS...147
PROPER SELECTION...147
TIGHTENING TORQUE SPECIFICATIONS...151
TIGHTENING TORQUE LIST...151
SAFETY CRITICAL PARTS...153
SAFETY CRITICAL PARTS LIST...153
MAINTENANCE SCHEDULE...154
MAINTENANCE SCHEDULE CHART...154
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...155
MAINTENANCE PROCEDURE...156
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...156
WHEN REQUIRED...157
AIR CLEANER ELEMENT-CHECK/CLEAN/REPLACE...157
COOLING SYSTEM COOLANT-CLEAN/CHANGE...159
BATTERY ELECTROLYTE LEVEL-CHECK...162
FUEL FILTER-CLEAN...163
TRACK TENSION (STEEL SHOES)-CHECK/ADJUST...164
RUBBER SHOES-CHECK...166
TRACK TENSION (RUBBER SHOES)-CHECK/ADJUST...168
RUBBER SHOES REPLACEMENT...170
BUCKET TEETH-CHECK/REPLACE...173
CAB SLIDE DOOR RAIL AND ROLLER-CHECK/CLEAN/LUBRICATE...175
FUEL TANK-DRAIN...176
CHECK BEFORE STARTING...177
EVERY 100 HOURS MAINTENANCE...178
LUBRICATING...178
EVERY 250 HOURS MAINTENANCE...179
ENGINE CRANKCASE OIL AND FILTER CARTRIDGE-CHANGE/REPLACE...179
FINAL DRIVE CASE OIL LEVEL-CHECK/ADD...180
HYDRAULIC OIL FILTER ELEMENT-REPLACE...180
COOLING FAN BELT TENSION-INSPECT/ADJUST...182
EVERY 500 HOURS MAINTENANCE...183
LUBRICATING...183
FUEL FILTER ELEMENT-REPLACE...184
RADIATOR CORE AND FINS-CHECK/CLEAN...186
FUEL FEED PUMP PRE-FILTER-REPLACE...186
EVERY 1000 HOURS MAINTENANCE...187
FINAL DRIVE CASE OIL-CHANGE...187
EVERY 2000 HOURS MAINTENANCE...188
HYDRAULIC OIL AND STRAINER-CHANGE/CLEAN...188
ALTERNATOR AND STARTING MOTOR-INSPECT...190
ENGINE VALVE CLEARANCES-INSPECT...190
SPECIFICATIONS...191
SPECIFICATIONS...192
ATTACHMENTS AND OPTIONS...194
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION...195
SAFETY FIRST...195
ATTACHMENT INSTALLATION...196
BUCKET WITH HOOK...197
HOOK CONDITION...197
PROHIBITED OPERATIONS...197
RADIO...198
CONTROL PANEL...198
CONTROLS OF RADIO...201
CARE FOR RADIO...202
WINDSHIELD WASHER...203
WINDSHIELD WASHER OPERATION...203
WINDSHIELD WASHER FLUID LEVEL-CHECK/ADD...203
ATTACHMENT GUIDE...204
ATTACHMENT COMBINATIONS...204
HYDRAULIC BREAKER...205
INDEX...208
SEAM035203 - Hydraulic Excavator PC20MRx-1 Operation & Maintenance Manual...211
COVER...211
FOREWORD...212
FOREWORD...213
SAFETY INFORMATION...216
INTRODUCTION...218
DIRECTIONS OF MACHINE...218
PRODUCT INFORMATION...219
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...219
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...219
SERVICE METER LOCATION...220
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...220
CONTENTS...221
SAFETY...224
SAFETY INFORMATION...225
WARNING LABELS AND PICTOGRAMS...227
WARNING LABELS AND PICTOGRAMS - LOCATION...227
WARNING LABELS AND PICTOGRAMS - ACTUAL...228
SAFETY INFORMATION...231
Asbestos Dust Hazard Prevention...238
Emergency Exit from Operator's Cab...238
Signalman's Signal and Signs...238
Ventilation for Enclosed Area...238
Ensure Good Visibility...237
Distance to High Voltage Cables...237
Safety at Jobsite...236
Unauthorized Modifications...236
Cab Widow Glasses...236
Attachment Combinations...236
Attachment Installation...236
Falling Objects, Flying Objects and Intruding Objects Prevention...235
Windshield Washer Fluid...235
Action If Fire Occurs...235
Fire Prevention and Explosion Prevention...234
Burn Prevention...234
No Persons on Attachments...233
Mounting and Dismounting...233
Handrails and Steps...233
Leaving Operator's Seat with Lock...232
Keep Operator's Compartment Clean...232
Keep Machine Clean...232
Safety Equipment...231
Fire Extinguisher and First Aid Kit...231
Working Wear and PersonaŁŁ Protective Items...231
If Abnormalities are Found...231
Safety Rules...231
SAFETY MACHINE OPERATION...239
BEFORE STARTING ENGINE...239
Checks Before Starting Engine...239
Safety Rules for Starting Engine...239
Starting Engine in Cold Weather...240
AFTER STARTING ENGINE...241
Checks After Starting Engine...241
Safety Rules for Changing Machine Directions...241
Safety Rules for Traveling...242
Traveling on Slopes...243
Operations on Slopes...244
Prohibited Operations...244
Operations on Snow...245
Parking Machine...246
TRANSPORTATION...247
Loading and Unloading...247
Shipping the Machine...247
BATTERY...248
Battery Hazard Prevention...248
Starting Engine with Booster Cables...249
TOWING...250
Safety Rules for Towing...250
LIFTING OBJECTS WITH BUCKET...251
Safety Rules for Lifting Objects...251
SAFETY MAINTENANCE INFORMATION...252
Warning Tag...252
Keep Work Place Clean and Tidy...252
Appoint Leader when Working with Others...252
Stop Engine Before Carrying Out Maintenance...253
Two Workers for Maintenance when Engine is Running...254
Proper Tools...254
Personnel...254
Attachments...255
Work Under the Machine...255
Noise...255
When Using Hammer...255
Welding Works...255
Removing Battery Terminals...256
Safety First when Using High-pressure Grease to Adjust Track Tension...256
Do Not Disassemble Recoil Springs...256
Safety Rules for High-pressure Oil...257
Safety Handling High-pressure Hoses...257
Waste Materials...257
Air Conditioner Maintenance...257
Compressed Air...258
Periodic Replacement of Safety Critical Parts...258
OPERATION...260
MACHINE VIEW ILLUSTRATIONS...261
OVERALL MACHINE VIEW...261
CONTROLS AND GAUGES...262
DETAILED CONTROLS AND GAUGES...263
MONITORING SYSTEM...263
SWITCHES...269
CONTROL LEVERS AND PEDALS...272
ENGINE HOOD...277
WINDSHIELD...279
SLIDING DOOR...282
EMERGENCY ESCAPE HAMMER...283
FUSE...284
BLOCK FUSE...284
COVER WITH LOCK...285
OPERATION MANUAL STORAGE...285
TOOL BOX...285
GREASE GUN HOLDER...286
MACHINE OPERATIONS AND CONTROLS...287
BEFORE STARTING ENGINE...287
STARTING ENGINE...299
AFTER STARTING ENGINE...302
STOPPING THE ENGINE...305
CHECK AFTER SHUT OFF ENGINE...305
MACHINE OPERATION...306
STEERING THE MACHINE...310
SWINGING...312
WORK EQUIPMENT CONTROLS AND OPERATIONS...313
PROHIBITED OPERATIONS...315
GENERAL OPERATION INFORMATION...318
TRAVELING ON SLOPES...319
ESCAPE FROM MUD...321
RECOMMENDED APPLICATIONS...321
BUCKET REPLACEMENT...324
PARKING MACHINE...325
MACHINE INSPECTION AFTER DAILY WORK...326
LOCKING...327
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)...328
TRANSPORTATION...332
TRANSPORTATION PROCEDURE...332
LOADING AND UNLOADING WITH TRAILER...332
LIFTING MACHINE...333
SHIPPING MACHINE INFORMATION...335
COLD WEATHER OPERATION...336
COLD WEATHER OPERATION INFORMATION...336
AFTER DAILY WORK COMPLETION...338
CAB HEATER IN COLD WEATHER...338
AFTER COLD WEATHER SEASON...338
LONG TERM STORAGE...339
BEFORE STORAGE...339
DURING STORAGE...339
AFTER STORAGE...339
STARTING MACHINE AFTER LONG-TERM STORAGE...340
TROUBLES AND ACTIONS...341
RUNNING OUT OF FUEL...341
PHENOMENA THAT ARE NOT FAILURES...341
TOWING THE MACHINE...342
SEVERE JOB CONDITION...342
DISCHARGED BATTERY...343
OTHER TROUBLE...347
MAINTENANCE...352
MAINTENANCE INFORMATION...353
LUBRICANTS, COOLANT AND FILTERS...355
OIL...355
ELECTRIC SYSTEM MAINTENANCE...356
WEAR PARTS...357
WEAR PARTS LIST...357
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS...358
PROPER SELECTION...358
TIGHTENING TORQUE SPECIFICATIONS...362
TIGHTENING TORQUE LIST...362
SAFETY CRITICAL PARTS...364
SAFETY CRITICAL PARTS LIST...364
MAINTENANCE SCHEDULE...365
MAINTENANCE SCHEDULE CHART...365
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...366
MAINTENANCE PROCEDURE...367
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...367
FUEL FILTER ELEMENT - REPLACE...395
ENGINE VALVE CLEARANCES - INSPECT...401
WHEN REQUIRED...368
AIR CLEANER ELEMENT - CHECK/CLEAN/REPLACE...368
COOLING SYSTEM COOLANT - CLEAN/ CHANGE...370
BATTERY ELECTROLYTE LEVEL - CHECK...373
FUEL FILTER - CLEAN...374
TRACK TENSION (STEEL SHOES)- CHECK/ADJUST...375
RUBBER SHOES - CHECK...377
TRACK TENSION (RUBBER SHOES)- CHECK/ADJUST...379
RUBBER SHOES REPLACEMENT...381
BUCKET TEETH - CHECK/REPLACE...384
CAB SLIDE DOOR RAIL AND ROLLER - CHECK/CLEAN/LUBRICATE...386
FUEL TANK - DRAIN...387
CHECK BEFORE STARTING...388
COOLING SYSTEM COOLANT - CLEAN/CHANGE...289
ENGINE CRANKCASE OIL LEVEL - CHECK/ADD...290
FUEL LEVEL - CHECK/REFILL...291
HYDRAULIC OIL LEVEL - CHECK/ADD...292
AIR CLEANER DUST INDICATOR - CHECK...293
FUEL FILTER - CHECK/CLEAN...293
ELECTRIC WIRING - INSPECT...294
HORN FUNCTION - CHECK...294
EVERY 100 HOURS MAINTENANCE...389
LUBRICATING...389
EVERY 250 HOURS MAINTENANCE...390
ENGINE CRANKCASE OIL AND FILTER CARTRIDGE - CHANGE/REPLACE...390
FINAL DRIVE CASE OIL LEVEL - CHECK/ADD...391
HYDRAULIC OIL FILTER ELEMENT - REPLACE...391
COOLING FAN BELT TENSION - INSPECT/ADJUST...393
EVERY 500 HOURS MAINTENANCE...394
LUBRICATING...394
FUEL FILTER ELEMENT - REPLACE...395
RADIATOR CORE AND FINS - CHECK/CLEAN...397
FUEL FEED PUMP PRE-FILTER - REPLACE...397
EVERY 1000 HOURS MAINTENANCE...398
FINAL DRIVE CASE OIL - CHANGE...398
EVERY 2000 HOURS MAINTENANCE...399
HYDRAULIC OIL AND STRAINER - CHANGE/CLEAN...399
ALTERNATOR AND STARTING MOTOR - INSPECT...401
ENGINE VALVE CLEARANCES - INSPECT...401
SPECIFICATIONS...402
SPECIFICATIONS...403
ATTACHMENT AND OPTIONS...406
ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION...407
SAFETY FIRST...407
ATTACHMENT INSTALLATION...408
BUCKET WITH HOOK...409
HOOK CONDITION...409
PROHIBITED OPERATIONS...409
RADIO...410
CONTROL PANEL...410
CONTROLS OF RADIO...413
CARE FOR RADIO...414
WINDSHIELD WASHER...415
WINDSHIELD WASHER OPERATION...415
WINDSHIELD WASHER FLUID LEVEL - CHECK/ADD...415
ATTACHMENT GUIDE...416
ATTACHMENT COMBINATIONS...416
HYDRAULIC BREAKER...417
INDEX...420
SEBM016602 - Hydraulic Excavator PC20MRX-1 Shop Manual...424
COVER PAGE...424
CONTENTS...425
00 FOREWARD...425
SAFETY...428
FOREWARD...430
HOW TO READ THE SHOP MANUAL...425
HOISTING INSTRUCTIONS...432
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...433
COATING MATERIALS...435
STANDARD TIGHTENING TORQUE...437
ELECTRIC WIRE CODE...440
CONVERSION TABLE...441
01 GENERAL...447
GENERAL ASSEMBLY DRAWING...448
SPECIFICATIONS...450
WEIGHT TABLE...454
LIST OF LUBRICANT AND WATER...456
10 STRUCTURE AND FUNCTION...457
RADIATOR, OIL COOLER...458
ENGINE CONTROL...459
PTO...460
POWER TRAIN DIAGRAM...461
SWING CIRCLE...462
SWING MACHINERY...463
TRACK FRAME...464
RECOIL SPRING...465
TRACK SHOE...466
HYDRAULIC PIPING DRAWING...467
HYDRAULIC TANK...469
HYDRAULIC PUMP...470
CONTROL VALVE...490
CLSS...498
CENTER SWIVEL JOINT...527
SWING MOTOR...528
TRAVEL MOTOR...529
VALVE CONTROL...533
PPC VALVE...534
SOLENOID VALVE...541
WORK EQUIPMENT...543
ELECTRICAL WIRING DIAGRAM...544
MACHINE MONITOR SYSTEM...546
20 TESTING AND ADJUSTING...551
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...552
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...553
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...561
TESTING AND ADJUSTING...563
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...564
MEASURING ENGINE SPEED...565
MEASURING EXHAUST COLOR...566
ADJUSTING VALVE CLEARANCE...567
MEASURING COMPRESSION PRESSURE...568
TESTING AND ADJUSTING FUEL INJECTION TIMING...569
MEASURING ENGINE OIL PRESSURE...570
TESTING AND ADJUSTING FAN BELT TENSION...571
ADJUSTING FUEL CONTROL LEVER...572
TESTING AND ADJUSTING TRACK SHOE TENSION...573
MEASURING SPROCKET WEAR...574
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...575
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE...577
ADJUSTING TCC VALVE...578
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE...579
MEASURING SWING HOLDING BRAKE INLET PORT PRESSURE...580
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...580
TESTING AND ADJUSTING TRAVEL DEVIATION...581
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER...582
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...584
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK...584
PRESSURIZING HYDRAULIC TANK...584
BLEEDING AIR...585
TROUBLESHOOTING...587
POINTS TO REMEMBER WHEN TROUBLESHOOTING...588
SEQUENCE OF EVENTS IN TROUBLESHOOTING...589
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...590
CHECKS BEFORE TROUBLESHOOTING...598
CONNECTOR TYPES AND MOUNTING LOCATIONS...599
CONNECTOR PIN ALLOCATION DRAWING...600
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...602
METHOD OF USING TROUBLESHOOTING CHARTS...609
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...611
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...612
E-1 ENGINE DOES NOT START...614
A) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)...614
B) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)...616
E-2 ENGINE DOES NOT STOP...618
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK IS CANCELED...619
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED...620
E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED...621
E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED...622
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...623
TABLE OF FAILURE MODES AND CAUSES...624
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...626
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...627
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...628
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...628
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...629
H-6 BOOM IS SLOW OR LACKS POWER...630
H-7 ARM IS SLOW OR LACKS POWER...630
H-8 BUCKET IS SLOW OR LACKS POWER...631
H-9 BOOM SWING IS SLOW OR LACKS POWER...631
H-10 BLADE IS SLOW OR LACKS POWER...632
H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL)...632
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE)...633
A) BOOM...633
B) ARM, BUCKET, BOOM SWING...633
C) BLADE...633
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...634
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...634
H-15 TRAVEL DEVIATION...635
A) DEVIATION IN NORMAL TRAVEL...635
B) DEVIATION WHEN STARTING...635
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER...636
H-17 STEERING DOES NOT TURN EASILY...636
H-18 TRAVEL SPEED DOES NOT SWITCH...637
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...637
H-20 SWING SPEED IS SLOW OR LACKS POWER...638
A) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS...638
B) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY (LEFT OR RIGHT)...638
H-21 DOES NOT SWING...639
A) DOES NOT SWING IN EITHER DIRECTION...639
B) DOES NOT SWING IN ONE DIRECTION (LEFT OR RIGHT)...639
H-22 SWING ACCELERATION IS POOR...640
A) ACCELERATION IS POOR IN BOTH DIRECTIONS...640
B) ACCELERATION IS POOR IN ONE DIRECTION ONLY (LEFT OR RIGHT)...640
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...641
A) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS...641
B) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY (LEFT OR RIGHT)...641
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY)...642
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...642
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING...642
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...643
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS...644
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN...645
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECONDS), LAMPS DO NOT GO...645
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS...646
A) NO GAUGE LAMPS LIGHT UP (FUEL, COOLANT TEMPERATURE)...646
B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE), PILOT LAMP (PREHEATING) DO NOT LIGHT UP...646
M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS), EVEN IF STARTING SWITCH IS TURNED TO START, SELF CHECK IS NOT COMP...646
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...647
M-6 WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE), CHARGE CAUTION LAMP DOES NOT LIGHT UP...648
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT...649
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP...649
M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP...650
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE...652
A) LEVEL DOES NOT RISE FROM SEGMENT C...652
B) LEVEL DOES NOT GO DOWN FROM SEGMENT H, OR ALL SEGMENTS GO OUT...652
C) COOLANT TEMPERATURE DOES NOT MATCH GUAGE DISPLAY...653
M-11 ABNORMALITY IN FUEL GAUGE...654
A) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT...654
B) LEVEL DOES NOT GO DOWN FROM SEGMENT F...654
C) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY...655
M-12 DEFECTIVE OPERATION OF ALARM BUZZER...656
A) BUZZER DOES NOT SOUND...656
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP...656
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE...657
A) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP...657
B) WHEN CHARGE CAUTION LAMP LIGHTS UP...657
C) PILOT LAMP DOES NOT FLASH (SERVICE METER IS ACTUATED)...657
M-14 NIGHT LIGHTING DOES NOT LIGHT UP...658
A) GAUGE LIGHTING DOES NOT LIGHT UP...658
B) SERVICE METER LIGHTING DOES NOT LIGHT UP...658
30 DISASSEMBLY AND ASSEMBLY...659
METHOD OF USING MANUAL...661
PRECAUTION WHEN CARRYING OUT OPERATION...662
SPECIAL TOOL LIST...664
STARTING MOTOR...665
REMOVAL AND INSTALLATION...665
ALTERNATOR...666
REMOVAL AND INSTALLATION...666
FUEL INJECTION PUMP...667
REMOVAL...667
INSTALLATION...668
NOZZLE HOLDER...669
REMOVAL AND INSTALLATION...669
WATER PUMP...670
REMOVAL AND INSTALLATION...670
THERMOSTAT...671
REMOVAL AND INSTALLATION...671
ENGINE FRONT SEAL...672
REMOVAL AND INSTALLATION...672
ENGINE REAR SEAL...673
REMOVAL...673
INSTALLATION...674
CYLINDER HEAD...675
REMOVAL...675
INSTALLATION...676
RADIATOR...677
REMOVAL AND INSTALLATION...677
ENGINE AND HYDRAULIC PUMP ...678
REMOVAL...678
INSTALLATION...681
FUEL TANK...682
REMOVAL AND INSTALLATION...682
DAMPER...683
REMOVAL AND INSTALLATION...683
CENTER SWIVEL JOINT...684
REMOVAL AND INSTALLATION...684
DISASSEMBLY AND ASSEMBLY...685
TRAVEL MOTOR...686
REMOVAL AND INSTALLATION...686
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR PHV190...687
SPROCKET...698
REMOVAL AND INSTALLATION...698
SWING MOTOR AND SWING MACHINERY...699
REMOVAL AND INSTALLATION...699
REVOLVING FRAME...700
REMOVAL...700
INSTALLATION...701
SWING CIRCLE...702
REMOVAL AND INSTALLATION...702
IDLER ...703
REMOVAL AND INSTALLATION...703
DISASSEMBLY...704
ASSEMBLY...705
RECOIL SPRING...707
REMOVAL AND INSTALLATION...707
DISASSEMBLY AND ASSEMBLY...708
TRACK ROLLER...709
REMOVAL AND INSTALLATION...709
DISASSEMBLY ...710
ASSEMBLY...711
RUBBER SHOE...712
REMOVAL AND INSTALLATION...712
HYDRAULIC TANK...713
REMOVAL AND INSTALLATION...713
HYDRAULIC OIL COOLER...714
REMOVAL AND INSTALLATION...714
HYDRAULIC PUMP...715
REMOVAL AND INSTALLATION...715
CONTROL VALVE...716
REMOVAL...716
INSTALLATION...718
DISASSEMBLY...719
ASSEMBLY...724
MAIN RELIEF VALVE...729
REMOVAL AND INSTALLATION...729
RIGHT/LEFT PPC VALVE...730
REMOVAL...730
INSTALLATION...731
PPC VALVE...732
DISASSEMBLY...732
ASSEMBLY...733
BOOM CYLINDER...734
REMOVAL...734
INSTALLATION...735
ARM CYLINDER...736
REMOVAL...736
INSTALLATION...737
BUCKET CYLINDER...738
REMOVAL...738
INSTALLATION...739
SWING CYLINDER...740
REMOVAL...740
INSTALLATION...741
BLADE CYLINDER...742
REMOVAL AND INSTALLATION...742
HYDRAULIC CYLINDER...743
DISASSEMBLY...743
ASSEMBLY...746
WORK EQUIPMENT...749
REMOVAL...749
INSTALLATION...750
BUCKET...751
REMOVAL AND INSTALLATION...751
QUICK BUCKET...752
REMOVAL AND INSTALLATION...752
ARM...753
REMOVAL...753
INSTALLATION...754
BUCKET AND ARM...755
REMOVAL...755
INSTALLATION...756
BOOM...757
REMOVAL...757
INSTALLATION...758
SWING BRACKET...759
REMOVAL...759
INSTALLATION...760
BLADE...761
REMOVAL AND INSTALLATION...761
SOLENOID VALVE...762
REMOVAL AND INSTALLATION...762
COUNTERWEIGHT...763
REMOVAL AND INSTALLATION...763
SEAT AND BRACKET...764
REMOVAL AND INSTALLATION...764
MONITOR...765
REMOVAL AND INSTALLATION...765
40 MAINTENANCE STANDARD...766
SWING CIRCLE...767
TRACK FRAME, RECOIL SPRING...768
IDLER...769
TRACK ROLLER...770
TRACK SHOE...771
HYDRAULIC PUMP...774
CONTROL PUMP...775
CONTROL VALVE...776
CENTER SWIVEL JOINT...782
TRAVEL MOTOR...783
PPC VALVE...784
HYDRAULIC CYLINDER...786
WORK EQUIPMENT...788
DIMENSION OF WORK EQUIPMENT...790
90 OTHERS...794
HYDRAULIC CIRCUIT DIAGRAM...795
ELECTRICAL CIRCUIT DIAGRAM...800
Komatsu Hydraulic Excavator PC20MRX Repair Service Manuals
