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Posted on June 8, 2025 by admin

Komatsu Hydraulic Excavator PC20MRX Repair Service Manuals

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

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Hydraulic Excavator PC20MR Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC20MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC20MR-2 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.

SEBM037001 – Hydraulic Excavator PC20MR-2 Shop Manual.pdf
TEN00101-02 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual.pdf
WEAM007000 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual.pdf

Total Pages: 886 pages
File Format: PDF
Language: English

SEBM037001 – Hydraulic Excavator PC20MR-2 Shop Manual…2
COVER…2
CONTENTS…3
SAFETY…7
    SAFETY NOTICE…7
FOREWORD…9
    GENERAL…9
    HOISTING INSTRUCTIONS…11
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…12
    COATING MATERIALS…14
    STANDARD TIGHTENING TORQUE…16
    ELECTRIC WIRE CODE…19
    CONVERSION TABLE…20
    UNITS…26
01 GENERAL…27
    SPECIFICATION DIMENSION DRAWING…28
    WORKING RANGE DRAWING…29
    SPECIFICATIONS…30
    WEIGHT TABLE…33
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…35
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…37
    PTO…38
    COOLING SYSTEM…40
    POWER TRAIN…42
    SWING CIRCLE…43
    TRACK FRAME…44
    IDLER CUSHION…45
    IDLER…46
    TRACK ROLLER…48
    CARRIER ROLLER…49
    SPROCKET…50
    TRACK SHOE…51
    HYDRAULIC COMPONENTS LAYOUT DRAWING…52
    HYDRAULIC TANK…53
    CENTER SWIVEL JOINT…54
    TRAVEL MOTOR…55
    HYDRAULIC CYLINDER…64
    SOLENOID VALVE…67
    MULTI-CONTROL VALVE (IF EQUIPPED)…70
    HYDRAULIC PUMP…72
    CONTROL VALVE…78
    CLSS…91
    OPERATION FOR EACH FUNCTION AND VALVE…94
    SWING MOTOR…114
    PPC VALVE…124
    WORK EQUIPMENT…133
    DIMENSIONS OF EACH PART OF WORK EQUIPMENT…136
    FLOOR…139
    ENGINE CONTROL…140
    ELECTRIC CONTROL SYSTEM…142
    COMPONENT PART OF SYSTEM…147
    MONITOR SYSTEM…148
    MONITOR PANEL…149
    SENSORS…151
20 TESTING AND ADJUSTING…153
    STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…154
    STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…155
    TESTING AND ADJUSTING…165
      LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS…166
      MEASURING ENGINE SPEED…168
      MEASUREMENT OF EXHAUST GAS COLOR…169
      ADJUSTING VALVE CLEARANCE…170
      MEASURING COMPRESSION PRESSURE…171
      MEASURING ENGINE OIL PRESSURE…172
      TESTING AND ADJUSTING FUEL INJECTION TIMING…173
      BLEEDING AIR FROM FUEL CIRCUIT…175
      TESTING AND ADJUSTING FAN BELT TENSION…176
      ADJUSTING FUEL CONTROL LEVER LINKAGE…177
      MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…178
      TESTING AND ADJUSTING TRACK SHOE TENSION…179
      TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, SWING, AND BLADE CIRCUITS…181
      MEASURING CONTROL CIRCUIT BASIC PRESSURE…184
      TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE…185
      MEASURING SOLENOID VALVE OUTPUT PRESSURE…187
      MEASURING PPC VALVE OUTPUT PRESSURE…189
      ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…191
      MEASURING SWING HOLDING BRAKE RELEASE PRESSURE…191
      MEASURING OF OIL LEAKAGE FROM CYLINDER…193
      RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…195
      BLEEDING AIR FROM CYLINDER…195
      PRESSURIZING HYDRAULIC TANK…196
      HOW TO OPEN AND CLOSE (TILT) FLOOR…197
      INSPECTION PROCEDURES FOR DIODE…199
    TROUBLESHOOTING…201
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…202
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…203
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…204
      CHECKS BEFORE TROUBLESHOOTING…212
      CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…213
      CONNECTORS LIST AND STEREOGRAM…216
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…224
      T-ADAPTER-BOXES AND T-ADAPTER TABLE…247
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (EXCEPT MONITOR PANEL E-MODE)…251
        BEFORE STARTING E-MODE TROUBLESHOOTING…252
        INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…254
        E-1 ENGINE DOES NOT START…255
        E-2 ENGINE DOES NOT STOP…261
        E-3 WHEN SAFETY LOCK LEVER IS IN FREE POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE SYSTEMS DO NOT WORK…263
        E-4 WHEN SAFETY LOCK LEVER IS IN LOCK POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING AND BLADE SYSTEMS WORK…266
        E-5 WHEN MACHINE STARTS TRAVELING, TRAVEL ALARM DOES NOT SOUND…268
        E-6 WHEN MACHINE STOPS TRAVELING, TRAVEL ALARM DOES NOT STOP SOUNDING…270
        E-7 WINDSHIELD WIPER DOES NOT OPERATE [CAB SPECIFICATION]…272
        E-8 WINDSHIELD WASHER DOES NOT OPERATE [CAB SPECIFICATION]…274
        E-9 HEATER DOES NOT OPERATE…276
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…279
        INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…280
        H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW…281
        H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS…284
        H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK …285
        H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP…288
        H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW…288
        H-6 SPEED OR POWER OF BOOM IS LOW…289
        H-7 SPEED OR POWER OF ARM IS LOW…290
        H-8 SPEED OR POWER OF BUCKET IS LOW…291
        H-9 SPEED OR POWER OF BOOM SWING IS LOW…292
        H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY…292
        H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE…293
        H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…294
        H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW…294
        H-14 MACHINE DEVIATES DURING TRAVEL…295
        H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW…297
        H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…297
        H-17 TRAVEL SPEED DOES NOT CHANGE…298
        H-18 TRAVEL MOTOR DOES NOT WORK (ONE SIDE ONLY)…298
        H-19 SPEED OR POWER OF SWING IS LOW…299
        H-20 MACHINE DOES NOT SWING…301
        H-21 SWING ACCELERATION PERFORMANCE IS LOW…303
        H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING…304
        H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING…305
        H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND…305
        H-25 HYDRAULIC DRIFT OF SWING IS LARGE…306
        H-26 SPEED OR POWER OF BLADE IS LOW…307
        H-27 BLADE DOES NOT MOVE…308
        H-28 HYDRAULIC DRIFT OF BLADE IS LARGE…308
      TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)…309
        BEFORE STARTING M-MODE TROUBLESHOOTING…310
        INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…312
        M-1 WHEN STARTING SWITCH IS TURNED ON, NO MONITOR/GAUGE OPERATES…314
        M-2 WHEN STARTING SWITCH IS TURNED ON, SOME MONITORS/GAUGES DO NO OPERATE…316
        M-3 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING…318
        M-4 WHILE ENGINE IS RUNNING, ENGINE OIL PRESSURE MONITOR FLASHES…320
        M-5 WHILE ENGINE IS RUNNING, CHARGE LEVEL MONITOR FLASHES…322
        M-6 PREHEATING SYSTEM DOES NOT OPERATE…324
        M-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…327
        M-8 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…330
        M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING…332
        M-10 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY…333
        M-11 MONITOR PANEL NIGHT LAMP AND WORKING LAMP DO NOT LIGHT UP…336
      TROUBLESHOOTING OF ENGINE (S MODE)…341
        TROUBLESHOOTING OF ENGINE (S-MODE)…342
30 DISASSEMBLY AND ASSEMBLY…349
    HOW TO READ THIS MANUAL…350
    PRECAUTIONS WHEN PERFORMING OPERATION…352
    SPECIAL TOOL LIST…354
    REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…356
    REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY…358
    REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…363
    REMOVAL AND INSTALLATION TRACK SHOE ASSEMBLY…365
    DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…366
    DISASSEMBLY AND ASSEMBLYOF RECOIL SPRING ASSEMBLY…368
    DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…371
    REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…372
    DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…374
    REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…376
    REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…381
    REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…382
    REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…384
    REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…386
    DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…387
    DISASSEMBLY AND ASSEMBLY OF HDYRAULIC CYLINDER ASSEMBLY…391
    REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY…395
    REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…396
90 OTHERS…405
    HYDRAULIC CIRCUIT DIAGRAM…407
    ELECTRICAL CIRCUIT DIAGRAM (1/2)…408
    ELECTRICAL CIRCUIT DIAGRAM (2/2)…409
TEN00101-02 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual…410
COVER…410
FOREWORD…411
    FOREWORD…412
    SAFETY INFORMATION…415
    INTRODUCTION…417
      DIRECTIONS OF MACHINE…417
    PRODUCT INFORMATION…418
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…418
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…418
      EPA NAMEPLATE…419
      SERVICE METER LOCATION…419
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…420
CONTENTS…421
SAFETY…424
    SAFETY INFORMATION…425
    SAFETY LABELS…427
      LOCATION OF SAFETY LABELS…427
      SAFETY LABELS…428
    SAFETY INFORMATION…433
      SAFETY RULES…433
      IF PROBLEMS ARE FOUND…433
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…433
      FIRE EXTINGUISHER AND FIRST AID KIT…433
      SAFETY EQUIPMENT…434
      KEEP MACHINE CLEAN…434
      KEEP OPERATOR'S COMPARTMENT CLEAN…434
      LEAVING OPERATOR'S SEAT WITH LOCK…434
      HANDRAILS AND STEPS…435
      MOUNTING AND DISMOUNTING…435
      NO PERSONS ON ATTACHMENTS…435
      BURN PREVENTION…436
      FIRE PREVENTION AND EXPLOSION PREVENTION…436
      ACTION IF FIRE OCCURS…437
      WINDSHIELD WASHER FLUID…437
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…438
      CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…438
      ATTACHMENT INSTALLATION…439
      ATTACHMENT COMBINATIONS…439
      CAB WINDOW GLASSES…439
      UNAUTHORIZED MODIFICATIONS…439
      SAFETY AT JOBSITE…439
      WORKING ON LOOSE GROUND…439
      DISTANCE TO HIGH VOLTAGE CABLES…440
      ENSURE GOOD VISIBILITY…440
      VENTILATION FOR ENCLOSED AREA…440
      SIGNALMAN'S SIGNAL AND SIGNS…440
      EMERGENCY EXIT FROM OPERATOR'S CAB…441
      ASBESTOS DUST HAZARD PREVENTION…441
    SAFETY MACHINE OPERATION…442
      STARTING ENGINE…442
        CHECKS BEFORE STARTING ENGINE…442
        SAFETY RULES FOR STARTING ENGINE…443
        STARTING ENGINE IN COLD WEATHER…443
      OPERATION…444
        CHECKS BEFORE OPERATION…444
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…444
        SAFETY RULES FOR TRAVELING…445
        TRAVELING ON SLOPES…446
        OPERATIONS ON SLOPES…447
        PROHIBITED OPERATIONS…447
        OPERATIONS ON SNOW…449
        PARKING MACHINE…449
      TRANSPORTATION…450
        LOADING AND UNLOADING…450
        SHIPPING THE MACHINE…450
      BATTERY…451
        BATTERY HAZARD PREVENTION…451
        STARTING ENGINE WITH BOOSTER CABLES…452
      TOWING…453
        SAFETY RULES FOR TOWING…453
      LIFTING OBJECTS WITH BUCKET…454
        SAFETY RULES FOR LIFTING OBJECTS…454
    SAFETY MAINTENANCE INFORMATION…455
      WARNING TAG…455
      KEEP WORK PLACE CLEAN AND TIDY…455
      APPOINT LEADER WHEN WORKING WITH OTHERS…455
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…456
      CAUTIONS FOR OPENING (TILTING) FLOOR…457
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…458
      PROPER TOOLS…458
      PERSONNEL…458
      ATTACHMENTS…459
      WORK UNDER THE MACHINE…459
      NOISE…459
      WHEN USING HAMMER…459
      WELDING WORKS…459
      REMOVING BATTERY TERMINALS…460
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…460
      DO NOT DISASSEMBLE RECOIL SPRINGS…460
      SAFETY RULES FOR HIGH-PRESSURE OIL…460
      SAFETY HANDLING HIGH-PRESSURE HOSES…461
      WASTE MATERIALS…461
      COMPRESSED AIR…461
      PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…461
OPERATION…462
    MACHINE VIEW ILLUSTRATIONS…463
      OVERALL MACHINE VIEW…463
      CONTROLS AND GAUGES…464
    DETAILED CONTROLS AND GAUGES…465
      MONITORING SYSTEM…465
      SWITCHES…473
      CONTROL LEVERS AND PEDALS…477
      WINDSHIELD…483
      SLIDING DOOR…487
      SLIDING WINDOW…487
      EMERGENCY ESCAPE HAMMER…488
      CAP WITH LOCK…489
      ENGINE REAR COVER…490
      COOLING COVER…490
      FRONT RIGHT COVER…491
      METHOD OF OPENING (TILTING) FLOOR…492
      FUSE…497
      BLOCK FUSE…498
      OPERATION MANUAL STORAGE…498
      TOOL BOX…498
      GREASE GUN HOLDER…499
      ASHTRAY…499
    MACHINE OPERATIONS AND CONTROLS…500
      BEFORE STARTING ENGINE…500
      STARTING ENGINE…515
      AFTER STARTING ENGINE…519
      STOPPING THE ENGINE…522
      MACHINE OPERATION…523
      STEERING THE MACHINE…528
      SWINGING…530
      WORK EQUIPMENT CONTROLS AND OPERATIONS…531
      PROHIBITED OPERATIONS…533
      GENERAL OPERATION INFORMATION…535
      TRAVELING ON SLOPES…537
      ESCAPE FROM MUD…539
      WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…540
      BUCKET REPLACEMENT…542
      PARKING MACHINE…543
      MACHINE INSPECTION AFTER DAILY WORK…544
      LOCKING…545
      RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…546
    TRANSPORTATION…551
      TRANSPORTATION PROCEDURE…551
      LOADING AND UNLOADING WITH TRAILER…552
      LIFTING MACHINE…558
    COLD WEATHER OPERATION…561
      COLD WEATHER OPERATION INFORMATION…561
      CAB HEATER IN COLD WEATHER…562
      AFTER DAILY WORK COMPLETION…563
      AFTER COLD WEATHER SEASON…563
    LONG TERM STORAGE…564
      BEFORE STORAGE…564
      DURING STORAGE…564
      AFTER STORAGE…564
    TROUBLES AND ACTIONS…565
      RUNNING OUT OF FUEL…565
      PHENOMENA THAT ARE NOT FAILURES…565
      TOWING THE MACHINE…566
      SEVERE JOB CONDITION…566
      DISCHARGED BATTERY…567
      OTHER TROUBLE…571
MAINTENANCE…574
    MAINTENANCE INFORMATION…575
    OUTLINE OF SERVICE…577
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…577
      ELECTRIC SYSTEM MAINTENANCE…580
      HANDLING HYDRAULIC SYSTEM…580
    WEAR PARTS…581
      WEAR PARTS LIST…581
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT…582
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN…584
    TIGHTENING TORQUE SPECIFICATIONS…585
      TIGHTENING TORQUE LIST…585
    SAFETY CRITICAL PARTS…586
      SAFETY CRITICAL PARTS LIST…586
    MAINTENANCE SCHEDULE…587
      MAINTENANCE SCHEDULE CHART…587
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…588
    MAINTENANCE PROCEDURE…589
      WHEN REQUIRED…589
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…589
        CLEAN INSIDE OF COOLING SYSTEM…592
        CHECK LEVEL OF BATTERY ELECTROLYTE…595
        CLEAN FUEL FILTER ELEMENT (WITH WATER SEPARATOR)…597
        DRAIN WATER AND SEDIMENT FROM FUEL TANK…597
        CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH STEEL SHOE)…598
        CHECK RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…600
        CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…602
        REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…604
        REPLACE BUCKET TEETH…607
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…610
        CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…611
        BLEEDING AIR FROM HYDRAULIC SYSTEM…612
      CHECK BEFORE STARTING…613
      EVERY 500 HOURS MAINTENANCE…614
        LUBRICATING…614
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…617
        REPLACE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)…618
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…619
        REPLACE FUEL FEED PUMP PRE-FILTER…620
        CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…620
        CHECK AND ADJUST COOLING FAN BELT TENSION…621
      EVERY 1000 HOURS MAINTENANCE…622
        CHANGE OIL IN FINAL DRIVE CASE…622
        REPLACE HYDRAULIC OIL FILTER ELEMENT…623
        CHECK ENGINE VALVE CLEARANCE, ADJUST…624
      EVERY 2000 HOURS MAINTENANCE…625
        CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…625
        CHECK ALTERNATOR, STARTING MOTOR…627
SPECIFICATIONS…628
    SPECIFICATIONS…629
ATTACHMENTS, OPTIONS…631
    ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…632
      SAFETY FIRST…632
      ATTACHMENT INSTALLATION…633
    BUCKET WITH HOOK…634
      PROHIBITED OPERATIONS…634
    WINDSHIELD WASHER…635
      WINDSHIELD WASHER OPERATION…635
      CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…635
    MACHINE READY FOR ATTACHMENT…636
      LOCATIONS…636
      HYDRAULIC CIRCUIT…638
      ATTACHMENT OPERATIONS…640
      LONG TERM STORAGE…641
      SPECIFICATIONS…641
    CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE…642
      CONTROL PATTERN CHANGE PROCEDURE…642
      MACHINE CONTROL PATTERNS…643
    ATTACHMENT GUIDE…644
      ATTACHMENT COMBINATIONS…644
    RECOMMENDED ATTACHMENT OPERATIONS…645
      HYDRAULIC BREAKER…645
INDEX…650
WEAM007000 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual…653
1.1 FOREWORD…655
1.2 INFORMATION ON SAFETY…656
1.3 INTRODUCTION…658
    1.3.1 INTENDED USES…658
    1.3.2 IMPROPER OR UNAUTHORIZED USES…658
    1.3.3 MAIN CHARACTERISTICS…658
    1.3.4 RUNNING-IN…659
    1.3.5 DIRECTIONS OF MACHINE…659
1.4 PRODUCT IDENTIFICATION…660
    1.4.1 MACHINE SERIAL NUMBER…660
    1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)…660
    1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE…661
    1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…661
    1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…662
    1.4.6 CAB SERIAL NUMBER…662
    1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…663
TABLE OF CONTENTS…664
2.1 SAFETY, NOISE AND VIBRATION PLATES…672
    2.1.1 POSITION OF THE SAFETY PLATES…672
    2.1.2 PICTOGRAMS AND RELEVANT MEANINGS…673
    2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB…678
    2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY…679
    2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…679
2.2 GENERAL PRECAUTIONS…680
    2.2.1 GENERAL SAFETY RULES…680
    2.2.2 SAFETY DEVICES AND GUARDS…680
    2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…680
    2.2.4 UNAUTHORIZED MODIFICATIONS…681
    2.2.5 LEAVING THE OPERATOR’S SEAT…681
    2.2.6 GETTING ON AND OFF THE MACHINE…682
    2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL…683
    2.2.8 PREVENTING BURNS…683
    2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…684
    2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…684
    2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT…685
    2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE…685
    2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT…685
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE…686
    2.3.1 SAFETY ON THE WORK SITE…686
    2.3.2 FIRE PREVENTION…686
    2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB…686
    2.3.4 ROOM VENTILATION…687
    2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS…687
    2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES…687
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING…688
    2.4.1 STARTING THE ENGINE…688
    2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE…688
    2.4.3 CHECKS FOR TRAVELLING IN REVERSE…689
    2.4.4 MOVING THE MACHINE…689
    2.4.5 MOVING ON SLOPES…690
    2.4.6 WORKING ON SLOPES…691
    2.4.7 UNAUTHORIZED OPERATIONS…691
    2.4.8 PREVENTING ELECTROCUTION…693
    2.4.9 VISIBILITY…693
    2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES…693
    2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…694
    2.4.12 WORKING ON LOOSE GROUND…694
    2.4.13 PARKING THE MACHINE…694
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES…695
    2.5.1 LOADING AND UNLOADING…695
    2.5.2 TRANSPORT…695
2.6 BATTERY…696
    2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…696
    2.6.2 STARTING WITH BOOSTER CABLES…696
2.7 PRECAUTIONS FOR THE REMOVAL…697
2.8 PRECAUTIONS FOR MAINTENANCE…698
    2.8.1 WARNING PLATES…698
    2.8.2 TOOLS…698
    2.8.3 PERSONNEL…698
    2.8.4 EQUIPMENT…699
    2.8.5 WORKING UNDER THE MACHINE…699
    2.8.6 CLEANING THE MACHINE…699
    2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS…700
    2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…700
    2.8.9 STOP THE ENGINE BEFORE CARRY ING OUT ANY MAINTENANCE OPER ATION OR INSPECTION…700
    2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP…701
    2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR…701
    2.8.12 USING LAMPS…701
    2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR…702
    2.8.14 PRECAUTIONS CONCERNING THE STARTER…702
    2.8.15 HANDLING HIGH-PRESSURE PIPES…702
    2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…703
    2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERA TURES AND HIGH PRESSURE…703
    2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION…704
    2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT…704
    2.8.20 HYDRAULIC ACCUMULATOR…704
    2.8.21 COOLING FAN AND BELT…705
    2.8.22 WASTE MATERIALS…705
    2.8.23 COMPRESSED AIR…705
    2.8.24 PRECAUTIONS FOR THE USE OF THE synthetic biodegrada ble oil type HEES…705
3.1 MACHINE VIEW ILLUSTRATIONS…708
    3.1.1 OVERALL MACHINE VIEW…708
    3.1.2 CONTROLS AND GAUGES…709
3.2 DETAILED CONTROLS AND GAUGES…710
    3.2.1 MONITORING SYSTEM…710
      3.2.1.1 EMERGENCY MONITORS…711
      3.2.1.2 METER DISPLAY PORTION…713
      3.2.1.3 PILOT LAMPS…715
      3.2.1.4 MONITOR SWITCHES PORTION…716
    3.2.2 SWITCHES…718
    3.2.3 CONTROL LEVERS AND PEDALS…721
    3.2.4 WINDSHIELD (Machines equipped with cab)…728
    3.2.5 SLIDING DOOR (Machines equipped with cab)…732
    3.2.6 SLIDING WINDOW (Machines equipped with cab)…732
    3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab)…733
    3.2.8 CAPS AND COVERS WITH LOCK…734
    3.2.9 ENGINE REAR COVER…735
    3.2.10 COOLING COVER…736
    3.2.11 TANK COVER…737
    3.2.12 METHOD OF OPENING (TILTING) FLOOR…738
    3.2.13 FUSE…742
    3.2.14 BLOCK FUSE…742
    3.2.15 OPERATION MANUAL STORAGE…743
    3.2.16 TOOL BOX…743
    3.2.17 GREASE GUN HOLDER…743
    3.2.18 ASHTRAY (Machines equipped with cab)…743
3.3 MACHINE OPERATIONS AND CONTROLS…744
    3.3.1 BEFORE STARTING ENGINE…744
      3.3.1.1 WALK-AROUND CHECKS…744
      3.3.1.2 CHECKS BEFORE STARTING…746
      3.3.1.3 ADJUSTMENT…752
      3.3.1.4 OPERATIONS BEFORE STARTING ENGINE…755
      3.3.1.5 STARTING ENGINE…757
    3.3.2 AFTER STARTING ENGINE…760
      3.3.2.1 BREAKING-IN THE NEW MACHINE…760
      3.3.2.2 WARMING-UP OPERATION…760
    3.3.3 STOPPING THE ENGINE…762
    3.3.4 MACHINE OPERATION…763
      3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF…763
      3.3.4.2 MOVING MACHINE FORWARD…763
      3.3.4.3 MOVING MACHINE BACKWARD…765
      3.3.4.4 STOPPING MACHINE…766
    3.3.5 STEERING THE MACHINE…767
      3.3.5.1 STEERING…767
    3.3.6 SWINGING…769
    3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS…770
    3.3.8 PROHIBITED OPERATIONS…772
    3.3.9 GENERAL OPERATION INFORMATION…774
    3.3.10 TRAVELING ON SLOPES…776
    3.3.11 ESCAPE FROM MUD…778
    3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…779
    3.3.13 CHANGING THE BUCKET…781
    3.3.14 PARKING MACHINE…782
    3.3.15 CHECK AFTER SHUT OFF ENGINE…783
    3.3.16 MACHINE INSPECTION AFTER DAILY WORK…783
    3.3.17 LOCKING…783
    3.3.18 RUBBER SHOES (Machines equipped only with rubber shoes)…784
      3.3.18.1 OPTIMAL USE OF THE RUBBER SHOES…784
      3.3.18.2 RUBBER SHOE WARRANTY…784
      3.3.18.3 USING THE RUBBER SHOES…784
3.4 TRANSPORTATION…788
    3.4.1 TRANSPORTATION PROCEDURE…788
    3.4.2 LOADING AND UNLOADING WITH TRAILER…788
    3.4.3 LIFTING MACHINE…794
3.5 COLD WEATHER OPERATION…796
    3.5.1 COLD WEATHER OPERATION INFORMATION…796
      3.5.1.1 FUEL AND LUBRICANTS…796
      3.5.1.2 COOLING SYSTEM COOLANT…796
      3.5.1.3 BATTERY…797
    3.5.2 CAB HEATER IN COLD WEATHER (Machines equipped with cab)…797
    3.5.3 AFTER DAILY WORK COMPLETION…798
    3.5.4 AFTER COLD WEATHER SEASON…798
3.6 LONG TERM STORAGE…799
    3.6.1 BEFORE STORAGE…799
    3.6.2 DURING STORAGE…799
    3.6.3 AFTER STORAGE…799
3.7 TROUBLES AND ACTIONS…800
    3.7.1 RUNNING OUT OF FUEL…800
    3.7.2 PHENOMENA THAT ARE NOT FAILURES…800
    3.7.3 TOWING THE MACHINE…800
    3.7.4 SEVERE JOB CONDITION…801
    3.7.5 DISCHARGED BATTERY…801
      3.7.5.1 BATTERY REMOVAL AND INSTALLATION…802
      3.7.5.2 BATTERY CHARGES…802
      3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES…803
    3.7.6 OTHER TROUBLE…805
      3.7.6.1 ELECTRICAL SYSTEM…805
      3.7.6.2 CHASSIS…806
      3.7.6.3 ENGINE…806
4.1 MAINTENANCE INFORMATION…810
4.2 LUBRICANTS, COOLANT AND FILTERS…813
    4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…813
      4.2.1.1 OIL…813
      4.2.1.2 FUEL…813
      4.2.1.3 COOLING SYSTEM COOLANT…814
      4.2.1.4 GREASE…814
      4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…815
      4.2.1.6 OIL AND FUEL STORAGE…816
      4.2.1.7 FILTERS…816
    4.2.2 ELECTRIC SYSTEM MAINTENANCE…817
    4.2.3 HANDLING HYDRAULIC SYSTEM…817
4.3 WEAR PARTS…818
    4.3.1 WEAR PARTS LIST…818
4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…819
    4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS…823
4.5 TIGHTENING TORQUE SPECIFICATIONS…824
    4.5.1 TIGHTENING TORQUE LIST…824
4.6 LUBRICATION…825
    4.6.1 LUBRICATION DIAGRAM…825
4.7 SAFETY CRITICAL PARTS…826
    4.7.1 SAFETY CRITICAL PARTS LIST…826
4.8 MAINTENANCE SCHEDULE…827
    4.8.1 MAINTENANCE SCHEDULE CHART…827
    4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…828
      4.8.2.a CHANGING THE HYDRAULIC OIL FIL TER…828
      4.8.2.b CHANGING THE HYDRAULIC OIL…828
4.9 MAINTENANCE PROCEDURE…829
    4.9.1 WHEN REQUIRED…829
      4.9.1.a CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…829
      4.9.1.b CLEAN INSIDE OF COOLING SYSTEM…831
      4.9.1.c CHECK LEVEL OF BATTERY ELECTROLYTE…834
      4.9.1.d CLEANING THE FUEL FILTER (WITH WATER SEPARATOR)…836
      4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK…836
      4.9.1.f CHECK AND ADJUST TRACK TENSION (Machines equipped with steel shoes)…837
      4.9.1.g CHECKING THE RUBBER SHOES (Machines equipped with rubber shoes)…839
      4.9.1.h CHECK AND ADJUST RUBBER SHOE TENSION (Machine equipped with rubber shoes)…841
      4.9.1.i REPLACE RUBBER SHOES (Machine equipped with rubber shoes)…843
      4.9.1.j CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab)…845
      4.9.1.k CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER (Machine equipped with cab)…846
      4.9.1.l BLEEDING AIR FROM HYDRAULIC SYSTEM…846
    4.9.2 CHECK BEFORE STARTING…847
    4.9.3 EVERY 500 HOURS MAINTENANCE…848
      4.9.3.a LUBRICATING…848
      4.9.3.b CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…850
      4.9.3.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)…851
      4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…852
      4.9.3.e REPLACE FEED PUMP PRE-FILTER…853
      4.9.3.f CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…853
      4.9.3.g CHECK AND ADJUST COOLING FAN BELT TENSION…854
    4.9.4 EVERY 1000 HOURS MAINTENANCE…855
      4.9.4.a CHANGING THE HYDRAULIC OIL FILTER ELEMENT…855
      4.9.4.b CHANGE OIL IN FINAL DRIVE CASE…856
      4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST…856
    4.9.5 EVERY 2000 HOURS MAINTENANCE…857
      4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…857
      4.9.5.b CHECK ALTERNATOR, STARTING MOTOR…858
5.1 SPECIFICATIONS…860
5.2 LIFTING CAPACITIES…862
    5.2.1 LIFTING CAPACITIES (WITH CANOPY)…862
    5.2.2 LIFTING CAPACITIES (WITH CABIN)…865
6.1 ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…870
    6.1.1 SAFETY FIRST…870
    6.1.2 ATTACHMENT INSTALLATION…871
    6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…872
      6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…872
6.2 MACHINE READY FOR ATTACHMENT…873
    6.2.1 LOCATIONS…873
    6.2.2 HYDRAULIC CIRCUIT…875
      6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT…875
      6.2.2.2 MAINTENANCE…876
      6.2.2.3 BLEEDING AIR…876
6.3 ATTACHMENT OPERATIONS…877
    6.3.1 LONG TERM STORAGE…878
    6.3.2 SPECIFICATIONS…878
6.4 ATTACHMENT GUIDE…879
    6.4.1 ATTACHMENT COMBINATIONS…879
6.5 RECOMMENDED ATTACHMENT OPERATIONS…880
    6.5.1 HYDRAULIC BREAKER…880

Komatsu Hydraulic Excavator PC20MR Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Hydraulic Excavators PC18MR Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC18MR-2, PC18MR-3, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC18MR-2, PC18MR-3 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.

SEBM038404 – Hydraulic Excavator PC18MR-2 Shop Manual.pdf
SEN04306-04 – Hydraulic Excavator PC18MR-3 Shop Manual.pdf
TEN00052-01 – Hydraulic Excavator GALEO PC18MR-2 Operation & Maintenance Manual.pdf
TEN00292-03 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
TEN00514-01 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
TEN00549-00 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,743 pages
File Format: PDF
Language: English

TABLE OF CONTENTS

SEBM038404 – Hydraulic Excavator PC18MR-2 Shop Manual…2
COVER…2
CONTENTS…3
01 GENERAL…28
SPECIFICATION DIMENSION DRAWING…29
WORKING RANGE DRAWING…30
SPECIFICATIONS…31
WEIGHT TABLE…34
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS…36
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD…37
PTO…38
COOLING SYSTEM…39
POWER TRAIN …41
SWING CIRCLE…42
TRACK FRAME…43
IDLER CUSHION…44
IDLER…46
TRACK ROLLER…47
SPROCKET…48
TRACK SHOE…49
HYDRAULIC COMPONENTS LAYOUT DRAWING…51
HYDRAULIC TANK…52
CENTER SWIVEL JOINT…53
TRAVEL MOTOR…54
HYDRAULIC CYLINDER…63
SOLENOID VALVE…66
VARIABLE GAUGE VALVE…69
MULTI-CONTROL VALVE…70
HYDRAULIC PUMP…71
CONTROL VALVE…77
CLSS…89
OPERATION FOR EACH FUNCTION AND VALVE…92
SWING MOTOR…105
PPC VALVE…108
WORK EQUIPMENT …116
DIMENSIONS OF EACH PART OF WORK EQUIPMENT…119
FLOOR…122
ENGINE CONTROL…123
ELECTRIC CONTROL SYSTEM…125
COMPONENT PARTS OF SYSTEM…130
MONITOR SYSTEM…131
MONITOR PANEL…132
SENSORS…134
20 TESTING AND ADJUSTING…136
STANDARD VALUE TABLE FOR ENGING RELATED PARTS…137
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…138
TESTING AND ADJUSTING…147
LIST OF TESTING, ADJUSTING,AND TROUBLESHOOTING TOOLS…148
MEASURING ENGINE SPEED…150
MEASURING OF EXHAUST GAS COLOR…151
ADJUSTING VALVE CLEARANCE…152
TESTING COMPRESSION PRESSURE…154
TESTING ENGINE OIL PRESSURE…155
TESTING AND ADJUSTING FUEL INJECTION TIMING…156
ADJUSTING ENGINE STOP SOLENOID…158
BLEEDING AIR FROM FUEL CIRCUIT…159
TESTING AND ADJUSTING FAN BELT TENSION…160
ADJUSTING FUEL CONTROL LEVER LINKAGE…161
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…162
TESTING AND ADJUSTING TRACK SHOE TENSION…163
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT,TRAVEL,SWING,AND BLADE CIRCUITS…165
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE…168
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE…170
MEASURING SOLENOID VALVE OUTPUT PRESSURE…172
MEASURING PPC VALVE OUTPUT PRESSURE…174
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…176
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE…176
TESTING OIL LEAKAGE FORM CYLINDER…178
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…180
BLEEDING AIR FROM CYLINDER…180
PRESSURIZING HYDRAULIC TANK…181
HOW TO OPEN AND CLOSE(TILT) FLOOR…182
INSPECTION PROCEDURES FOR DIODE…184
TROUBLESHOOTING…185
POINTS TO REMEMBER WHEN TROUBLESHOOTING…186
SEQUENCE OF EVENTS IN TROUBLESHOOTING…187
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…188
CHECKS BEFORE TROUBLESHOOTING…196
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…197
CONNECTORS LIST AND CONNECTORS ARRANGEMENT STEREOGRAM …199
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…203
T-ADAPTER-BOXES AND T-ADAPTER TABLE…226
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…229
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM(E MODE)…230
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…232
E-1 ENGINE DOES NOT START…233
E-2 ENGINE DOES NOT STOP…239
E-3 ENGINE OIL PRESSURE MONITOR DOES NOT INDICATE NORMALLY…241
E-4 CHARGE LEVEL MONITOR DOES NOT INDICATE NORMALLY…244
E-5 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…247
E-6 SERVICE METER DOES NOT OPERATE NORMALLY…250
E-7 PREHEATING SYSTEM DOES NOT OPERATE NORMALLY…252
E-8 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY…255
E-9 ENGINE COOLANT TEMPERATURE MONITOR DOES NOT INDICATE NORMALLY…259
E-10 LOCK LEVER DOES NOT OPERATE NORMALLY…263
E-11 BLADE/VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE NORMALLY…266
E-12 NIGHT LAMP OF MACHINE MONITOR AND WORKING LAMP DO NOT LIGHT UP…269
E-13 TRAVEL ALARM DOES NOT SOUND OR DOES NOT SOUNDING…272
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…275
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE …276
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT,TRAVEL,SWING,AND BLADE IS LOW…277
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS…278
H-3 WHOLE WORK EQUIPMENT,TRAVEL SYSTEM,SWING SYSTEM,AND BLADE DO NOT MOVE…279
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP…280
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW…280
H-6 SPEED OR POWER OF BOOM IS LOW…281
H-7 SPEED OR POWER OF ARM IS LOW…282
H-8 SPEED OR POWER OF BUCKET IS LOW…283
H-9 SPEED OR POWER OF BOOM SWING IS LOW…284
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY…284
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE…285
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…286
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT,SPEED OF PART LOADED MORE IS LOW…286
H-14 MACHINE DEVIATES DURING TRAVEL…287
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW…289
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…289
H-17 TRAVEL SPEED DOES NOT CHANGE…290
H-18 TRAVEL MOTOR DOES NOT WORK(ONE SIDE ONLY)…290
H-19 SPEED OR POWER OF SWING IS LOW…291
H-20 MACHINE DOES NOT SWING…293
H-21 SWING ACCELERATION PERFORMANCE IS LOW…295
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING…296
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING…297
H-24 WHEN UPPER STRUCTURE STOPS SWINGING,IT MAKES LARGE SOUND…297
H-25 HYDRAULIC DRIFT OF SWING IS LARGE…298
H-26 SPEED OR POWER OF BLADE IS LOW…299
H-27 BLADE DOES NOT MOVE…300
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE…300
H-29 VARIABLE GAUGE DOES NOT MOVE…301
H-30 TROUBLESHOOTING FOR HYDRAULIC BREAKER…302
TROUBLESHOOTING OF ENGINE(S MODE)…305
TROUBLESHOOTING CHART…306
30 DISASSEMBLY AND ASSEMBLY…310
HOW TO READ THIS MANUAL…311
PRECAUTIONS WHEN PERFORMING OPERATION…313
SPECIAL TOOL LIST…315
SKETCH OF SPECIAL TOOLS…317
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…321
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…322
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…324
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…325
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…329
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…330
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING…331
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…333
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY…334
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…343
REMOVAL AND INSTALLATION OF REVOLVING FRAME…348
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…351
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY…352
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…361
REMOVAL AND INSTALLATION OF HYDRAULIC SYSTEM AND CENTER SWIVEL JOINT ASSEMBLY …365
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…367
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY…369
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY…370
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…377
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…379
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC BREAKER ASSEMBLY…383
90 OTHERS…390
HYDRAULIC CIRCUIT DIAGRAM …391
ELECTRICAL CIRCUIT DIAGRAM …392
SEN04306-04 – Hydraulic Excavator PC18MR-3 Shop Manual…393
COVER…393
00 Index and foreword…0
100 Index…394
Composition of shop manual…395
Table of contents…397
200 Foreword and general information…402
Safety notice…403
How to read the shop manual…408
Explanation of terms for maintenance standard…410
Handling of electric equipment and hydraulic component…412
Handling of connectors newly used for engines…421
How to read electric wire code…424
Precautions when carrying out operation…427
Method of disassembling and connecting push-pull type coupler…430
Standard tightening torque table…433
Conversion table…437
01 Specification…0
100 Specification and technical data…444
Specification dimension drawing…445
Working range drawing…446
Specifications…447
Weight table…450
Table of fuel, coolant and lubricants…452
10 Structure, function and maintenance standard…0
100 Engine and cooling system…454
PTO…455
Cooling system…457
200 Power train…460
Power train…461
Swing circle…462
300 Undercarriage and frame…464
Track frame…465
Idler cushion…466
Idler…468
Track roller…469
Sprocket…470
Track shoe…471
410 Hydraulic system, Part 1…474
Hydraulic components layout drawing…475
Hydraulic tank…476
Center swivel joint…477
Travel motor…478
Hydraulic cylinder…487
Solenoid valve…491
Variable gauge valve…494
Multi-control valve (If equipped)…495
420 Hydraulic system, Part 2…498
Hydraulic pump…499
Control valve…505
430 Hydraulic system, Part 3…516
CLSS…517
Operation for each function and valve…521
Swing motor…535
PPC valve…538
500 Work equipment…548
Work equipment…550
Dimensions of each part of work equipment…553
600 Cab and its attachments…558
Floor…559
700 Electrical system…562
Engine control system…563
Electric control system…565
Component parts of system…570
KOMTRAX system…571
Monitor system…574
Sensors…577
20 Standard value table…0
100 Standard service value table…580
Standard value table for engine related parts…581
Standard value table for chassis related parts…582
30 Testing and adjusting…0
100 Testing and adjusting…592
List of testing, adjusting, and troubleshooting tools…594
Measuring engine speed…596
Measurement of exhaust gas color…597
Adjusting valve clearance…598
Testing compression pressure…600
Testing engine oil pressure…601
Testing and adjusting fuel injection timing…602
Adjusting engine stop solenoid…604
Bleeding air from fuel circuit…605
Testing and adjusting fan belt tension…606
Adjusting fuel control lever linkage…607
Measurement of clearance in swing circle bearings…608
Testing and adjusting track shoe tension…609
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits…611
Testing and adjusting control circuit basic pressure…614
Testing and adjusting pump LS differential pressure…616
Measuring solenoid valve output pressure…618
Measuring PPC valve output pressure…620
Adjusting play of work equipment and swing PPC valves…622
Measuring swing holding brake release pressure…622
Testing oil leakage from cylinder…624
Releasing residual pressure from hydraulic circuit…626
Bleeding air from cylinder…626
Pressurizing hydraulic tank…627
How to open and close (tilt) floor…628
Inspection procedures for diode…630
How to start operation of KOMTRAX terminal…631
Lamp display of KOMTRAX terminal…635
Removal and installation of KOMTRAX terminal…638
Preparation work for troubleshooting of electrical system…639
40 Troubleshooting…0
100 General information on troubleshooting…642
Points to remember when troubleshooting…643
Sequence of events in troubleshooting…644
Checks before troubleshooting…645
Classification and procedures of troubleshooting…646
Connection table for connector pin numbers…649
T- branch box and T- branch adapter table…685
200 Troubleshooting of electrical system (E-mode)…690
Before carrying out troubleshooting for electrical system (E-mode)…691
Information contained in troubleshooting table…693
E-1 Engine does not start…694
E-2 Engine does not stop…701
E-3 When starting switch is turned ON, any item does not operate…703
E-4 When starting switch is turned ON, some items do not operate…705
E-5 Alarm buzzer is abnormal…706
E-6 Engine oil pressure caution is turned ON…708
E-7 Charge level caution is turned ON…709
E-8 Preheating system does not operate or preheater does not become hot…711
E-9 Coolant temperature gauge is abnormal…713
E-10 Fuel level gauge is abnormal…717
E-11 Service meter does not operate while engine is running…721
E-12 2nd travel speed is not selected…724
E-13 Working lamp does not light up…727
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves…729
E-15 Blade/Variable gauge selector system does not operate normally…732
300 Troubleshooting of hydraulic and mechanical system (H-mode)…736
Information contained in troubleshooting table…738
H-1 Speed or power of whole work equipment, travel, swing, and blade is low…739
H-2 Engine speed lowers extremely or engine stalls…740
H-3 Whole work equipment, travel system, swing system, and blade do not move…741
H-4 Abnormal sound comes out from around hydraulic pump…742
H-5 Fine control performance or response is low…742
H-6 Speed or power of boom is low…743
H-7 Speed or power of arm is low…744
H-8 Speed or power of bucket is low…745
H-9 Speed or power of boom swing is low…746
H-10 Work equipment does not move singly…746
H-11 Work equipment hydraulic drift is large…747
H-12 Time lag of work equipment is large…748
H-13 In compound operation of work equipment, speed of part loaded more is low…748
H-14 Machine deviates during travel…749
H-15 Travel speed or travel power is low…751
H-16 Machine is not steered well or steering power is low…751
H-17 Travel speed does not change…752
H-18 Travel motor does not work (one side only)…752
H-19 Speed or power of swing is low…753
H-20 Machine does not swing…755
H-21 Swing acceleration performance is low…757
H-22 Machine overruns when it stops swinging…758
H-23 Large shock is made when machine stops swinging…759
H-24 When upper structure stops swinging, it makes large sound…759
H-25 Hydraulic drift of swing is large…760
H-26 Speed or power of blade is low…761
H-27 Blade does not move…762
H-28 Hydraulic drift of blade is large…762
H-29 Variable gauge does not move…763
H-30 Troubleshooting for hydraulic breaker…764
400 Troubleshooting of engine (S-mode)…768
Troubleshooting chart…769
50 Disassembly and assembly…0
100 General information on disassembly and assembly…774
How to read this manual…775
Coating materials list…777
Special tool list…780
Sketches of special tools…782
200 Engine and cooling system…786
Removal and installation of fuel injection pump assembly…787
Removal and installation of radiator assembly…788
Removal and installation of hydraulic oil cooler assembly…790
Removal and installation of engine and hydraulic pump assembly…791
300 Power train…798
Removal and installation of swing circle assembly…799
400 Undercarriage and frame…802
Removal and installation of track shoe assembly…803
Disassembly and assembly of idler assembly…804
Disassembly and assembly of recoil spring…806
Disassembly and assembly of track roller assembly…808
Assembly of travel motor assembly…810
Removal and installation of floor frame assembly…819
Removal and installation of revolving frame…823
500 Hydraulic system…828
Disassembly and assembly of hydraulic pump assembly…829
Disassembly and assembly of control valve assembly…839
Removal and installation of hydraulic system and center swivel joint assembly…845
Disassembly and assembly of center swivel joint assembly…847
Removal and installation of swing motor assembly…849
Disassembly and assembly of swing motor assembly…850
Disassembly and assembly of hydraulic cylinder assembly…857
Disassembly and assembly of hydraulic breaker assembly…861
600 Work equipment…870
Removal and installation of work equipment assembly…871
700 Cab and its attachments…874
Removal and installation of canopy…875
800 Electrical system…878
Removal and installation of KOMTRAX terminal…879
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…882
Hydraulic circuit diagram…884
200 Electrical diagrams and drawings…887
Electrical circuit diagram…889
Connector list and stereogram…890
TEN00052-01 – Hydraulic Excavator GALEO PC18MR-2 Operation & Maintenance Manual…893
COVER…893
FOREWORD…894
FOREWORD…895
SAFETY INFORMATION…898
INTRODUCTION…900
DIRECTIONS OF MACHINE…900
PRODUCT INFORMATION…901
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…901
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…901
EPA NAMEPLATE…902
SERVICE METER LOCATION…902
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…903
CONTENTS…904
SAFETY…908
SAFETY INFORMATION…909
SAFETY LABELS…911
LOCATION OF SAFETY LABELS…911
SAFETY LABELS…912
SAFETY INFORMATION…917
SAFETY MACHINE OPERATION…926
STARTING ENGINE…926
OPERATION…928
TRANSPORTATION…934
BATTERY…935
TOWING…937
LIFTING OBJECTS WITH BUCKET…938
SAFETY MAINTENANCE INFORMATION…939
OPERATION…946
MACHINE VIEW ILLUSTRATIONS…947
OVERALL MACHINE VIEW…947
CONTROLS AND GAUGES…948
DETAILED CONTROLS AND GAUGES…949
MONITORING SYSTEM…949
SWITCHES…955
CONTROL LEVERS AND PEDALS…959
COVER WITH LOCK…964
ENGINE REAR COVER…965
COOLING COVER…966
BATTERY COVER…967
METHOD OF OPENING (TILTING) FLOOR…968
FUSE…972
BLOCK FUSE…972
OPERATION MANUAL STORAGE…973
TOOL BOX…973
MACHINE OPERATIONS AND CONTROLS…974
BEFORE STARTING ENGINE…974
STARTING ENGINE…987
AFTER STARTING ENGINE…991
STOPPING THE ENGINE…994
MACHINE OPERATION…995
STEERING THE MACHINE…1000
SWINGING…1002
WORK EQUIPMENT CONTROLS AND OPERATIONS…1003
PROHIBITED OPERATIONS…1006
GENERAL OPERATION INFORMATION…1008
TRAVELING ON SLOPES…1010
ESCAPE FROM MUD…1012
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1013
BUCKET REPLACEMENT…1015
PARKING MACHINE…1016
MACHINE INSPECTION AFTER DAILY WORK…1017
LOCKING…1018
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1019
TRANSPORTATION…1024
TRANSPORTATION PROCEDURE…1024
LOADING AND UNLOADING WITH TRAILER…1024
LIFTING MACHINE…1030
COLD WEATHER OPERATION…1033
COLD WEATHER OPERATION INFORMATION…1033
AFTER DAILY WORK COMPLETION…1035
AFTER COLD WEATHER SEASON…1035
LONG TERM STORAGE…1036
BEFORE STORAGE…1036
DURING STORAGE…1036
AFTER STORAGE…1036
TROUBLES AND ACTIONS…1037
RUNNING OUT OF FUEL…1037
PHENOMENA THAT ARE NOT FAILURES…1037
TOWING THE MACHINE…1038
SEVERE JOB CONDITION…1038
DISCHARGED BATTERY…1039
OTHER TROUBLE…1043
MAINTENANCE…1046
MAINTENANCE INFORMATION…1047
OUTLINE OF SERVICE…1049
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1049
ELECTRIC SYSTEM MAINTENANCE…1052
HANDLING HYDRAULIC SYSTEM…1052
WEAR PARTS…1053
WEAR PARTS LIST…1053
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1054
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1056
TIGHTENING TORQUE SPECIFICATIONS…1057
TIGHTENING TORQUE LIST…1057
SAFETY CRITICAL PARTS…1058
SAFETY CRITICAL PARTS LIST…1058
MAINTENANCE SCHEDULE…1059
MAINTENANCE SCHEDULE CHART…1059
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1060
MAINTENANCE PROCEDURE…1061
WHEN REQUIRED…1061
CHECK BEFORE STARTING…1083
EVERY 500 HOURS MAINTENANCE…1084
EVERY 1000 HOURS MAINTENANCE…1091
EVERY 2000 HOURS MAINTENANCE…1094
SPECIFICATIONS…1096
SPECIFICATIONS…1097
ATTACHMENTS AND OPTIONS…1100
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1101
SAFETY FIRST…1101
ATTACHMENT INSTALLATION…1102
BUCKET WITH HOOK…1103
PROHIBITED OPERATIONS…1103
MACHINE READY FOR ATTACHMENT…1104
LOCATIONS…1104
HYDRAULIC CIRCUIT…1106
ATTACHMENT OPERATIONS…1108
LONG TERM STORAGE…1109
SPECIFICATIONS…1109
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1110
CONTROL PATTERN CHANGE PROCEDURE…1110
MACHINE CONTROL PATTERNS…1111
ATTACHMENT GUIDE…1112
ATTACHMENT COMBINATIONS…1112
RECOMMENDED ATTACHMENT OPERATIONS…1113
HYDRAULIC BREAKER…1113
INDEX…1118
TEN00292-03 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1122
COVER…1122
FOREWORD…1123
FOREWORD…1124
SAFETY INFORMATION…1125
INTRODUCTION…1127
DIRECTIONS OF MACHINE…1127
PRODUCT INFORMATION…1128
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1128
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1128
EPA NAMEPLATE…1129
SERVICE METER LOCATION…1129
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1130
CONTENTS…1131
SAFETY…1135
SAFETY…1136
SAFETY LABELS…1138
LOCATION OF SAFETY LABELS…1138
SAFETY LABELS…1139
GENERAL PRECAUTIONS…1144
SAFETY MACHINE OPERATION…1153
STARTING ENGINE…1153
OPERATION…1155
TRANSPORTATION…1161
BATTERY…1162
TOWING…1164
LIFTING OBJECTS WITH BUCKET…1165
SAFETY MAINTENANCE INFORMATION…1166
OPERATION…1175
MACHINE VIEW ILLUSTRATIONS…1176
OVERALL MACHINE VIEW…1176
CONTROLS AND GAUGES…1177
DETAILED CONTROLS AND GAUGES…1178
MONITORING SYSTEM…1178
SWITCHES…1184
CONTROL LEVERS AND PEDALS…1187
COVER WITH LOCK…1193
ENGINE REAR COVER…1194
COOLING COVER…1195
BATTERY COVER…1196
METHOD OF OPENING (TILTING) FLOOR…1197
AUXILIARY ELECTRIC POWER…1201
FUSE…1201
BLOCK FUSE…1202
OPERATION MANUAL STORAGE…1202
TOOL BOX…1203
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1204
MACHINE OPERATIONS AND CONTROLS…1205
BEFORE STARTING ENGINE…1205
STARTING ENGINE…1218
AFTER STARTING ENGINE…1222
STOPPING THE ENGINE…1225
MACHINE OPERATION…1226
STEERING THE MACHINE…1231
SWINGING…1233
WORK EQUIPMENT CONTROLS AND OPERATIONS…1234
PROHIBITED OPERATIONS…1237
GENERAL OPERATION INFORMATION…1239
TRAVELING ON SLOPES…1241
ESCAPE FROM MUD…1243
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1244
BUCKET REPLACEMENT…1246
PARKING MACHINE…1247
MACHINE INSPECTION AFTER DAILY WORK…1248
LOCKING…1249
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1250
TRANSPORTATION…1255
TRANSPORTATION PROCEDURE…1255
LOADING AND UNLOADING WITH TRAILER…1256
LIFTING MACHINE…1262
COLD WEATHER OPERATION…1265
COLD WEATHER OPERATION INFORMATION…1265
AFTER DAILY WORK COMPLETION…1267
AFTER COLD WEATHER SEASON…1267
LONG TERM STORAGE…1268
BEFORE STORAGE…1268
DURING STORAGE…1268
AFTER STORAGE…1268
TROUBLES AND ACTIONS…1270
RUNNING OUT OF FUEL…1270
PHENOMENA THAT ARE NOT FAILURES…1270
TOWING THE MACHINE…1271
SEVERE JOB CONDITION…1271
DISCHARGED BATTERY…1272
OTHER TROUBLE…1276
MAINTENANCE…1279
MAINTENANCE INFORMATION…1280
OUTLINE OF SERVICE…1282
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1282
ELECTRIC SYSTEM MAINTENANCE…1286
HANDLING HYDRAULIC SYSTEM…1286
WEAR PARTS…1287
WEAR PARTS LIST…1287
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1288
TIGHTENING TORQUE SPECIFICATIONS…1290
TIGHTENING TORQUE LIST…1290
SAFETY CRITICAL PARTS…1291
SAFETY CRITICAL PARTS LIST…1291
MAINTENANCE SCHEDULE…1292
MAINTENANCE SCHEDULE CHART…1292
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1293
MAINTENANCE PROCEDURE…1294
WHEN REQUIRED…1294
CHECK BEFORE STARTING…1317
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1317
EVERY 500 HOURS MAINTENANCE…1318
EVERY 1000 HOURS MAINTENANCE…1326
EVERY 1500 HOURS MAINTENANCE…1329
EVERY 2000 HOURS MAINTENANCE…1330
SPECIFICATIONS…1335
SPECIFICATIONS…1336
ATTACHMENTS, OPTIONS…1339
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1340
SAFETY FIRST…1340
ATTACHMENT INSTALLATION…1341
BUCKET WITH HOOK…1342
HOOK CONDITION…1342
PROHIBITED OPERATIONS…1342
MACHINE READY FOR ATTACHMENT…1343
LOCATIONS…1343
HYDRAULIC CIRCUIT…1346
ATTACHMENT OPERATIONS…1347
LONG TERM STORAGE…1348
SPECIFICATIONS…1348
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1349
CONTROL PATTERN CHANGE PROCEDURE…1349
MACHINE CONTROL PATTERNS…1350
ATTACHMENT GUIDE…1351
ATTACHMENT COMBINATIONS…1351
HANDLING ARM WITH BUILT-IN BREAKER…1352
REMOVING AND INSTALLING CHISEL…1352
PROCEDURE FOR BREAKER OPERATIONS…1355
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1356
INSTALLATION OF BUCKET…1357
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1359
STOWING CHISEL, DUMMY CHISEL…1359
CHECK BEFORE STARTING…1360
SPECIFICATIONS…1361
RECOMMENDED ATTACHMENT OPERATIONS…1362
HYDRAULIC BREAKER…1362
INDEX…1367
TEN00514-01 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1371
COVER…1371
FOREWORD…1372
FOREWORD…1373
SAFETY INFORMATION…1374
INTRODUCTION…1376
DIRECTIONS OF MACHINE…1376
PROTECTIVE STRUCTURE…1376
PRODUCT INFORMATION…1377
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1377
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1377
EPA NAMEPLATE…1378
SERVICE METER LOCATION…1378
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1379
CONTENTS…1380
SAFETY…1384
SAFETY…1385
SAFETY LABELS…1387
LOCATION OF SAFETY LABELS…1387
SAFETY LABELS…1388
GENERAL PRECAUTIONS…1393
SAFETY MACHINE OPERATION…1402
STARTING ENGINE…1402
OPERATION…1404
TRANSPORTATION…1410
BATTERY…1411
TOWING…1413
LIFTING OBJECTS WITH BUCKET…1414
SAFETY MAINTENANCE INFORMATION…1415
OPERATION…1424
MACHINE VIEW ILLUSTRATIONS…1425
OVERALL MACHINE VIEW…1425
CONTROLS AND GAUGES…1426
DETAILED CONTROLS AND GAUGES…1427
MONITORING SYSTEM…1427
SWITCHES…1433
CONTROL LEVERS AND PEDALS…1436
COVER WITH LOCK…1442
ENGINE REAR COVER…1443
COOLING COVER…1444
BATTERY COVER…1445
METHOD OF OPENING (TILTING) FLOOR…1446
AUXILIARY ELECTRIC POWER…1450
FUSE…1450
OPERATION MANUAL STORAGE…1451
TOOL BOX…1452
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1453
MACHINE OPERATIONS AND CONTROLS…1454
BEFORE STARTING ENGINE…1454
STARTING ENGINE…1467
AFTER STARTING ENGINE…1471
STOPPING THE ENGINE…1474
MACHINE OPERATION…1475
STEERING THE MACHINE…1480
SWINGING…1482
WORK EQUIPMENT CONTROLS AND OPERATIONS…1483
PROHIBITED OPERATIONS…1486
GENERAL OPERATION INFORMATION…1488
TRAVELING ON SLOPES…1490
ESCAPE FROM MUD…1492
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1493
BUCKET REPLACEMENT…1495
PARKING MACHINE…1496
MACHINE INSPECTION AFTER DAILY WORK…1497
LOCKING…1498
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1499
TRANSPORTATION…1504
TRANSPORTATION PROCEDURE…1504
LOADING AND UNLOADING WITH TRAILER…1505
LIFTING MACHINE…1511
COLD WEATHER OPERATION…1514
COLD WEATHER OPERATION INFORMATION…1514
AFTER DAILY WORK COMPLETION…1516
AFTER COLD WEATHER SEASON…1516
LONG TERM STORAGE…1517
BEFORE STORAGE…1517
DURING STORAGE…1517
AFTER STORAGE…1517
TROUBLES AND ACTIONS…1518
RUNNING OUT OF FUEL…1518
PHENOMENA THAT ARE NOT FAILURES…1518
TOWING THE MACHINE…1519
SEVERE JOB CONDITION…1519
DISCHARGED BATTERY…1520
OTHER TROUBLE…1524
MAINTENANCE…1528
MAINTENANCE INFORMATION…1529
OUTLINE OF SERVICE…1531
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1531
ELECTRIC SYSTEM MAINTENANCE…1534
HANDLING HYDRAULIC SYSTEM…1535
WEAR PARTS…1536
WEAR PARTS LIST…1536
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1537
TIGHTENING TORQUE SPECIFICATIONS…1539
TIGHTENING TORQUE LIST…1539
SAFETY CRITICAL PARTS…1540
SAFETY CRITICAL PARTS LIST…1540
MAINTENANCE SCHEDULE…1541
MAINTENANCE SCHEDULE CHART…1541
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1542
MAINTENANCE PROCEDURE…1543
WHEN REQUIRED…1543
CHECK BEFORE STARTING…1565
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1565
EVERY 500 HOURS MAINTENANCE…1566
EVERY 1000 HOURS MAINTENANCE…1574
EVERY 1500 HOURS MAINTENANCE…1577
EVERY 2000 HOURS MAINTENANCE…1578
SPECIFICATIONS…1584
SPECIFICATIONS…1585
ATTACHMENTS, OPTIONS…1588
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1589
SAFETY FIRST…1589
ATTACHMENT INSTALLATION…1590
BUCKET WITH HOOK…1591
HOOK CONDITION…1591
PROHIBITED OPERATIONS…1591
MACHINE READY FOR ATTACHMENT…1592
LOCATIONS…1592
HYDRAULIC CIRCUIT…1595
ATTACHMENT OPERATIONS…1596
LONG TERM STORAGE…1597
SPECIFICATIONS…1597
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1598
CONTROL PATTERN CHANGE PROCEDURE…1598
MACHINE CONTROL PATTERNS…1599
ATTACHMENT GUIDE…1600
ATTACHMENT COMBINATIONS…1600
HANDLING ARM WITH BUILT-IN BREAKER…1601
REMOVING AND INSTALLING CHISEL…1601
PROCEDURE FOR BREAKER OPERATIONS…1604
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1605
INSTALLATION OF BUCKET…1606
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1608
STOWING CHISEL, DUMMY CHISEL…1608
CHECK BEFORE STARTING…1609
SPECIFICATIONS…1610
RECOMMENDED ATTACHMENT OPERATIONS…1611
HYDRAULIC BREAKER…1611
INDEX…1616
TEN00549-00 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1620
COVER…1620
FOREWORD…1621
FOREWORD…1622
SAFETY INFORMATION…1623
INTRODUCTION…1625
DIRECTIONS OF MACHINE…1625
PROTECTIVE STRUCTURE…1625
PRODUCT INFORMATION…1626
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1626
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1626
EPA NAMEPLATE…1627
SERVICE METER LOCATION…1627
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1628
CONTENTS…1629
SAFETY…1633
SAFETY…1634
SAFETY LABELS…1636
LOCATION OF SAFETY LABELS…1636
SAFETY LABELS…1637
GENERAL PRECAUTIONS…1642
SAFETY MACHINE OPERATION…1651
STARTING ENGINE…1651
OPERATION…1653
TRANSPORTATION…1659
BATTERY…1660
TOWING…1662
LIFTING OBJECTS WITH BUCKET…1663
SAFETY MAINTENANCE INFORMATION…1664
OPERATION…1673
MACHINE VIEW ILLUSTRATIONS…1674
OVERALL MACHINE VIEW…1674
CONTROLS AND GAUGES…1675
DETAILED CONTROLS AND GAUGES…1676
MONITORING SYSTEM…1676
SWITCHES…1682
CONTROL LEVERS AND PEDALS…1685
COVER WITH LOCK…1691
ENGINE REAR COVER…1692
COOLING COVER…1693
BATTERY COVER…1694
METHOD OF OPENING (TILTING) FLOOR…1695
AUXILIARY ELECTRIC POWER…1699
FUSE…1699
BLOCK FUSE…1700
OPERATION MANUAL STORAGE…1700
TOOL BOX…1701
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1702
MACHINE OPERATIONS AND CONTROLS…1703
BEFORE STARTING ENGINE…1703
STARTING ENGINE…1716
AFTER STARTING ENGINE…1720
STOPPING THE ENGINE…1723
MACHINE OPERATION…1724
STEERING THE MACHINE…1729
SWINGING…1731
WORK EQUIPMENT CONTROLS AND OPERATIONS…1732
PROHIBITED OPERATIONS…1735
GENERAL OPERATION INFORMATION…1737
TRAVELING ON SLOPES…1739
ESCAPE FROM MUD…1741
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1742
BUCKET REPLACEMENT…1744
PARKING MACHINE…1745
MACHINE INSPECTION AFTER DAILY WORK…1746
LOCKING…1747
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1748
TRANSPORTATION…1753
TRANSPORTATION PROCEDURE…1753
LOADING AND UNLOADING WITH TRAILER…1754
LIFTING MACHINE…1760
COLD WEATHER OPERATION…1763
COLD WEATHER OPERATION INFORMATION…1763
AFTER DAILY WORK COMPLETION…1765
AFTER COLD WEATHER SEASON…1765
LONG TERM STORAGE…1766
BEFORE STORAGE…1766
DURING STORAGE…1766
AFTER STORAGE…1766
TROUBLES AND ACTIONS…1767
RUNNING OUT OF FUEL…1767
PHENOMENA THAT ARE NOT FAILURES…1767
TOWING THE MACHINE…1768
SEVERE JOB CONDITION…1768
DISCHARGED BATTERY…1769
OTHER TROUBLE…1773
MAINTENANCE…1777
MAINTENANCE INFORMATION…1778
OUTLINE OF SERVICE…1780
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1780
ELECTRIC SYSTEM MAINTENANCE…1783
HANDLING HYDRAULIC SYSTEM…1784
WEAR PARTS…1785
WEAR PARTS LIST…1785
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1786
TIGHTENING TORQUE SPECIFICATIONS…1788
TIGHTENING TORQUE LIST…1788
SAFETY CRITICAL PARTS…1789
SAFETY CRITICAL PARTS LIST…1789
MAINTENANCE SCHEDULE…1790
MAINTENANCE SCHEDULE CHART…1790
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1791
MAINTENANCE PROCEDURE…1792
WHEN REQUIRED…1792
CHECK BEFORE STARTING…1814
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1814
EVERY 500 HOURS MAINTENANCE…1815
EVERY 1000 HOURS MAINTENANCE…1823
EVERY 1500 HOURS MAINTENANCE…1826
EVERY 2000 HOURS MAINTENANCE…1827
SPECIFICATIONS…1833
SPECIFICATIONS…1834
ATTACHMENTS, OPTIONS…1837
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1838
SAFETY FIRST…1838
ATTACHMENT INSTALLATION…1839
BUCKET WITH HOOK…1840
HOOK CONDITION…1840
PROHIBITED OPERATIONS…1840
MACHINE READY FOR ATTACHMENT…1841
LOCATIONS…1841
HYDRAULIC CIRCUIT…1844
ATTACHMENT OPERATIONS…1845
LONG TERM STORAGE…1846
SPECIFICATIONS…1846
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1847
CONTROL PATTERN CHANGE PROCEDURE…1847
MACHINE CONTROL PATTERNS…1848
ATTACHMENT GUIDE…1849
ATTACHMENT COMBINATIONS…1849
HANDLING ARM WITH BUILT-IN BREAKER…1850
REMOVING AND INSTALLING CHISEL…1850
PROCEDURE FOR BREAKER OPERATIONS…1853
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1854
INSTALLATION OF BUCKET…1855
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1857
STOWING CHISEL, DUMMY CHISEL…1857
CHECK BEFORE STARTING…1858
SPECIFICATIONS…1859
RECOMMENDED ATTACHMENT OPERATIONS…1860
HYDRAULIC BREAKER…1860
INDEX…1865

Komatsu Hydraulic Excavators PC18MR Repair Service Manual

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Hydraulic Excavator PC15MR Repair Service Manual (SEBM019002)

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC15MR-1, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC15MR-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.

SEAM044900T – Hydraulic Excavator PC15MRX-1 Operation & Maintenance Manual.pdf
SEBM019002 – Hydraulic Excavator PC15MR-1 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
COVER…1
CONTENTS…2
01 GENERAL…25
GENERAL ASSEMBLY DRAWING…26
SPECIFICATIONS…27
WEIGHT TABLE…30
LIST OF LUBRICANT AND WATER…32
10 STRUCTURE AND FUNCTION…34
SWING CIRCLE…35
TRACK FRAME, RECOIL SPRING…36
HYDRAULIC EQUIPMENT LAYOUT…37
HYDRAULIC TANK…38
HYDRAULIC PUMP…39
CONTROL VALVE…43
CLSS…51
CENTER SWIVEL JOINT…68
SWING MOTOR…70
TRAVEL MOTOR…72
VALVE CONTROL…78
PPC VALVE…79
PPC LOCK SOLENOID VALVE…83
TRAVEL 2-SPEED SELECTER VALVE…85
ELECTRIC WIRING DIAGRAM…86
MONITOR SYSTEM…88
20 TESTING AND ADJUSTING…91
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…92
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…93
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…101
TESTING AND ADJUSTING…103
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…104
MEASURING ENGINE SPEED…105
MEASURING EXHAUST COLOR…106
ADJUSTING VALVE CLEARANCE…107
MEASURING COMPRESSION PRESSURE…108
TESTING AND ADJUSTING FUEL INJECTION TIMING…109
MEASURING ENGINE OIL PRESSURE…110
TESTING AND ADJUSTING FAN BELT TENSION…111
ADJUSTING FUEL CONTROL LEVER…112
MEASURING SPROCKET WEAR…113
TESTING AND ADJUSTING TRACK SHOE TENSION…114
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…115
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE…117
ADJUSTING PC VALVE SPRING…119
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…120
TESTING PPC LOCK VALVE…121
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE…122
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…124
TESTING AND ADJUSTING TRAVEL DEVIATION…125
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER…126
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…127
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK…128
PRESSURIZING HYDRAULIC TANK…128
BLEEDING AIR…129
TROUBLESHOOTING…131
POINTS TO REMEMBER WHEN TROUBLESHOOTING…132
SEQUENCE OF EVENTS IN TROUBLESHOOTING…133
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…134
CHECKS BEFORE TROUBLESHOOTING…142
CONNECTOR TYPES AND MOUNTING LOCATIONS…143
CONNECTOR PIN ALLOCATION DRAWING…144
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…146
METHOD OF USING TROUBLESHOOTING CHARTS…156
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…158
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…159
E-1 ENGINE DOES NOT START…161
a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)…161
b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)…163
E-2 ENGINE DOES NOT STOP…165
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED…166
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED…168
E-5 TRAVEL ALARM DOES NOT SOUND…169
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…170
TABLE OF FAILURE MODES AND CAUSES…171
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…173
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…174
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…174
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…175
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…175
H-6 BOOM IS SLOW OR LACKS POWER…176
H-7 ARM IS SLOW OR LACKS POWER…176
H-8 BUCKET IS SLOW OR LACKS POWER…177
H-9 BOOM SWING IS SLOW OR LACKS POWER…177
H-10 BLADE IS SLOW OR LACKS POWER…178
H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL)…178
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE)…179
a) BOOM, BUCKET, BOOM SWING, BLADE…179
b) ARM…179
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…179
a) BOOM, ARM…179
b) BUCKET…179
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…180
H-15 TRAVEL DEVIATION…181
a) DEVIATION IN NORMAL TRAVEL…181
b) DEVIATION WHEN STARTING…181
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER…182
H-17 STEERING DOES NOT TURN EASILY…182
H-18 TRAVEL SPEED DOES NOT SWITCH…182
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…183
H-20 SWING SPEED IS SLOW OR LACKS POWER…183
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS…183
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY…183
H-21 DOES NOT SWING…184
a) DOES NOT SWING IN EITHER DIRECTION…184
b) DOES NOT SWING IN ONE DIRECTION ONLY…184
H-22 SWING ACCELERATION IS POOR…185
a) ACCELERATION IS POOR IN BOTH DIRECTIONS…185
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY…185
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…186
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS…186
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY…186
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY)…186
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…187
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…187
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…188
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS…189
M-1 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP SYSTEM…190
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON…190
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)…190
M-2 ABNORMALITY IN CHARGE CAUTION LAMP SYSTEM…192
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON…192
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (BATTERY CHARGE IS NORMAL)…192
M-3 ABNORMALITY IN ENGINE WATER TEMPERATURE CAUTION LAMP SYSTEM…194
a) LAMP DOES NOT STAY LIGHTED UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON…194
b) LAMP DOES NOT GO OUT AFTER STARTING SWITCH HAS BEEN AN ON FOR 3 SECONDS…194
c) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE WATER TEMPERATURE IS NORMAL)…195
M-4 ABNORMALITY IN PREHEATING PILOT LAMP…196
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO HEAT…196
b) LAMP DOES NOT GO OUT WHEN STARTING SWITCH IS AT HEAT AND PREHEATING TIME (APPROX. 18 SEC.) IS COMPLETED…196
c) LAMP LIGHTS UP WHEN STARTING SWITCH IS AT POSITION OTHER THAN HEAT…197
M-5 ABNORMALITY IN FUEL GAUGE SYSTEM…198
a) GAUGE DOES NOT GO UP FROM E WHEN FUEL IS ADDED TO FUEL TANK…198
b) GAUGE DOES NOT GO DOWN FROM F EVEN WHEN THERE IS NO FUEL IN FUEL TANK…198
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY…199
M-6 ABNORMALITY IN SERVICE METER SYSTEM…200
a) SERVICE METER DOES NOT ADVANCE WHEN STARTING SWITCH IS AT ON…200
b) SERVICE METER ADVANCES WHEN STARTING SWITCH IS AT OFF…200
c) PILOT LAMP DOES NOT FLASH WHEN SERVICE METER IS ADVANCING…200
M-7 ABNORMALITY IN NIGHT LIGHTING SYSTEM…202
a) NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON…202
b) NIGHT LIGHTING LIGHTS UP WHEN LAMP SWITCH IS TURNED OFF…202
30 DISASSEMBLY AND ASSEMBLY…204
METHOD OF USING MANUAL…205
PRECAUTIONS WHEN CARRYING OUT OPERATION…206
SPECIAL TOOL LIST…208
ENGINE AND HYDRAULIC PUMP…209
REMOVAL…209
INSTALLATION…213
CENTER SWIVEL JOINT…214
REMOVAL…214
INSTALLATION…214
DISASSEMBLY…215
ASSEMBLY…215
SWING MOTOR…216
REMOVAL…216
INSTALLATION…216
REVOLVING FRAME…217
REMOVAL…217
INSTALLATION…218
SWING CIRCLE…219
REMOVAL…219
INSTALLATION…219
IDLER…220
ASSEMBLY…220
TRACK ROLLER…221
ASSEMBLY…221
RUBBER SHOE…222
REMOVAL…222
INSTALLATION…222
CONTROL VALVE…223
DISASSEMBLY…223
ASSEMBLY…228
HYDRAULIC CYLINDER…235
ASSEMBLY…235
40 MAINTENANCE STANDARD…238
SWING CIRCLE…239
TRACK FRAME, RECOIL SPRING…240
IDLER…241
TRACK ROLLER…242
TRACK SHOE…243
HYDRAULIC PUMP…245
CONTROL VALVE…246
CENTER SWIVEL JOINT…250
SWING MOTOR…251
TRAVEL MOTOR…252
PPC VALVE…253
HYDRAULIC CYLINDER…254
WORK EQUIPMENT…255
90 OTHERS…257
HYDRAULIC CIRCUIT DIAGRAM (VARIABLE GAUGE TYPE)…258
HYDRAULIC CIRCUIT DIAGRAM (FIXED GAUGE TYPE)…259
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 10001-10634)…260
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 10635 AND UP)…261

COVER…1
FOREWORD…2
FOREWORD…3
SAFETY INFORMATION…6
INTRODUCTION…8
DIRECTIONS OF MACHINE…8
PRODUCT INFORMATION…9
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…9
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…9
EMISSION CONTROL INFORMATION LABEL…10
SERVICE METER LOCATION…10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…10
CONTENTS…11
SAFETY…15
SAFETY INFORMATION…16
POSITION FOR ATTACHING SAFETY LABELS…18
POSITION FOR ATTACHING SAFETY LABELS…19
SAFETY LABELS…20
SAFETY INFORMATION…24
SAFETY RULES…24
IF ABNORMALITIES ARE FOUND…24
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…24
FIRE EXTINGUISHER AND FIRST AID KIT…24
SAFETY EQUIPMENT…25
KEEP MACHINE CLEAN…25
KEEP OPERATOR'S COMPARTMENT CLEAN…25
LEAVING OPERATOR'S SEAT WITH LOCK…25
HANDRAILS AND STEPS…26
CRUSHING OR CUTTING PREVENTION…26
MOUNTING AND DISMOUNTING…27
NO PERSONS ON ATTACHMENTS…27
BURN PREVENTION…27
FIRE PREVENTION AND EXPLOSION PREVENTION…28
ACTION IF FIRE OCCURS…29
WINDSHIELD WASHER FLUID…29
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…29
ATTACHMENT INSTALLATION…29
ATTACHMENT COMBINATIONS…30
CAB WIDOW GLASSES…30
UNAUTHORIZED MODIFICATIONS…30
SAFETY AT JOBSITE…30
WORKING ON LOOSE GROUND…30
DISTANCE TO HIGH VOLTAGE CABLES…31
ENSURE GOOD VISIBILITY…31
VENTILATION FOR ENCLOSED AREA…32
SIGNALMAN'S SIGNAL AND SIGNS…32
ASBESTOS DUST HAZARD PREVENTION…32
SAFETY MACHINE OPERATION…33
STARTING ENGINE…33
CHECKS BEFORE STARTING ENGINE…33
SAFETY RULES FOR STARTING ENGINE…34
STARTING ENGINE IN COLD WEATHER…34
OPERATION…35
CHECKS AFTER STARTING ENGINE…35
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…35
SAFETY RULES FOR TRAVELING…36
TRAVELING ON SLOPES…37
OPERATIONS ON SLOPES…38
PROHIBITED OPERATIONS…38
OPERATIONS ON SNOW…40
PARKING MACHINE…40
TRANSPORTATION…41
LOADING AND UNLOADING…41
SHIPPING THE MACHINE…42
BATTERY…43
BATTERY HAZARD PREVENTION…43
STARTING ENGINE WITH BOOSTER CABLES…44
TOWING…45
SAFETY RULES FOR TOWING…45
LIFTING OBJECTS WITH BUCKET…46

Komatsu Hydraulic Excavator PC15MR Repair Service Manual (SEBM019002)

INSTANT DOWNLOAD

Posted on June 8, 2025 by admin

Komatsu Hydraulic Excavator PC12R, PC15R Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC12R-8, PC15R-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC12R-8, PC15R-8 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.

WEBM000100 – Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
WEBM000101 – Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
WEBM002800 – Hydraulic Excavator PC15R-8 Shop Manual.pdf
SEBM013103 – Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
SEAM015102T – Hydraulic Excavator PC12R-8, PC15R-8 Operation & Maintenance Manual.pdf
WEAM002702 – Hydraulic Excavator PC12R-8, PC12R-8 HS, PC15R-8, PC15R-8 HS Operation & Maintenance Manual.pdf
WEAM003000 – Hydraulic Excavator PC15R-8 Operation & Maintenance Manual.pdf
WEAM003001 – Hydraulic Excavator PC15R-8 Deluxe Operation & Maintenance Manual.pdf

Total Pages: 2,030 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
SEAM015102T – Hydraulic Excavator PC12R-8, PC15R-8 Operation & Maintenance Manual….2
COVER….2
1. FOREWORD….3
2. SAFETY INFORMATION….6
3. INTRODUCTION….7
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….8
5. CONTENTS….9
SAFETY….13
6. GENERAL PRECAUTIONS ….14
7. PRECAUTIONS DURING OPERATION….19
7.1 BEFORE STARTING ENGINE….19
7.2 AFTER STARTING ENGINE….21
7.3 TRANSPORTATION….28
7.4 BATTERY….29
7.5 TOWING….31
8. PRECAUTIONS FOR MAINTENANCE….32
8.1 BEFORE CARRYING OUT MAINTENANCE….32
8.2 DURING MAINTENANCE….36
9. POSITION FOR ATTACHING SAFETY LABELS….41
OPERATION….44
10. GENERAL VIEW ….45
10.1 GENERAL VIEW OF MACHINE….45
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….46
11. EXPLANATION OF COMPONENTS….47
11.1 MACHINE MONITOR….47
11.2 SWITCHES ….50
11.3 CONTROL LEVERS AND PEDALS….52
11.4 ENGINE HOOD….56
11.5 OPERATOR'S SEAT….57
11.6 MANUAL STORAGE SPACE・TOOL BOX….57
11.7 BATTERY HOOK….57
11.8 FRONT WINDOW (FOR MACHINE EQUIPPED WITH CAB (OPTION))….58
11.9 DOOR LOCK (FOR MACHINE EQUIPPED WITH CAB (OPTION))….60
11.10 HAMMER FOR EMERGENCY ESCAPE (FOR MACHINE EQUIPPED WITH CAB (OPTION))….61
11.11 CAP, COVER WITH LOCK….61
11.12 FUSE….63
11.13 FUSIBLE LINK….63
12. OPERATION….64
12.1 CHECK BEFORE STARTING ENGINE….64
12.2 STARTING ENGINE….71
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….74
12.4 MOVING MACHINE OFF….76
12.5 STEERING MACHINE….79
12.6 STOPPING MACHINE….81
12.7 SWINGING….82
12.8 OPERATION OF WORK EQUIPMENT….83
12.9 PROHIBITIONS FOR OPERATION….84
12.10 PRECAUTIONS FOR OPERATION….87
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….88
12.12 HOW TO ESCAPE FROM MUD….90
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….91
12.14 REPLACEMENT OF BUCKET….93
12.15 PARKING MACHINE….94
12.16 CHECK AFTER FINISHING WORK….95
12.17 STOPPING ENGINE….95
12.18 CHECK AFTER STOPPING ENGINE….96
12.19 LOCKING….96
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)….97
13. TRANSPORTATION….103
13.1 LOADING, UNLOADING WORK….103
13.2 PRECAUTIONS FOR LOADING….105
13.3 PRECAUTIONS FOR TRANSPORTATION….105
13.4 METHOD OF LIFTING MACHINE….106
14. COLD WEATHER OPERATION….107
14.1 PRECAUTIONS FOR LOW TEMPERATURE….107
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….109
14.3 AFTER COLD WEATHER….109
15. LONG-TERM STORAGE….110
15.1 BEFORE STORAGE….110
15.2 DURING STORAGE….111
15.3 AFTER STORAGE….111
16. TROUBLESHOOTING….112
16.1 PHENOMENA THAT ARE NOT FAILURES….112
16.2 METHOD OF TOWING MACHINE….112
16.3 IF BATTERY IS DISCHARGED….113
16.4 OTHER TROUBLE….118
MAINTENANCE….122
17. GUIDES TO MAINTENANCE….123
18. OUTLINES OF SERVICE….125
18.1 OUTLINE OF OIL,FUEL,COOLANT….125
18.2 OUTLINE OF ELECTRIC SYSTEM….128
18.3 OUTLINE OF HYDRAULIC SYSTEM….128
19. WEAR PARTS LIST….129
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….130
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….134
21.1 INTRODUCTION OF NECESSARY TOOLS….134
21.2 TORQUE LIST….135
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….136
23. MAINTENANCE SCHEDULE CHART….138
23.1 MAINTENANCE SCHEDULE CHART….138
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….140
24. SERVICE PROCEDURE….141
24.1 INITIAL 250 HOURS SERVICE….141
24.2 WHEN REQUIRED….142
24.3 CHECK BEFORE STARTING….160
24.4 EVERY 100 HOURS SERVICE….164
24.5 EVERY 250 HOURS SERVICE….165
24.6 EVERY 500 HOURS SERVICE….170
24.7 EVERY 1000 HOURS SERVICE….175
24.8 EVERY 2000 HOURS SERVICE….176
SPECIFICATIONS….179
25. SPECIFICATIONS….180
OPTIONS, ATTACHMENTS….186
26. GENERAL PRECAUTIONS….187
26.1 PRECAUTIONS RELATED TO SAFETY….187
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….188
27. USING SEAT BELT….189
27.1 SEAT BELT….189
28. HANDLING BUCKET WITH HOOK….191
28.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….191
28.2 PROHIBITED OPERATIONS….191
28.3 PRECAUTIONS DURING OPERATIONS….191
29. HANDLING 2-WAY PIPING….192
29.1 SWITCHING BETWEEN 1-WAY AND 2-WAY….192
29.2 OPERATING PEDAL….192
30. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS….193
30.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS….193
30.2 SELECTION OF TRACK SHOES (STEEL SHOE)….194
30.3 COMBINATIONS TABLE OF ATTACHMENTS….195
30.4 PRECAUTIONS FOR OPERATING WITH HYDRAULIC BREAKER….196
30.5 OPERATION OF QUICK BREAKER ARM….199
SEBM013103 – Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual….214
COVER….214
CONTENTS….215
SAFETY….218
00 FOREWORD….220
01 GENERAL….238
General assembly drawing….239
Specifications….243
List of lubricant and water….247
10 STRUCTURE AND FUNCTION….248
Power Train….249
Swing circle….250
Track frame and recoil spring….251
Hydraulic piping….252
Hydraulic tank….253
Hydraulic pump….254
Control valve (PC12R-8)….258
CLSS (PC12R-8)….266
Control valve (PC15R-8)….289
CLSS (PC15R-8)….297
Center swivel joint….318
Swing motor….320
Travel motor….322
Valve control….325
PPC valve….326
Work equipment….330
Machine monitor system….331
20 TESTING AND ADJUSTING….334
STANDARD VALUE TABLE….335
Standard value table for engine related parts….335
Standard value table for chassis related parts….337
Standard value table for electrical parts….351
TESTING AND ADJUSTING….353
Tools for testing, adjusting, and troubleshooting….354
Measuring engine speed….355
Measuring exhaust color….356
Adjusting valve clearance….357
Measuring compression pressure….358
Testing and adjusting fuel injection timing….359
Measuring engine oil pressure….360
Testing and adjusting fan belt tension….361
Testing and adjusting fuel control lever….362
Measuring sprocket wear….363
Testing and adjusting track shoe tension….364
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ….365
Testing and adjusting LS differential pressure….371
Adjusting PC valve spring….373
Testing and adjusting control circut pressure….374
Measuring output pressure of PPC lock valve and travel boost valve….376
Testing PPC valve output pressure and swing holding brake inlet port pressure….377
Adjusting work equipment, swing PPC valve ….379
Testing and adjusting travel deviation….380
Measuring oil leakage inside work equipment cylinder….381
Releasing remaining pressure from hydraulic circuit….382
Releasing remaining pressure from hydraulic tank ….382
Pressurizing hydraulic tank….382
Bleeding air….383
TROUBLESHOOTING….385
Type of connector and position of installation….386
Connection table for connector pin numbers ….389
Troubleshooting of engine electrical system (E mode)….399
E-Mode related electrical circuit diagram….400
E-1 Engine does not start….401
a) When starting motor does not turn (starting system)….401
b) When starting motor turns (engine stop solenoid system)….403
E-2 Engine does not stop….405
Troubleshooting of hydraulic, mechanical system (H mode)….406
Table of failure modes and causes….407
H- 1 Speeds of all work equipment, swing, travel are slow or lack power….411
H- 2 There is excessive drop in engine speed, or engine stalls….413
H- 3 No work equipment, travel, swing move….414
H- 4 Abnormal noise generated (from around pump)….415
H- 5 Fine control ability is poor or response is poor (PC15R)….415
H- 6 Boom is slow or lacks power….416
H- 7 Arm is slow or lacks power….416
H- 8 Bucket is slow or lacks power….417
H- 9 Boom swing is slow or lacks power….417
H-10 Blade is slow or lacks power….418
H-11 Boom, arm, bucket do not move (boom swing, blade, travel and swing are normal)….418
H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade)….419
a) Boom, bucket, boom swing, blade….419
b) Arm….419
H-13 Excessive time lag (engine at low idling)….419
a) Boom, arm….419
b) Bucket….419
H-14 In compound operations, work equipment with larger load is slow….420
H-15 Travel deviation….421
a) Deviation in normal travel….421
b) Deviation when starting….421
H-16 Travel speed is slow or lacks power….422
H-17 Steering does not turn easily….422
H-18 Travel speed does not switch….423
H-19 Travel does not move (one side only)….423
H-20 Swing speed is slow or lacks power….424
a) Speed is slow or lacks power in both directions….424
b) Speed is slow or lacks power in one direction only (left or right)….424
H-21 Does not swing….425
a) Does not swing in either direction….425
b) Does not swing in one direction (left or right)….425
H-22 Swing acceleration is poor….426
a) Acceleration is poor in both directions….426
b) Acceleration is poor in one direction only (left or right)….426
H-23 Excessive overrun when stopping swing….427
a) Overrun when stopping is excessive in both directions….427
b) Overrun when stopping is excessive in one direction only (left or right)….427
H-24 Excessive shock when stopping swing (in one direction only)….427
H-25 Excessive abnormal noise when stopping swing….428
H-26 Excessive hydraulic drift of swing….428
Troubleshooting of machine monitor system (M mode)….429
Electrical circuit diagram for M Mode related parts….430
M-1 Abnormality in engine oil pressure caution lamp system….431
a) Lamp does not light up when starting switch is turned ON….431
b) Lamp lights up when engine is running (engine oil pressure is normal)….431
M-2 Abnormality in charge caution lamp system….433
a) Lamp does not light up when starting switch is turned ON….433
b) Lamp lights up when engine is running (battery charge is normal)….433
M-3 Abnormality in engine water temperature caution lamp system….435
a) Lamp does not stay lighted up for 3 seconds when starting switch is turned ON….435
b) Lamp does not go out after starting switch has been at ON for 3 seconds….435
c) Lamp lights up when engine is running (engine water temperature is normal)….436
M-4 Abnormality in preheating pilot lamp….437
a) Lamp does not light up when starting switch is turned to HEAT….437
b) Lamp does not go out when starting switch is at HEAT and preheating time (approx. 18 sec.) is completed….437
c) Lamp lights up when starting switch is at position other than HEAT….438
M-5 Abnormality in fuel gauge system….439
a) Gauge does not go up from E when fuel is added to fuel tank….439
b) Gauge does not go down from F even when there is no fuel in fuel tank….439
c) Fuel level does not match gauge display….440
M-6 Abnormality in service meter system….441
a) Service meter does not advance when starting switch is at ON….441
b) Service meter advances when starting switch is at OFF….441
c) Pilot lamp does not flash when service meter is advancing….441
M-7 Abnormality in night lighting system….443
a) Night lighting does not light up when lamp switch is turned ON….443
b) Night lighting lights up when lamp switch is turned OFF ….443
30 DISASSEMBLY AND ASSEMBLY….445
Method of using manual….447
Precautions when carrying out operation….448
Special tool list….450
Starting motor….451
Removal and installation….451
Alternator ….452
Removal and installation….452
Fuel injection pump ….453
Removal and installation….453
Nozzle holder ….454
Removal and installation….454
Water pump ….455
Removal and installation….455
Thermostat ….456
Removal and installation….456
Engine front seal….457
Removal and installation….457
Engine rear seal….458
Removal….458
Installation….459
Cylinder head….460
Removal….460
Installation….461
Radiator….462
Removal….462
Installation….463
Engine, hydraulic pump….464
Removal….445
Installation….466
Fuel tank….467
Removal and installation….467
Damper….468
Removal and installation….468
Center swivel joint….469
Removal and installation….469
Disassembly and assembly….470
Travel motor….471
Removal and installation….471
Sprocket….472
Removal and installation….472
Swing motor….473
Removal and installation….473
Revolving frame….474
Removal….474
Installation….475
Swing circle….476
Removal and installation….476
Idler….477
Removal and installation….477
Disassembly….478
Assembly….479
Idler cushion (rubber shoe)….480
Removal and installation….480
Disassembly and assembly….481
Idler cushion (steel shoe)….482
Disassembly….445
Assembly….483
Track roller….484
Removal and installation….484
Disassembly and assembly….485
Rubber shoe….486
Removal and installation….486
Steel shoe….487
Removal and installation….487
Hydraulic tank….488
Removal….488
Installation….489
Hydraulic oil cooler….490
Removal and installation….490
Hydraulic pump….491
Removal and installation….491
Control valve….492
Removal….492
Installation….493
Disassembly….494
Assembly….499
PPC valve….506
Removal and installation….506
Disassembly….507
Assembly….508
Boom cylinder….509
Removal….509
Installation….510
Arm cylinder….511
Removal….511
Installation….512
Bucket cylinder….513
Removal….513
Installation….514
Swing cylinder….515
Removal….515
Installation….516
Blade cylinder….517
Removal and installation….517
Hydraulic cylinder….518
Disassembly….518
Assembly….521
Work equipment….525
Removal….525
Installation….526
Bucket….527
Removal and installation….527
Arm….528
Removal….528
Installation….529
Bucket, arm….530
Removal….530
Installation….531
Boom….532
Removal ….532
Installation….533
Swing bracket….534
Removal….534
Installation….535
Blade….536
Removal and installation….536
Canopy….537
Removal and installation….537
40 MAINTENANCE STANDARD….538
Swing circle….539
Track frame, recoil spring….540
Idler….541
Track roller….542
Track shoe….543
Hydraulic pump (PC15R-8)….545
Control valve (PC12R-8)….546
Control valve (PC15R-8)….552
Center swivel joint….558
Swing motor….559
PPC valve….560
Hydraulic cylinder….561
Work equipment….563
90 OTHERS….565
Hydraulic circuit diagram PC12R-8….566
Hydraulic circuit diagram PC15R-8….567
Electric circuit diagram PC12R,15R-8….568
WEAM002702 – Hydraulic Excavator PC12R-8, PC12R-8 HS, PC15R-8, PC15R-8 HS Operation & Maintenance Manual….569
1.1 FOREWORD….571
1.2 INFORMATION ON SAFETY….572
1.3 INTRODUCTION….574
1.3.1 INTENDED USES….574
1.3.2 IMPROPER OR UNAUTHORIZED USES….574
1.3.3 MAIN CHARACTERISTICS….575
1.3.4 RUNNING-IN….575
1.4 PRODUCT IDENTIFICATION….576
1.4.1 MACHINE SERIAL NUMBER….576
1.4.2 MACHINE IDENTIFICATION PLATE….576
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE….577
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER….577
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER….578
1.4.6 CAB SERIAL NUMBER….578
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS….579
TABLE OF CONTENTS….581
1.1 FOREWORD 1….581
1.2 INFORMATION ON SAFETY 2….581
1.3 INTRODUCTION 4….581
1.3.1 INTENDED USES 4….581
1.3.2 IMPROPER OR UNAUTHORIZED USES 4….581
1.3.3 MAIN CHARACTERISTICS 5….581
1.3.4 RUNNING-IN 5….581
1.4 PRODUCT IDENTIFICATION 6….581
1.4.1 MACHINE SERIAL NUMBER 6….581
1.4.2 MACHINE IDENTIFICATION PLATE 6….581
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE 7….581
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER 7….581
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER 8….581
1.4.6 CAB SERIAL NUMBER 8….581
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS 9….581
2.1 SAFETY, NOISE AND VIBRATION PLATES 20….581
2.1.1 POSITION OF THE SAFETY PLATES 20….581
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS 22….581
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB 26….581
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY 27….581
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 28….581
2.2 GENERAL PRECAUTIONS 29….581
2.2.1 GENERAL SAFETY RULES 29….581
2.2.2 SAFETY DEVICES AND GUARDS 29….581
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS 29….581
2.2.4 UNAUTHORIZED MODIFICATIONS 30….581
2.2.5 LEAVING THE OPERATOR’S SEAT 30….581
2.2.6 GETTING ON AND OFF THE MACHINE 31….581
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL 31….581
2.2.8 PREVENTING BURNS 32….581
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER 32….581
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 32….581
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT 33….581
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE 33….581
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT 33….581
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 34….581
2.3.1 SAFETY ON THE WORK SITE 34….581
2.3.2 FIRE PREVENTION 34….581
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB 34….581
2.3.4 ROOM VENTILATION 35….581
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS 35….581
2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES 35….581
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 36….582
2.4.1 STARTING THE ENGINE 36….582
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE 36….582
2.4.3 CHECKS FOR TRAVELLING IN REVERSE 36….582
2.4.4 MOVING THE MACHINE 37….582
2.4.5 MOVING ON SLOPES 38….582
2.4.6 WORKING ON SLOPES 39….582
2.4.7 UNAUTHORIZED OPERATIONS 39….582
2.4.8 PREVENTING ELECTROCUTION 40….582
2.4.9 VISIBILITY 41….582
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES 41….582
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 41….582
2.4.12 WORKING ON LOOSE GROUND 41….582
2.4.13 PARKING THE MACHINE 42….582
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 43….582
2.5.1 LOADING AND UNLOADING 43….582
2.5.2 TRANSPORT 43….582
2.6 BATTERY 44….582
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY 44….582
2.6.2 STARTING WITH BOOSTER CABLES 44….582
2.7 PRECAUTIONS FOR THE REMOVAL 45….582
2.8 PRECAUTIONS FOR MAINTENANCE 46….582
2.8.1 WARNING PLATES 46….582
2.8.2 TOOLS 46….582
2.8.3 PERSONNEL 46….582
2.8.4 EQUIPMENT 47….582
2.8.5 WORKING UNDER THE MACHINE 47….582
2.8.6 CLEANING THE MACHINE 47….582
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS 48….582
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 48….582
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 48….582
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP 49….582
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR 49….582
2.8.12 USING LAMPS 49….582
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR 50….582
2.8.14 PRECAUTIONS CONCERNING THE STARTER 50….582
2.8.15 HANDLING HIGH-PRESSURE PIPES 51….582
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL 51….582
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE 51….582
2.8.18 COOLING FAN AND BELT 52….582
2.8.19 WASTE MATERIALS 52….582
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES 52….582
3.1 SAFETY LOCKS 54….583
3.1.1 MACHINE LOCKS 54….583
3.2 GENERAL VIEWS 55….583
3.2.1 FRONT GENERAL VIEW 55….583
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY 56….583
3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT 57….583
3.3 INSTRUMENTS AND CONTROLS 58….583
3.3.1 INSTRUMENTS 58….583
3.3.2 WARNING LIGHTS 59….583
3.3.3 SWITCHES AND PUSH BUTTONS 61….583
3.3.4 ELECTRICAL ACCESSORIES 64….583
3.3.5 MACHINE CONTROLS 66….583
3.4 FUSES AND RELAYS 75….583
3.4.1 FUSES 75….583
3.4.2 RELAYS 76….583
3.5 GUARDS AND DRIVER’S SEAT 77….583
3.5.1 ENGINE HOOD 77….583
3.5.2 CANOPY 78….583
3.5.3 CAB 78….583
3.5.3.1 SLIDING DOOR 79….583
3.5.3.2 FRONT OPENING WINDSHIELD 80….583
3.5.3.3 FRONT WINDSHIELD (LOWER PART) 81….583
3.5.3.4 SIDE OPENING WINDOW 82….583
3.5.4 VENTILATION AND HEATING 83….583
3.5.5 SEAT 83….583
3.5.6 SAFETY BELT 84….583
3.5.7 EMERGENCY EXIT 84….583
3.5.8 TECHNICAL DOCUMENTATION CASE 85….583
3.5.9 FIRE EXTINGUISHER 85….583
3.5.10 FIRST AID KIT 85….583
3.6 USE OF THE MACHINE 87….583
3.6.1 CHECKS BEFORE STARTING THE ENGINE 87….583
3.6.1.1 VISUAL CHECKS 87….583
3.6.1.2 DAILY CHECKS 87….583
3.6.1.3 OPERATIONAL CHECKS 88….583
3.6.2 STARTING THE ENGINE 89….583
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES 89….583
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES 90….583
3.6.3 WARMING THE ENGINE 91….583
3.6.4 HEATING THE HYDRAULIC OIL 91….583
3.6.5 HOW TO MOVE THE MACHINE 91….583
3.6.5.1 STEERING (CHANGING DIRECTION) 93….583
3.6.5.2 MOVING ON SLOPES 94….583
3.6.5.3 MAXIMUM IMMERSION DEPTH 95….583
3.7 PARKING THE MACHINE 96….584
3.7.1 PARKING ON LEVEL GROUND 96….584
3.7.2 PARKING ON SLOPES 97….584
3.8 STOPPING THE ENGINE 98….584
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 99….584
3.9.1 LOADING AND UNLOADING THE MACHINE 99….584
3.9.2 TRANSPORT 100….584
3.10 LIFTING THE MACHINE 101….584
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 102….584
3.11.1 FUEL AND LUBRICANTS 102….584
3.11.2 COOLANT 102….584
3.11.3 BATTERY 102….584
3.11.4 OTHER PRECAUTIONS 103….584
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK 103….584
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 104….584
3.13 USING THE WORK EQUIPMENT 105….584
3.13.1 ORGANIZING THE WORK AREA 105….584
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS 106….584
3.13.3 DIGGING METHOD 107….584
3.13.4 CHANGING THE BUCKET 108….584
3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE 109….584
3.14.1 HOW TO USE THE VARIABLE TRACK GAUGE 109….584
3.14.2 ADJUSTING THE BLADE 110….584
3.15 LONG PERIODS OF INACTIVITY 111….584
3.15.1 BEFORE THE PERIOD OF INACTIVITY 111….584
3.15.2 DURING THE PERIOD OF INACTIVITY 112….584
3.15.3 AFTER THE PERIOD OF INACTIVITY 112….584
3.16 TROUBLESHOOTING 113….584
3.16.1 OCCURRENCES THAT ARE NOT FAILURES 113….584
3.16.2 HOW TO REMOVE THE MACHINE 113….584
3.16.3 AFTER THE FUEL HAS RUN OUT 114….584
3.16.4 IF THE BATTERY IS DOWN 114….584
3.16.4.1 STARTING WITH BOOSTER CABLES 115….584
3.16.5 OTHER TROUBLES 116….584
3.16.5.1 ELECTRICAL CIRCUIT 116….584
3.16.5.2 HYDRAULIC SYSTEM 116….584
3.16.5.3 ENGINE 117….584
4.1 GUIDE TO MAINTENANCE 120….585
4.2 MAINTENANCE NOTES 122….585
4.2.1 NOTES REGARDING THE ENGINE 122….585
4.2.1.1 ENGINE OIL 122….585
4.2.1.2 COOLANT 122….585
4.2.1.3 FUEL 123….585
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM 123….585
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM 124….585
4.2.4 NOTES REGARDING LUBRICATION 124….585
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING 125….585
4.3 FUEL, COOLANT AND LUBRICANTS 126….585
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS 128….585
4.4 DRIVING TORQUES FOR SCREWS AND NUTS 129….585
4.4.1 STANDARD DRIVING TORQUES 129….585
4.4.2 SPECIFIC DRIVING TORQUES 129….585
4.5 LUBRICATION 130….585
4.5.1 LUBRICATION DIAGRAM PC12R 130….585
4.5.2 LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE) 131….585
4.5.3 LUBRICATION DIAGRAM PC15R 132….585
4.5.4 LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE) 133….585
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 134….585
4.6.1 CRITICAL PARTS FOR SAFETY 135….585
4.7 MAINTENANCE PLAN 138….585
4.7.1 WHEN REQUIRED 141….585
4.7.1.a WASHING THE COOLING CIRCUIT 141….585
4.7.1.b DRAINING THE FUEL TANK 142….585
4.7.1.c CHECKING THE ELECTRICAL SYSTEM 142….585
4.7.1.d CHECKING THE STEEL TRACK TENSION 143….585
4.7.1.e CHECKING THE RUBBER TRACKS 145….585
4.7.1.f CHECKING THE RUBBER TRACK TENSION 147….585
4.7.1.g CHANGING THE RUBBER TRACK 149….585
4.7.1.h LUBRICATING THE ARTICULATIONS 151….585
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER) 152….585
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER 152….585
4.7.2.b CHANGING THE HYDRAULIC OIL 152….585
4.7.3 CHECKS BEFORE STARTING 153….585
4.7.3.a VARIOUS CHECKS 153….585
4.7.3.b CHECKING THE COOLANT LEVEL 153….585
4.7.3.c CHECKING THE FUEL LEVEL 154….585
4.7.3.d CHECKING THE ENGINE OIL LEVEL 154….585
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT 155….585
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…..585
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION 157….586
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING 157….586
4.7.5.b LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (PC12R HS – PC15R HS) 159….586
4.7.5.c CLEANING THE AIR CLEANER CARTRIDGE 160….586
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION 161….586
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION 161….586
4.7.7.a ADJUSTING THE FAN BELT TENSION 161….586
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL 162….586
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS 163….586
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER 164….586
4.7.7.e CHANGING THE ENGINE OIL 165….586
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…..586
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION 166….586
4.7.9.a CHANGING THE ENGINE OIL FILTER 166….586
4.7.9.b CHANGING THE FUEL FILTER 167….586
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER 168….586
4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE 169….586
4.7.9.e CLEANING THE OUTSIDE OF THE RADIATORS 169….586
4.7.9.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o…..586
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION 171….586
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS 171….586
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION 172….586
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER 172….586
4.7.11.b CHANGING THE COOLANT 174….586
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE 174….586
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER 174….586
5.1 TECHNICAL DATA 176….586
5.1.1 STANDARD OVERALL DIMENSIONS PC12R 176….586
5.1.2 TECHNICAL CHARACTERISTICS PC12R 177….586
5.1.3 STANDARD OVERALL DIMENSIONS PC12R HS (VARIABLE TRACK GAUGE) 178….586
5.1.4 TECHNICAL CHARACTERISTICS PC12R HS (VARIABLE TRACK GAUGE) 179….586
5.1.5 STANDARD OVERALL DIMENSIONS PC15R 180….586
5.1.6 TECHNICAL CHARACTERISTICS PC15R 181….586
5.1.7 STANDARD OVERALL DIMENSIONS PC15R HS (VARIABLE TRACK GAUGE) 182….586
5.1.8 TECHNICAL CHARACTERISTICS PC15R HS (VARIABLE TRACK GAUGE) 183….586
5.1.9 LIFTING CAPACITY WITH RAISED BLADE PC12R 184….586
5.1.10 LIFTING CAPACITY WITH LOWERED BLADE PC12R 185….586
5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) 186….587
5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) 187….587
5.1.13 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) 188….587
5.1.14 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) 189….587
5.1.15 LIFTING CAPACITY WITH RAISED BLADE PC15R 190….587
5.1.16 LIFTING CAPACITY LOWERED BLADE PC15R 191….587
5.1.17 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED) 192….587
5.1.18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED) 193….587
5.1.19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED) 194….587
5.1.20 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED) 195….587
6.1 AUTHORIZED OPTIONAL EQUIPMENT 198….587
6.1.1 PRECAUTIONS REGARDING SAFETY 198….587
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT 199….587
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT 200….587
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 201….587
6.2.1 DESCRIPTION AND CONTROL 201….587
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED 201….587
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 205….587
6.2.3.1 INSTALLING THE HAMMER 205….587
6.2.3.2 REMOVING THE HAMMER 206….587
6.2.4 MAINTENANCE 206….587
2.1 SAFETY, NOISE AND VIBRATION PLATES….590
2.1.1 POSITION OF THE SAFETY PLATES….590
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS….592
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB….596
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY….597
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED….598
2.2 GENERAL PRECAUTIONS….599
2.2.1 GENERAL SAFETY RULES….599
2.2.2 SAFETY DEVICES AND GUARDS….599
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS….599
2.2.4 UNAUTHORIZED MODIFICATIONS….600
2.2.5 LEAVING THE OPERATOR’S SEAT….600
2.2.6 GETTING ON AND OFF THE MACHINE….601
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL….601
2.2.8 PREVENTING BURNS….602
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER….602
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….602
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT….603
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE….603
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT….603
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….604
2.3.1 SAFETY ON THE WORK SITE….604
2.3.2 FIRE PREVENTION….604
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB….604
2.3.4 ROOM VENTILATION….605
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS….605
2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES….605
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING….606
2.4.1 STARTING THE ENGINE….606
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE….606
2.4.3 CHECKS FOR TRAVELLING IN REVERSE….606
2.4.4 MOVING THE MACHINE….607
2.4.5 MOVING ON SLOPES….608
2.4.6 WORKING ON SLOPES….609
2.4.7 UNAUTHORIZED OPERATIONS….609
2.4.8 PREVENTING ELECTROCUTION….610
2.4.9 VISIBILITY….611
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES….611
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….611
2.4.12 WORKING ON LOOSE GROUND….611
2.4.13 PARKING THE MACHINE….612
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES….613
2.5.1 LOADING AND UNLOADING….613
2.5.2 TRANSPORT….613
2.6 BATTERY….614
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY….614
2.6.2 STARTING WITH BOOSTER CABLES….614
2.7 PRECAUTIONS FOR THE REMOVAL….615
2.8 PRECAUTIONS FOR MAINTENANCE….616
2.8.1 WARNING PLATES….616
2.8.2 TOOLS….616
2.8.3 PERSONNEL….616
2.8.4 EQUIPMENT….617
2.8.5 WORKING UNDER THE MACHINE….617
2.8.6 CLEANING THE MACHINE….617
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS….618
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY….618
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION….618
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP….619
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR….619
2.8.12 USING LAMPS….619
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR….620
2.8.14 PRECAUTIONS CONCERNING THE STARTER….620
2.8.15 HANDLING HIGH-PRESSURE PIPES….621
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL….621
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE….621
2.8.18 COOLING FAN AND BELT….622
2.8.19 WASTE MATERIALS….622
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES….622
3.1 SAFETY LOCKS….624
3.1.1 MACHINE LOCKS….624
3.2 GENERAL VIEWS….625
3.2.1 FRONT GENERAL VIEW….625
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY….626
3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT….627
3.3 INSTRUMENTS AND CONTROLS….628
3.3.1 INSTRUMENTS….628
3.3.2 WARNING LIGHTS….629
3.3.3 SWITCHES AND PUSH BUTTONS….631
3.3.4 ELECTRICAL ACCESSORIES….634
3.3.5 MACHINE CONTROLS….636
A – (STANDARD PEDAL)….643
B – (OPTIONAL PEDAL)….643
3.4 FUSES AND RELAYS….645
3.4.1 FUSES….645
3.4.2 RELAYS….646
3.5 GUARDS AND DRIVER’S SEAT….647
3.5.1 ENGINE HOOD….647
3.5.2 CANOPY….648
3.5.3 CAB….648
3.5.3.1 SLIDING DOOR….649
3.5.3.2 FRONT OPENING WINDSHIELD….650
3.5.3.3 FRONT WINDSHIELD (LOWER PART)….651
3.5.3.4 SIDE OPENING WINDOW….652
3.5.4 VENTILATION AND HEATING….653
3.5.5 SEAT….653
3.5.6 SAFETY BELT….654
3.5.7 EMERGENCY EXIT….654
3.5.8 TECHNICAL DOCUMENTATION CASE….655
3.5.9 FIRE EXTINGUISHER….655
3.5.10 FIRST AID KIT….655
3.6 USE OF THE MACHINE….657
3.6.1 CHECKS BEFORE STARTING THE ENGINE….657
3.6.1.1 VISUAL CHECKS….657
3.6.1.2 DAILY CHECKS….657
3.6.1.3 OPERATIONAL CHECKS….658
3.6.2 STARTING THE ENGINE….659
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES….659
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES….660
3.6.3 WARMING THE ENGINE….661
3.6.4 HEATING THE HYDRAULIC OIL….661
3.6.5 HOW TO MOVE THE MACHINE….661
3.6.5.1 STEERING (CHANGING DIRECTION)….663
CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING….663
CHANGING DIRECTION WHEN THE MACHINE IS MOVING (the left and right travel levers are in the same p…..663
HOW TO CARRY OUT A COUNTER-ROTATION (with the machine not moving)….663
3.6.5.2 MOVING ON SLOPES….664
3.6.5.3 MAXIMUM IMMERSION DEPTH….665
3.7 PARKING THE MACHINE….666
3.7.1 PARKING ON LEVEL GROUND….666
3.7.2 PARKING ON SLOPES….667
3.8 STOPPING THE ENGINE….668
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES….669
3.9.1 LOADING AND UNLOADING THE MACHINE….669
3.9.2 TRANSPORT….670
3.10 LIFTING THE MACHINE….671
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON….672
3.11.1 FUEL AND LUBRICANTS….672
3.11.2 COOLANT….672
3.11.3 BATTERY….672
3.11.4 OTHER PRECAUTIONS….673
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK….673
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON….674
3.13 USING THE WORK EQUIPMENT….675
3.13.1 ORGANIZING THE WORK AREA….675
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS….676
3.13.3 DIGGING METHOD….677
3.13.4 CHANGING THE BUCKET….678
3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE….679
3.14.1 HOW TO USE THE VARIABLE TRACK GAUGE….679
3.14.2 ADJUSTING THE BLADE….680
3.15 LONG PERIODS OF INACTIVITY….681
3.15.1 BEFORE THE PERIOD OF INACTIVITY….681
3.15.2 DURING THE PERIOD OF INACTIVITY….682
3.15.3 AFTER THE PERIOD OF INACTIVITY….682
3.16 TROUBLESHOOTING….683
3.16.1 OCCURRENCES THAT ARE NOT FAILURES….683
3.16.2 HOW TO REMOVE THE MACHINE….683
3.16.3 AFTER THE FUEL HAS RUN OUT….684
3.16.4 IF THE BATTERY IS DOWN….684
3.16.4.1 STARTING WITH BOOSTER CABLES….685
3.16.5 OTHER TROUBLES….686
3.16.5.1 ELECTRICAL CIRCUIT….686
3.16.5.2 HYDRAULIC SYSTEM….686
3.16.5.3 ENGINE….687
4.1 GUIDE TO MAINTENANCE….690
4.2 MAINTENANCE NOTES….692
4.2.1 NOTES REGARDING THE ENGINE….692
4.2.1.1 ENGINE OIL….692
4.2.1.2 COOLANT….692
4.2.1.3 FUEL….693
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM….693
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM….694
4.2.4 NOTES REGARDING LUBRICATION….694
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING….695
4.3 FUEL, COOLANT AND LUBRICANTS….696
LUBRICATION WITH GREASE….696
4.4 DRIVING TORQUES FOR SCREWS AND NUTS….699
4.4.1 STANDARD DRIVING TORQUES….699
4.4.2 SPECIFIC DRIVING TORQUES….699
4.5 LUBRICATION….700
4.5.1 LUBRICATION DIAGRAM PC12R….700
4.5.2 LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE)….701
4.5.3 LUBRICATION DIAGRAM PC15R….702
4.5.4 LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE)….703
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY….704
4.7 MAINTENANCE PLAN….708
4.7.1 WHEN REQUIRED….711
4.7.1.a WASHING THE COOLING CIRCUIT….711
4.7.1.b DRAINING THE FUEL TANK….712
4.7.1.c CHECKING THE ELECTRICAL SYSTEM….712
4.7.1.d CHECKING THE STEEL TRACK TENSION….713
4.7.1.e CHECKING THE RUBBER TRACKS….715
4.7.1.f CHECKING THE RUBBER TRACK TENSION….717
4.7.1.g CHANGING THE RUBBER TRACK….719
4.7.1.h LUBRICATING THE ARTICULATIONS….721
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)….722
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER….722
4.7.2.b CHANGING THE HYDRAULIC OIL….722
4.7.3 CHECKS BEFORE STARTING….723
4.7.3.a VARIOUS CHECKS….723
4.7.3.b CHECKING THE COOLANT LEVEL….723
4.7.3.c CHECKING THE FUEL LEVEL….724
4.7.3.d CHECKING THE ENGINE OIL LEVEL….724
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT….725
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…..726
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION….727
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING….727
4.7.5.b LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (PC12R HS – PC15R HS)….729
4.7.5.c CLEANING THE AIR CLEANER CARTRIDGE….730
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION….731
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION….731
4.7.7.a ADJUSTING THE FAN BELT TENSION….731
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL….732
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS….733
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER….734
4.7.7.e CHANGING THE ENGINE OIL….735
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…..736
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION….736
4.7.9.a CHANGING THE ENGINE OIL FILTER….736
4.7.9.b CHANGING THE FUEL FILTER….737
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER….738
4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE….739
4.7.9.e CLEANING THE OUTSIDE OF THE RADIATORS….739
4.7.9.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o…..740
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION….741
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS….741
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION….742
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER….742
4.7.11.b CHANGING THE COOLANT….744
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE….744
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER….744
5.1 TECHNICAL DATA….746
5.1.1 STANDARD OVERALL DIMENSIONS PC12R….746
WITH CAB….746
WITH CANOPY….746
5.1.2 TECHNICAL CHARACTERISTICS PC12R….747
5.1.3 STANDARD OVERALL DIMENSIONS PC12R HS (VARIABLE TRACK GAUGE)….748
WITH CAB….748
WITH CANOPY….748
5.1.4 TECHNICAL CHARACTERISTICS PC12R HS (VARIABLE TRACK GAUGE)….749
5.1.5 STANDARD OVERALL DIMENSIONS PC15R….750
WITH CAB….750
WITH CANOPY….750
5.1.6 TECHNICAL CHARACTERISTICS PC15R….751
5.1.7 STANDARD OVERALL DIMENSIONS PC15R HS (VARIABLE TRACK GAUGE)….752
WITH CAB….752
WITH CANOPY….752
5.1.8 TECHNICAL CHARACTERISTICS PC15R HS (VARIABLE TRACK GAUGE)….753
5.1.9 LIFTING CAPACITY WITH RAISED BLADE PC12R….754
5.1.10 LIFTING CAPACITY WITH LOWERED BLADE PC12R….755
5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED)….756
5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED)….757
5.1.13 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED)….758
5.1.14 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED)….759
5.1.15 LIFTING CAPACITY WITH RAISED BLADE PC15R….760
5.1.16 LIFTING CAPACITY LOWERED BLADE PC15R….761
5.1.17 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED)….762
5.1.18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED)….763
5.1.19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED)….764
5.1.20 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED)….765
6.1 AUTHORIZED OPTIONAL EQUIPMENT….768
6.1.1 PRECAUTIONS REGARDING SAFETY….768
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT….769
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT….770
(PC12R-PC12R HS)….770
(PC15R-PC15R HS)….770
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)….771
6.2.1 DESCRIPTION AND CONTROL….771
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED….771
FOR A CORRECT USE, IT IS NECESSARY TO:….771
ALWAYS AVOID THE FOLLOWING INCORRECT USES:….773
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER….775
6.2.3.1 INSTALLING THE HAMMER….775
6.2.3.2 REMOVING THE HAMMER….776
6.2.4 MAINTENANCE….776
WEAM003000 – Hydraulic Excavator PC15R-8 Operation & Maintenance Manual….777
COVER….777
CONTENTS….787
1.1 FOREW0RD….778
1.2 INFORMATION ON SAFETY….779
1.3 INTRODUCTION….781
1.3.1 INTENDED USES….781
1.3.2 IMPROPER OR UNAUTHORIZED USES….781
1.3.3 MAIN CHARACTERISTICS….782
1.3.4 RUNNING-IN….782
1.4 PRODUCT IDENTIFICATION….783
1.4.1 MACHINE SERIAL NUMBER….783
1.4.2 MACHINE IDENTIFICATION PLATE….783
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL….784
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER….784
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER….784
1.4.6 CAB SERIAL NUMBER….785
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS….786
SAFETY AND ACCIDENT PREVENTION….794
2.1 SAFETY PLATES….795
2.1.1 POSITION OF THE SAFETY PLATES….795
2.1.2 POSITION OF THE PICTOGRAMS….810
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS….812
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED….814
2.2 GENERAL PRECAUTIONS….815
2.2.1 GENERAL SAFETY RULES….815
2.2.2 SAFETY DEVICES AND GUARDS….815
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS….815
2.2.4 UNAUTHORIZED MODIFICATIONS….816
2.2.5 LEAVING THE OPERATOR'S SEAT….816
2.2.6 GETTING ON AND OFF THE MACHINE ….817
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL….817
2.2.8 PREVENTING BURNS….818
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWER….818
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….818
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT….819
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE….819
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT….819
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….820
2.3.1 SAFETY ON THE WORK SITE….820
2.3.2 FIRE PREVENTION….820
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB….820
2.3.4 ROOM VENTILATION….821
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS….821
2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES….821
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING….822
2.4.1 STARTING THE ENGINE….822
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE….822
2.4.3 CHECKS FOR TRAVELING IN REVERSE….822
2.4.4 MOVING THE MACHINE….823
2.4.5 MOVING THE SLOPES….824
2.4.6 WORKING THE SLOPES….825
2.4.7 UNAUTHORIZED OPERATIONS….825
2.4.8 PREVENTING ELECTROCUTION….826
2.4.9 VISIBILITY….827
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES….827
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….827
2.4.12 WORKING ON LOOSE GROUND….827
2.4.13 PARKING THE MACHINE….828
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES….829
2.5.1 LOADING AND UNLOADING….829
2.5.2 TRANSPORT….829
2.6 BATTERY….830
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY….830
2.6.2 STARTING WITH BOOSTER CABLES….830
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY….831
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE….832
2.8.1 WARNING PLATES….832
2.8.2 TOOLS….832
2.8.3 PERSONNEL….833
2.8.4 EQUIPMENT….833
2.8.5 WORKING UNDER THE MACHINE….833
2.8.6 CLEANING THE MACHINE….833
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS….834
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY….834
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION….834
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP….835
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR….835
2.8.12 USING LAMPS….835
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR….836
2.8.14 PRECAUTIONS CONCERNING THE STARTER….836
2.8.15 HANDLING HIGH-PRESSURE PIPES….837
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH PRESSURE OIL….837
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE….837
2.8.18 COOLING FAN AND BELT….838
2.8.19 WASTE MATERIALS….838
THE MACHINE AND ITS OPERATIONS….840
3.1 SAFETY LOCKS….841
3.1.1 MACHINE LOCKS….841
3.2 GENERAL VIEWS….842
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB (OPTIONAL)….842
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY….843
3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT….844
3.3. INSTRUMENTS AND CONTROLS….845
3.3.1 INSTRUMENTS….845
3.3.2 WARNINGS LIGHTS….846
3.3.3 SWITCHES AND PUSH BUTTONS….848
3.3.4 ELECTRICAL ACCESSORIES….851
3.3.5 MACHINE CONTROLS….853
3.4 FUSES AND RELAYS….862
3.4.1 FUSES….862
3.4.2 RELAYS….863
3.5 GUARDS AND DRIVER'S SEAT….864
3.5.1 ENGINE HOOD….864
3.5.2 CANOPY….865
3.5.3 CAB (OPTIONAL)….865
3.5.3.1 SLIDING DOOR….866
3.5.3.2 FRONT OPENING WINDSHEILD….867
3.5.3.3 FRONT WINDSHEILD (LOWER PART)….868
3.5.3.4 SIDE OPENING WINDOW….869
3.5.4 VENTILATION AND HEATING (ONLY ON MACHINES WITH CAB)….870
3.5.5 SEAT….870
3.5.6 SAFETY BELT….871
3.5.7 EMERGENCY EXIT (ONLY ON MACHINES WITH CAB)….871
3.5.8 TECHNICAL DOCUMENTATION CASE….872
3.5.9 FIRE EXTINGUISHER….872
3.5.10 FIRST AID KIT….872
3.6 USE OF THE MACHINE….874
3.6.1 CHECKS BEFORE STARTING THE ENGINE….874
3.6.1.1 VISUAL CHECKS….874
3.6.1.2 DAILY CHECKS….874
3.6.1.3 OPERATIONAL CHECKS….875
3.6.2 STARTING THE ENGINE….876
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES….876
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES….877
3.6.3 WARMING THE ENGINE….878
3.6.4 HEATING THE HYDRAULIC OIL….878
3.6.5 HOW TO MOVE THE MACHINE….878
3.6.5.1 STEERING (CHANGING DIRECTION)….880
3.6.5.2 MOVING ON SLOPES….881
3.6.5.3 MAXIMUM IMMERSION DEPTH….882
3.7 PARKING THE MACHINE….883
3.7.1 PARKING ON LEVEL GROUND….883
3.7.2 PARKING ON SLOPES….884
3.8 STOPPING THE ENGINE….885
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES….886
3.9.1 LOADING AND UNLOADING THE MACHINE….886
3.9.2 TRANSPORT….887
3.10 LIFTING THE MACHINE….888
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON….889
3.11.1 FUEL AND LUBRICANTS….889
3.11.2 COOLANT….889
3.11.3 BATTERY….889
3.11.4 OTHER PRECAUTIONS….890
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF THE END OF WORK….890
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON….891
3.13 USING THE WORK EQUIPMENT….892
3.13.1 ORGANIZING THE WORK AREA….892
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS….893
3.13.3 DIGGING METHOD….894
3.13.4 CHANING THE BUCKET….895
3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE….896
3.14.1 HOW TO SEE THE VARIABLE TRACK GAUGE….896
3.14.2 ADJUSTING THE BLADE….897
3.15 LONG PERIODS OF INACTIVITY….898
3.15.1 BEFORE THE PERIOD OF INACTIVITY….898
3.15.2 DURING THE PERIOD OF INACTIVITY….899
3.15.3 AFTER THE PERIOD OF INACTIVITY….899
3.16 TROUBLESHOOTING….900
3.16.1 OCCURRENCES THAT ARE NOT FAILURES….900
3.16.2 HOW TO REMOVE THE MACHINE….900
3.16.3 AFTER THE FUEL HAS RUN OUT….901
3.16.4 IF THE BATTERY IS DOWN….901
3.16.4.1 STARTING WITH BOOSTER CABLES….902
3.16.5 OTHER TROUBLES….903
3.16.5.1 ELECTRICAL CIRCUT….903
3.16.5.2 HYDRAULIC SYSTEM….903
3.16.5.3 ENGINE….904
MAINTENANCE….906
4.1 GUIDE TO MAINTENANCE….907
4.2 MAINTENANCE NOTES….909
4.2.1 NOTES REGARDING THE ENGINE….909
4.2.1.1 ENGINE OIL….909
4.2.1.2 COOLANT….909
4.2.1.3 FUEL….910
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM….910
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM….911
4.2.4 NOTES REGARDING LUBRICATION….911
4.2.5 PARTS SUJECT TO WEAR THAT PERIODICALLY NEED CHANGING….912
4.3 FUEL, COOLANT AND LUBRICANTS….913
4.4 NUT AND BOLT TIGHTEN TOU….917
4.4.1 STANDARD TIGHTENING TORQUES….917
4.4.2 SPECIFIC TIGHTENING TORQUES….917
4.5 LUBRICATION….918
4.5.1 LUBRICATION DIAGRAM….918
4.5.2 LUBRICATION DIAGRAM (VARIABLE TRACK GAUGE)….919
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY….920
4.6.1 CRITICAL PARTS FOR SAFETY….921
4.7 MAINTENANCE PLAN….923
4.7.1 WHEN REQUIRED….926
4.7.1.A WASHING THE COOLING CIRCUIT….926
4.7.1.B DRAINING THE FUEL TANK….927
4.7.1.C CHECKING THE ELECTRICAL SYSTEM….927
4.7.1.D CHECKING THE STEEL TRACK TENSION….928
4.7.1.E CHECKING THE RUBBER TRACKS….930
4.7.1.F CHECKING THE RUBBER TRACK TENSION….932
4.7.1.G CHANGING THE RUBBER TRACK….934
4.7.2 MAINTENANCE INTERVALS IN CASE OF THE DEMOLITION HAMMER (BREAKER)….936
4.7.2 A CHANGING THE HYDRAULIC OIL FILTER….936
4.7.2.B CHANGING THE HYDRAULIC OIL….936
4.7.3 CHECKS BEFORE STARTING….937
4.7.3.A VARIOUS CHECKS….937
4.7.3.B CHECKING THE COOLANT LEVEL….937
4.7.3 C CHECKING THE FUEL LEVEL….938
4.7.3.D CHECKING THE ENGINE OIL LEVEL….938
4.7.3.E CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT….939
4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION….940
4.7.4.A LUBRICATING THE JOINTS AND THE BALL – BEARING RING….940
4.7.4.B LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (ONLY <<HS>> VERSION)….941
4.7.4.C. CLEANING THE AIR CLEANER CARTRIDGE….942
4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION….943
4.7.6 MAINTENANCE EVERY N250 HOURS OF OPERATION….943
4.7.6.A ADJUSTING THE FAN BELT TENSION….943
4.7.6.B CHECKING THE BATTERY ELECTROLYTE LEVEL….944
4.7.6.C CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS….945
4.7.6.D CHANGING THE HYDRAULIC SYSTEM OIL FILTER….946
4.7.6.E CHANGING THE ENGINE OIL….947
4.7.7 MAINTENANCE EVERY 500 HOURS OF OPERATION….948
4.7.7.A CHANGING THE ENGINE OIL FILTER….948
4.7.7.B CHANGING THE FUEL FILTER….949
4.7.7.C CHANGING THE FUEL PUMP PRECLEANER….950
4.7.7.D CHANGING THE AIR CLEANER CARTRIDGE….951
4.7.7.E CLEANING THE OUTSIDE OF THE RADIATORS….951
4.7.8 MAINTENANCE EVERY 1000 HOURS OF OPERATION….952
4.7.8.A CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS….952
4.7.9 MAINTENANCE EVERY 2000 HOURS OF OPERATION….953
4.7.9.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER….953
4.7.9.B CHANGING THE COOLANT….955
4.7.9.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE….955
4.7.9.D CHECKING THE ALTERNATOR AND THE STARTER….955
TECHNICAL SPECIFICATIONS….956
5.1 TECHNICAL DATA….957
5.1.1 STANDARD OVERALL DIMENSIONS….957
5.1.2 TECHNICAL CHARACTERISTICS….958
5.1.3 OVERALL DIMENSIONS (ONLY <<HS>> VERSION)….959
5.1.4 TECHNICAL CHARACTERISTICS (ONLY <<HS>> VERSION)….960
5.1.5 LIFTING CAPACITY….961
5.1.6 LIFTING CAPACITY (ONLY <<HS>> VERSION)….962
AUTHORIZED OPTIONAL EQUIPMENT….964
6.1 AUTHORIZED OPTIONAL EQUIPMENT….965
6.1.1 PRECAUTIONS REGARDING SAFETY….965
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT….966
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT….967
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)….968
6.2.1 DESCRIPTION AND CONTROL….968
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED….968
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER….972
6.2.3.1 INSTALLING THE HAMMER….972
6.2.3.2 REMOVING THE HAMMER….973
6.2.4 MAINTENANCE….973
WEAM003001 – Hydraulic Excavator PC15R-8 Deluxe Operation & Maintenance Manual….974
COVER….974
1.1 FOREWARD….975
1.2 INFORMATION ON SAFETY….976
1.3 INTRODUCTION….978
1.3.1 INTENDED USES….978
1.3.2 IMPROPER OR UNAUTHORIZED USES….978
1.3.3 MAIN CHARACTERISTICS….979
1.3.4 RUNNING-IN….979
1.4 PRODUCT IDENTIFICATION….980
1.4.1 MACHINE SERIAL NUMBER….980
1.4.2 MACHINE IDENTIFICATION PLATE….980
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL….981
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER….981
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER….981
1.4.6 CAB SERIAL NUMBER….982
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS….983
CONTENTS….984
SAFETY AND ACCIDENT PREVENTION….991
2.1 SAFETY PLATES….992
2.1.1 POSITION OF THE SAFETY PLATES….992
2.1.2 POSITION OF THE PICTOGRAMS….1007
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS….1009
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED….1011
2.2 GENERAL PRECAUTIONS….1012
2.2.1 GENERAL SAFETY RULES….1012
2.2.2 SAFETY DEVICES AND GUARDS….1012
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS….1012
2.2.4 UNAUTHORIZED MODIFICATIONS….1013
2.2.5 LEAVING THE OPERATOR'S SEAT….1013
2.2.6 GETTING ON AND OFF THE MACHINE….1014
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL….1014
2.2.8 PREVENTING BURNS….1015
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER….1015
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….1015
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT….1016
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE….1016
2.2.12 PRECAUTIONS CONCERNING THE EQUIPMENT….1016
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….1017
2.3.1 SAFETY ON THE WORK SITE….1017
2.3.2 FIRE PREVENTION….1017
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB….1017
2.3.4 ROOM VENTILATION….1018
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS….1018
2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES….1018
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING….1019
2.4.1 STARTING THE ENGINE….1019
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE….1019
2.4.3 CHECKS FOR TRAVELLING IN REVERSE….1019
2.4.4 MOVING THE MACHINE….1020
2.4.5 MOVING ON SLOPES….1021
2.4.6 WORKING ON SLOPES….1022
2.4.7 UNAUTHORIZED OPERATIONS….1022
2.4.8 PREVENTING ELECTROCUTION….1023
2.4.9 VISIBILITY….1024
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES….1024
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….1024
2.4.12 WORKING ON LOOSE GROUND….1024
2.4.13 PARKING THE MACHINE….1025
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES….1026
2.5.1 LOADING AND UNLOADING….1026
2.5.2 TRANSPORT….1026
2.6 BATTERY….1027
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY….1027
2.6.2 STARTING WITH THE BOOSTER CABLES….1027
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY….1028
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE….1029
2.8.1 WARNING PLATES….1029
2.8.2 TOOLS….1029
2.8.3 PERSONNEL….1030
2.8.4 EQUIPMENT….1030
2.8.5 WORKING UNDER THE MACHINE….1030
2.8.6 CLEANING THE MACHINE….1030
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS….1031
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY….1031
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION….1031
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP….1032
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR….1032
2.8.12 USING LAMPS….1032
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR….1033
2.8.14 PRECAUTIONS CONCERNING THE STARTER….1033
2.8.15 HANDLING HIGH-PRESSURE PIPES….1034
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL….1034
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE….1034
2.8.18 COOLING FAN AND BELT….1035
2.8.19 WASTE MATERIALS….1035
2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES….1035
THE MACHINE AND ITS OPERATIONS….1037
3.1 SAFETY LOCKS….1038
3.1.1 MACHINE LOCKS….1038
3.2 GENERAL VIEWS….1039
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB (OPTIONAL)….1039
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY….1040
3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT….1041
3.3 INSTRUMENTS AND CONTROLS….1042
3.3.1 INSTRUMENTS….1042
3.3.2 WARNING LIGHTS….1043
3.3.3 SWITCHES AND PUSH BUTTONS….1045
3.3.4 ELECTRICAL ACCESSORIES….1048
3.3.5 MACHINE CONTROLS….1050
3.4 FUSES AND RELAYS….1059
3.4.1 FUSES….1059
3.4.2 RELAYS….1060
3.5 GUARDS AND DRIVER'S SEAT….1061
3.5.1 ENGINE HOOD….1061
3.5.2 CANOPY….1062
3.5.3 CAB (OPTIONAL)….1062
3.5.3.1 SLIDING DOOR….1063
3.5.3.2 FRONT OPENING WINDSHIELD….1064
3.5.3.3 FRONT WINDSHIELD (LOWER PART)….1065
3.5.3.4 SIDE OPENING WINDOW….1066
3.5.4 VENTILATION AND HEATING (ONLY ON MACHINES WITH CAB)….1067
3.5.5 SEAT….1067
3.5.6 SAFETY BELT….1068
3.5.7 EMERGENCY EXIT (ONLY ON MACHINES WITH CAB)….1068
3.5.8 TECHNICAL DOCUMENTATION CASE….1069
3.5.9 FIRE EXTINGUISHER….1069
3.5.10 FIRST AID KIT….1069
3.6 USE OF THE MACHINE….1071
3.6.1 CHECKS BEFORE STARTING MACHINE….1071
3.6.1.1 VISUAL CHECKS….1071
3.6.12 DAILY CHECKS….1071
3.6.1.3 OPERATIONAL CHECKS….1072
3.6.2 STARTING THE ENGINE….1073
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES….1073
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES….1074
3.6.3 WARMING THE ENGINE….1075
3.6.4 HEATING THE HYDRAULIC OIL….1075
3.6.5 HOW TO MOVE THE MACHINE….1075
3.6.5.1 STEERING (CHANGING DIRECTION)….1077
3.6.5.2 MOVING ON SLOPES….1078
3.6.5.3 MAXIMUM IMMERSION DEPTH….1079
3.7 PARKING THE MACHINE….1080
3.7.1 PARKING ON LEVEL GROUND….1080
3.7.2 PARKING ON SLOPES….1081
3.8 STOPPING THE ENGINE….1082
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES….1083
3.9.1 LOADING AND UNLOADING THE MACHINE….1083
3.9.2 TRANSPORT….1084
3.10 LIFTING THE MACHINE….1085
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON….1086
3.11.1 FUEL AND LUBRICANTS….1086
3.11.2 COOLANT….1086
3.11.3 BATTERY….1086
3.11.4 OTHER PRECAUTIONS….1087
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK….1087
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON….1088
3.13 USING THE WORK EQUIPMENT….1089
3.13.1 ORGANIZING THE WORK AREA….1089
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS….1090
3.13.3 DIGGING METHOD….1091
3.13.4 CHANGING THE BUCKET….1092
3.14 USING THE MACHINE WITH VARIABLE TRACK GUAGE….1093
3.14.1 HOW TO USE THE VARIABLE TRACK GUAGE….1093
3.14.2 ADJUSTING THE BLADE….1094
3.15 LONG PERIODS OF INACTIVITY….1095
3.15.1 BEFORE THE PERIOD OF INACTIVITY….1095
3.15.2 DURING THE PERIOD OF INACTIVITY….1096
3.15.3 AFTER THE PERIOD OF INACTIVITY….1096
3.16 TROUBLESHOOTING….1097
3.16.1 OCCURENCES THAT ARE NOT FAILURES….1097
3.16.2 HOW TO REMOVE THE MACHINE….1097
3.13.3 AFTER THE FUEL HAS RUN OUT….1098
3.16.4 IF THE BATTERY IS DOWN….1098
3.16.4.1 STARTING WITH BOOSTER CABLES….1099
3.16.5 OTHER TROUBLES….1100
3.16.5.1 ELECTRICAL CIRCUIT….1100
3.16.5.2 HYDRAULIC SYSTEM….1100
3.16.5.3 ENGINE….1101
MAINTENANCE….1103
4.1 GUIDE TO MAINTENANCE….1104
4.2 MAINTENANCE NOTES….1106
4.2.1 NOTES REGARDING THE ENGINE….1106
4.2.1.1 ENGINE OIL….1106
4.2.1.2 COOLANT….1106
4.2.1.3 FUEL….1107
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM….1107
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM….1108
4.2.4 NOTES REGARDING LUBRICATION….1108
4.2.5 PARTS SUBJEST TO WEAR THAT PERIODICALLY NEED CHANGING….1109
4.3 FUEL, COOLANT AND LUBRICANTS….1110
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS….1114
4.4 NUT AND BOLT TIGHTENING TORQUES….1115
4.4.1 STANDARD TIGHTENING TORQUES….1115
4.4.2 SPECIFIC TIGHTENING TORQUES….1115
4.5 LUBRICATION….1116
4.5.1 LUBRICATION DIAGRAM….1116
4.5.2 LUBRICATION DIAGRAM (VARIABLE TRACK GUAGE)….1117
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY….1118
4.6.1 CRITICAL PARTS FOR SAFETY….1119
4.7 MAINTENANCE PLAN….1121
4.7.1 WHEN REQUIRED….1124
4.7.1.a WASHING THE COOLING CIRCUIT….1124
4.7.1.b DRAINING THE FUEL TANK….1125
4.7.1.c CHECKING THE ELECTRICAL SYSTEM….1125
4.7.1.d CHECKING THE STEEL TRACK TENSION….1126
4.7.1.e CHECKING THE RUBBER TRACKS….1128
4.7.1.f CHECKING THE RUBBER TRACKS TENSION….1130
4.7.1.g CHANGING THE RUBBER TRACK….1132
4.7.1.h LUBRICATING THE ARTICULATIONS….1134
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)….1135
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER….1135
4.7.2.b CHANGING THE HYDRAULIC OIL….1135
4.7.3 CHECKS BEFORE STARTING….1136
4.7.3.a VARIOUS CHECKS….1136
4.7.3.b CHECKING THE COOLANT LEVEL….1136
4.7.3.c CHECKING THE FUEL LEVEL….1137
4.7.3.d CHECKING THE ENGINE OIL LEVEL….1137
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT….1138
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES….1139
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION….1140
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING….1140
4.7.5.b LUBRICATING THE VARIABLE TRACK GUAGE SLIDING GUIDES (ONLY IN <HS> VERSION)….1141
4.7.5.c CLEANING THE AIR CLEANER CARTRIDGE….1142
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION….1143
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION….1143
4.7.7.a ADJUSTING THE FAN BELT TENSION….1143
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL….1144
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS….1145
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER….1146
4.7.7.e CHANGING THE ENGINE OIL….1147
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (ONLY FOR MACHINE IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES….1148
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION….1148
4.7.9.a CHAINGING THE ENGINE OIL FILTER….1148
4.7.9.b CHANGING THE FUEL FILTER….1149
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER….1150
4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE….1151
4.7.9.e CLEANING THE OUTSIDE OF THE RADIATORS….1151
4.7.9.f DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES IS USED)….1152
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION….1153
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS….1153
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION….1154
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER….1154
4.7.11.b CHANGING THE COOLANT….1156
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE….1156
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER….1156
TECHNICAL SPECIFICATIONS….1157
5.1 TECHNICAL DATA….1158
5.1.1 STANDARD OVERALL DIMENSIONS….1158
5.1.2 TECHNICAL CHARACTERISTICS….1159
5.1.3 OVERALL DIMENSIONS (ONLY <HS> VERSION)….1160
5.1.4 TECHNICAL CHARACTERISTICS (ONLY <HS> VERSION)….1161
5.1.5 LIFTING CAPACITY….1162
5.1.6 LIFTING CAPACITY (ONLY <HS> VERISON)….1163
AUTHORIZED OPTIONAL EQUIPMENT….1165
6.1 AUTHORIZED OPTIONAL EQUIPMENT….1166
6.1.1 PRECAUTIONS REGARDING SAFETY….1166
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT….1167
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT….1168
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)….1169
6.2.1 DESCRIPTION AND CONTROL….1169
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED….1169
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER….1173
6.2.3.1 INSTALLING THE HAMMER….1173
6.2.3.2 REMOVING THE HAMMER….1174
6.2.4 MAINTENANCE….1174
WEBM000100 – Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual….1175
CONTENTS….1177
LIST OF REVISED PAGES….1179
SAFETY….1181
FOREWORD….1183
HOW TO READ THE SHOP MANUAL….1184
HOISTING INSTRUCTIONS….1185
STANDARD TIGHTENING TORQUE….1186
COATING MATERIALS….1187
ELECTRIC WIRE CODE….1188
WEIGHT TABLE….1189
TABLE OF OIL AND COOLANT QUANTITIES….1190
10. STRUCTURE AND FUNCTION….1191
POWER TRAIN….1192
SWING CIRCLE….1194
SWING MOTOR….1195
FINAL DRIVE….1196
TRACK FRAME AND RECOIL SPRING….1197
CARRIER ROLLER….1199
STEEL SHOE….1200
HYDRAULIC SYSTEM….1201
HYDRAULIC CIRCUIT DIAGRAM….1205
HYDRAULIC PUMP….1209
CONTROL VALVE….1214
CLSS….1222
SWIVEL JOINT….1265
TRAVEL MOTOR….1267
CYLINDERS….1270
VALVE CONTROL….1274
ACCUMULATOR….1275
PPC VALVE….1276
SOLENOID VALVE….1281
CUTTING SHOVEL CONTROL VALVE….1283
ELECTRICAL CIRCUIT DIAGRAM….1285
20. TESTING AND ADJUSTMENTS….1287
NORMAL OR STANDARD TECHNICAL DATA….1288
SPECIAL TOOLS….1309
CHECKING THE ENGINE SPEED….1311
ADJUSTMENT OF VALVE CLEARANCE….1312
MEASUREMENT OF THE COMPRESSION PRESSURE….1313
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT….1314
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING….1315
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE….1317
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER….1318
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER….1319
CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL….1320
ADJUSTMENT OF THE PPC VALVE CLEARANCES….1321
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT….1322
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION….1323
CONTROL AND REGULATION OF PRESSURE IN THE HYDRAULIC CIRCUIT….1324
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE….1330
REGULATION OF THE PC VALVE….1332
CONTROL AND REGULATION OF THE SERVOCONTROL POWER SUPPLY….1333
ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK….1335
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS….1336
CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSES OF A DRIFT….1338
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS….1344
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR….1345
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT….1346
30. REMOVAL AND INSTALLATION….1349
HOW TO READ THE MANUAL….1351
PRECAUTIONS TO BE TAKEN WHILE WORKING….1352
SPECIAL TOOLS….1353
STARTER MOTOR….1355
ALTERNATOR….1356
PUMP GROUP….1357
INJECTION NOZZLES….1358
CYLINDER HEAD….1359
OIL COOLER….1363
RADIATOR….1364
ENGINE HOOD….1365
CAB AND CANOPY….1366
HEATING FAN….1368
REAR COUNTERWEIGHT….1369
TOP COVER AND SIDE PANELS….1370
HYDRAULIC OIL TANK….1372
FUEL TANK….1375
ENGINE PUMP GROUP….1376
PUMP….1379
ENGINE PUMP COUPLING….1380
CONTROL VALVE….1381
RIGHT-HAND PPC VALVE (BOOM-BUCKET)….1383
LEFT-HAND PPC VALVE (ARM-BUCKET)….1384
SERVOCONTROL SOLENOID GROUP….1385
SWIVEL JOINT….1387
SWING MOTOR….1388
REVOLVING FRAME….1389
SWING CIRCLE….1391
TRAVEL MOTOR….1392
RUBBER TRACK SHOES….1393
TRACK SHOES….1394
SPROCKET WHEEL….1395
FINAL DRIVE….1396
IDLER AND RECOIL SPRING ASSEMBLY….1407
TRACK ROLLERS….1410
BOOM CYLINDER….1411
ARM CYLINDER….1412
BUCKET CYLINDER….1413
BOOM SWING CYLINDER….1414
BLADE CYLINDER….1415
WORKING EQUIPMENT CYLINDER….1416
UPPER WORKING EQUIPMENT….1422
BUCKET….1424
ARM….1425
BOOM….1427
BOOM SWING SUPPORT….1429
BLADE….1430
40. STANDARD MAINTENANCE….1431
SWING CIRCLE….1432
TRACK FRAME AND RECOIL SPRING….1433
IDLER….1434
FINAL DRIVE….1435
SPROCKET….1436
TRACK ROLLER….1437
TRACK SHOE….1438
HYDRAULIC PUMP….1440
CONTROL VALVE….1442
SWIVEL JOINT….1454
SWING MOTOR….1455
TRAVEL MOTOR….1456
PPC VALVE….1460
CYLINDERS….1464
WORK EQUIPMENT….1466
WEBM000101 – Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual….1471
COVER….1471
CONTENTS….1473
LIST OF REVISED PAGES….1475
SAFETY….1477
FOREWORD….1479
HOW TO READ THE SHOP MANUAL….1480
HOISTING INSTRUCTIONS….1481
STANDARD TIGHTENING TORQUE….1482
COATING MATERIALS….1483
ELECTRIC WIRE CODE….1484
WEIGHT TABLE….1485
TABLE OF OIL AND COOLANT QUANTITIES….1486
10.STRUCTURE AND FUNCTION….1489
POWER TRAIN….1490
SWING CIRCLE….1492
SWING MOTOR….1493
FINAL DRIVE….1494
TRACK FRAME AND RECOIL SPRING….1495
VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING….1497
CARRIER ROLLER….1498
STEEL SHOE….1499
HYDRAULIC SYSTEM PC12R-8….1501
HYDRAULIC SYSTEM PC15R-8….1503
HYDRAULIC CIRCUIT DIAGRAM PC12R-8….1505
HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL….1507
HYDRAULIC CIRCUIT DIAGRAM PC12R-8 HS….1509
HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL HS….1511
HYDRAULIC CIRCUIT DIAGRAM PC15R-8….1513
HYDRAULIC CIRCUIT DIAGRAM PC15R-8 HS….1515
HYDRAULIC CIRCUIT DIAGRAM….1516
HYDRAULIC PUMP….1517
CONTROL VALVE PC12R-8 PC12R-8 MISTRAL….1522
CONTROL VALVE PC12R-8 HS PC12R-8 MISTRAL HS….1524
CLSS….1532
CONTROL VALVE PC15R-8….1550
CLSS….1560
SWIVEL JOINT….1577
TRAVEL MOTOR….1580
CYLINDERS….1583
VALVE CONTROL….1587
ACCUMULATOR….1588
PPC VALVE….1589
PPC VALVE….1591
SOLENOID VALVE….1594
VARIABLE GAUGE UNDERCARRIAGE SERVOCONTROL….1597
SAFETY VALVE….1598
CUTTING SHOVEL CONTROL VALVE….1599
ELECTRICAL CIRCUIT DIAGRAM….1601
20.TESTING AND ADJUSTMENTS….1605
NORMAL OR STANDARD TECHNICAL DATA….1606
SPECIAL TOOLS….1627
CHECKING THE ENGINE SPEED….1629
ADJUSTMENT OF VALVE CLEARANCE….1630
MEASUREMENT OF THE COMPRESSION PRESSURE….1631
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT….1632
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING….1633
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE….1635
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER….1636
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER….1637
CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL….1638
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT….1639
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION….1640
CONTROL AND REGULATION OF THE PRESSURE IN THE HYDRAULIC CIRCUITS (PC12R)….1641
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS (PC15R)….1644
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE….1647
REGULATION OF THE PC VALVE….1649
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC12R)….1650
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC15R)….1651
ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK….1652
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS….1653
CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSES OF A DRIFT….1655
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS….1661
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR….1662
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT….1663
30.REMOVAL AND INSTALLATION….1671
HOW TO READ THE MANUAL….1673
PRECAUTIONS TO BE TAKEN WHILE WORKING….1674
SPECIAL TOOLS….1675
STARTER MOTOR….1677
ALTERNATOR….1678
PUMP GROUP….1679
INJECTION NOZZLES….1680
CYLINDER HEAD….1681
OIL COOLER….1685
RADIATOR….1686
ENGINE HOOD….1687
CAB AND CANOPY….1688
HEATING FAN….1690
REAR COUNTERWEIGHT….1691
TOP COVER AND SIDE PANELS….1692
HYDRAULIC OIL TANK….1694
FUEL TANK….1697
ENGINE-PUMP GROUP….1698
PUMP….1701
ENGINE-PUMP COUPLING….1702
CONTROL VALVE….1703
RIGHT-HAND PPC VALVE (BOOM-BUCKET)….1705
LEFT-HAND PPC VALVE (ARM-BUCKET)….1706
SERVOCONTROL SOLENOID GROUP (PC12 WITHOUT TRAVEL INCREMENT)….1707
SERVOCONTROL SOLENOID GROUP (PC12 WITH TRAVEL INCREMENT – PC15R)….1708
SWIVEL JOINT….1709
SWING MOTOR….1710
REVOLVING FRAME….1711
SWING CIRCLE….1713
TRAVEL MOTOR….1714
RUBBER TRACK SHOES….1715
TRACK-SHOES….1716
SPROCKET WHEEL….1717
COMPLETE FINAL DRIVE….1718
FINAL DRIVE….1719
IDLER AND RECOIL SPRING ASSEMBLY….1729
IDLER….1730
SPRING RECOIL AND THRUST CYLINDER GROUPS….1731
TRACK ROLLERS….1732
BOOM CYLINDER….1733
ARM CYLINDER….1734
BUCKET CYLINDER….1735
BOOM SWING CYLINDER….1736
BLADE CYLINDER….1737
WORKING EQUIPMENT CYLINDER….1738
UPPER WORKING EQUIPMENT….1744
BUCKET….1746
ARM….1747
BOOM….1749
BOOM SWING SUPPORT….1751
BLADE….1752
40.STANDARD MAINTENANCE….1755
SWING CIRCLE….1756
TRACK FRAME AND RECOIL SPRING….1757
VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING….1758
IDLER….1759
FINAL DRIVE….1760
SPROCKET….1761
TRACK ROLLER….1762
TRACK SHOE….1763
HYDRAULIC PUMP….1765
CONTROL VALVE….1767
SWIVEL JOINT….1779
SWING MOTOR….1781
TRAVEL MOTOR….1782
CYLINDERS PC12R-8….1788
CYLINDERS PC15R-8….1789
WORK EQUIPMENT PC12R-8….1790
WORK EQUIPMENT PC15R-8….1792
WEBM002800 – Hydraulic Excavator PC15R-8 Shop Manual….1795
COVER….1795
FOREWARD….1800
HOW TO READ THE SHOP MANUAL….1803
HOISTING INSTRUCTIONS….1804
STANDARD TIGHTENING TORQUE….1805
COATING MATERIALS….1807
WEIGHT TABLE….1809
TABLE OF OIL AND COOLANT QUANTIES….1810
CONTENTS….1796
10 STRUCTURE AND FUNCTION….1813
POWER TRAIN….1814
SWING CIRCLE….1815
SWING MOTOR….1816
FINAL DRIVE….1817
TRACK FRAME AND RECOIL SPRING….1818
CARRIER ROLLER….1820
STEEL SHOE….1821
HYDRAULIC SYSTEM….1822
HYDRAULIC CIRCUIT DIAGRAM….1823
HYDRAULIC PUMP….1825
CONTROL VALVE….1829
CLSS….1837
SWIVEL JOINT….1854
TRAVEL MOTOR….1855
CYLINDERS….1857
VALVE CONTROL….1860
ACCUMULATOR….1861
PPC VALVE….1862
SOLENOID VALVE ….1867
CUTTING SHOVEL CONTROL VALVE….1868
ELECTRICAL CIRCUIT DIAGRAM….1869
20 TESTING AND ADJUSTING….1873
NORMAL OR STANDARD TECHNICAL DATA….1874
SPECIAL TOOLS….1885
CHECKING THE ENGINE SPEED….1886
ADJUSTMENT OF VALVE CLEARANCE….1887
MEASUREMENT OF THE COMPRESSOR PRESSURE….1888
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT….1889
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING….1890
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE ….1892
ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER….1893
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER….1894
CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL….1895
ADJUSTMENT OF THE PPC VALVE CLEARANCES….1896
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT….1897
CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION….1898
CONTROL AND REGULATION OF THE PREEURES IN THE HYDRAULIC CIRCUTIS….1899
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE….1902
REGULATION OF THE PC VALVE….1904
CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY….1905
ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK….1906
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS….1907
CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSES OF A DRIFT….1909
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS….1915
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR….1916
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT….1917
30 REMOVAL AND INSTALLATION….1922
HOW TO READ THE MANUAL….1924
PRECAUTIONS TO BE TAKEN WHILE WORKING….1925
SPECIAL TOOLS….1926
STARTER MOTOR….1928
REMOVAL….1928
INSTALLATION….1928
ALTERNATOR….1929
REMOVAL….1929
INSTALLATION….1929
PUMP GROUP….1930
REMOVAL….1930
INSTALLATION….1930
INJECTION NOZZLES….1931
REMOVAL….1931
INSTALLATION….1931
CYLINDER HEAD….1932
REMOVAL….1932
INSTALLATION….1935
OIL COOLER….1936
REMOVAL ….1936
INSTALLATION….1936
RADIATOR….1937
REMOVAL….1937
INSTALLATION….1937
ENGINE HOOD….1938
REMOVAL….1938
INSTALLATION….1938
CAB AND CANOPY….1939
REMOVAL….1939
INSTALLATION….1940
HEATING FAN….1941
REMOVAL….1941
INSTALLATION….1941
REAR COUNTERWEIGHT….1942
REMOVAL….1942
INSTALLATION….1942
TOP COVER AND SIDE PANELS….1943
REMOVAL….1943
INSTALLATION….1944
HYDRAULIC OIL TANK….1945
REMOVAL….1945
INSTALLATION….1946
FUEL TANK….1948
REMOVAL….1948
INSTALLATION….1948
ENGINE-PUMP GROUP….1949
REMOVAL….1949
INSTALLATION….1951
PUMP….1952
REMOVAL….1952
INSTALLATION….1952
ENGINE-PUMP COUPLING….1953
REMOVAL….1953
INSTALLATION….1953
CONTROL VALVE….1954
REMOVAL….1954
INSTALLATION….1955
RIGHT-HAND PPC VALVE….1956
REMOVAL….1956
INSTALLATION….1956
LEFT-HAND PPC VALVE….1957
REMOVAL….1957
INSTALLATION….1957
SERVOCONTROL SOLENNIOD GROUP (PC-12R)….1958
REMOVAL….1958
INSTALLATION….1958
SERVOCONTROL SOLENNIOD GROUP (PC12R WITH TRAVEL INCREMENT – PC15R)….1958
REMOVAL….1958
INSTALLATION….1958
SWIVEL JOINT….1959
REMOVAL….1959
INSTALLATION….1959
SWING MOTOR….1960
REMOVAL….1960
INSTALLATION….1960
REVOLVING FRAME….1961
REMOVAL….1961
INSTALLATION….1962
SWING CIRCLE….1963
REMOVAL….1963
INSTALLATION….1963
TRAVEL MOTOR….1964
REMOVAL….1964
INSTALLATION….1964
RUBBER TRACK-SHOES….1965
REMOVAL….1965
INSTALLATION….1965
TRACK-SHOES….1966
REMOVAL….1966
INSTALLATION….1966
SPROCKET WHEEL….1967
REMOVAL….1967
INSTALLATION….1967
COMPLETE FINAL DRIVE….1968
REMOVAL….1968
INSTALLATION….1968
FINAL DRIVE….1969
DISASSEMBLY….1969
ASSEMBLY….1974
IDLER AND RECOIL SPRING ASSEMBLY….1979
REMOVAL….1979
INSTALLATION….1979
IDLER….1980
DISASSEMBLY….1980
ASSEMBLY….1980
SPRING RECOIL AND THRUST CYLINDER GROUPS….1981
DISASSEMBLY….1981
ASSEMBLY….1981
TRACK ROLLERS….1982
REMOVAL ….1982
INSTALLATION….1982
BOOM CYCLINDER….1983
REMOVAL….1983
INSTALLATION….1983
ARM CYLINDER….1984
REMOVAL….1984
INSTALLATION….1984
BUCKET CYLINDER….1985
REMOVAL….1985
INSTALLATION….1985
BOOM SWING CYLINDER….1986
REMOVAL….1986
INSTALLATION….1986
BLADE CYLINDER….1987
REMOVAL….1987
INSTALLATION….1987
WORKING EQUIPMENT CYLINDERS….1988
DISASSEMBLY….1988
ASSEMBLY….1990
UPPER WORKING EQUIPMENT….1994
REMOVAL….1994
INSTALLATION….1995
ARM….1996
REMOVAL….1996
INSTALLATION….1997
BOOM….1998
REMOVAL….1998
INSTALLATION….1999
BOOM SWING SUPPORT….2000
REMOVAL….2000
INSTALLATION….2000
BLADE….2001
REMOVAL….2001
NSTALLATION….2001
40 MAINTENANCE STANDARD….2003
SWING CIRCLE….2004
TRACK FRAME AND RECOIL SPRING….2005
ILDER….2006
FINAL DRIVE….2007
SPROCKET….2008
TRACK ROLLER….2009
TRACK SHOE….2010
HYDRAULIC PUMP….2012
CONTROL VALVE….2013
SWIVEL JOINT….2019
SWING MOTOR….2020
TRAVEL MOTOR….2021
PPC VALVE….2023
CYLINDERS….2026
WORK EQUIPMENT….2028

Komatsu Hydraulic Excavator PC12R, PC15R Repair Service Manuals

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