Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC09-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC09-1 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM026105 – Hydraulic Excavator PC09-1 Shop Manual.pdf
SEAM044501T – Hydraulic Excavator GALEO PC09-1 Operation & Maintenance Manual.pdf
SEAM044502 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
TEN00062-04 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
TEN00555-00 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
Total Pages: 1,027 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
SEAM044501T – Hydraulic Excavator GALEO PC09-1 Operation & Maintenance Manual….2
COVER….2
FOREWORD….3
FOREWORD….4
SAFETY INFORMATION….7
INTRODUCTION….9
DIRECTIONS OF MACHINE….9
PRODUCT INFORMATION….10
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….10
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….10
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….11
SERVICE METER LOCATION….11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….12
CONTENTS….13
SAFETY….16
SAFETY INFORMATION….17
SAFETY LABELS….19
LOCATION OF SAFETY LABELS….19
SAFETY LABELS….20
SAFETY INFORMATION….23
SAFETY RULES….23
IF ABNORMALITIES ARE FOUND….23
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….23
FIRE EXTINGUISHER AND FIRST AID KIT….23
SAFETY EQUIPMENT….23
KEEP MACHINE CLEAN….24
OPERATOR'S SEAT EQUIPMENT….24
LEAVING OPERATOR'S SEAT WITH LOCK….24
HANDRAILS AND STEPS….25
MOUNTING AND DISMOUNTING….25
NO PERSONS ON ATTACHMENTS….25
BURN PREVENTION….26
FIRE PREVENTION AND EXPLOSION PREVENTION….27
ACTION IF FIRE OCCURS….27
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….28
ATTACHMENT INSTALLATION….28
ATTACHMENT COMBINATIONS….28
UNAUTHORIZED MODIFICATIONS….28
SAFETY AT JOBSITE….29
WORKING ON LOOSE GROUND….29
DISTANCE TO HIGH VOLTAGE CABLES….29
ENSURE GOOD VISIBILITY….30
VENTILATION FOR ENCLOSED AREA….30
SIGNALMAN'S SIGNAL AND SIGNS….30
ASBESTOS DUST HAZARD PREVENTION….30
SAFETY MACHINE OPERATION….31
STARTING ENGINE….31
CHECKS BEFORE STARTING ENGINE….31
SAFETY RULES FOR STARTING ENGINE….31
SAFETY ENGINE IN COLD WEATHER….31
OPERATION….32
CHECKS BEFORE OPERATION….32
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….32
SAFETY RULES FOR TRAVELING….33
TRAVELING ON SLOPES….34
OPERATIONS ON SLOPES….35
PROHIBITED OPERATIONS….35
OPERATIONS ON SNOW….37
PARKING MACHINE….37
TRANSPORTATION….39
LOADING AND UNLOADING….39
SHIPPING THE MACHINE….39
BATTERY….40
BATTERY HAZARD PREVENTION….40
STARTING ENGINE WITH BOOSTER CABLES….41
TOWING….42
SAFETY RULES FOR TOWING….42
LIFTING OBJECTS WITH BUCKET….43
SAFETY RULES FOR LIFTING OBJECTS….43
SAFETY MAINTENANCE INFORMATION….44
WARNING TAG….44
KEEP WORK PLACE CLEAN AND TIDY….44
APPOINT LEADER WHEN WORKING WITH OTHERS….44
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….45
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….46
PROPER TOOLS….46
PERSONNEL….46
ATTACHMENTS….47
WORK UNDER THE MACHINE….47
NOISE….47
WHEN USING HAMMER….47
WELDING WORKS….47
REMOVING BATTERY TERMINALS….48
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….48
SAFETY RULES FOR HIGH-PRESSURE OIL….48
SAFETY HANDLING HIGH-PRESSURE HOSES….49
WASTE MATERIALS….49
COMPRESSED AIR….49
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….49
OPERATION….50
MACHINE VIEW ILLUSTRATIONS….51
OVERALL MACHINE VIEW….51
CONTROLS AND GAUGES….52
DETAILED CONTROLS AND GAUGES….53
METERS,LAMPS….53
SWITCHES….55
CONTROL LEVERS AND PEDALS….57
VARIABLE BLADE….64
ENGINE HOOD….64
FUSE….65
BLOCK FUSE….65
OPERATION MANUAL STORAGE….66
MACHINE OPERATIONS AND CONTROLS….67
BEFORE STARTING ENGINE….67
STARTING ENGINE….78
AFTER STARTING ENGINE….81
STOPPING THE ENGINE….84
CHECK AFTER SHUT OFF ENGINE….84
MACHINE OPERATION….85
STEERING THE MACHINE….89
SWINGING….91
WORK EQUIPMENT CONTROLS AND OPERATIONS….92
PROHIBITED OPERATIONS….94
GENERAL OPERATION INFORMATION….97
TRAVELING ON SLOPES….98
ESCAPE FROM MUD….100
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….101
BUCKET REPLACEMENT….103
PARKING MACHINE….105
MACHINE INSPECTION AFTER DAILY WORK….106
RUBBER SHOES(MACHINE WITH RUBBER SHOES ONLY)….107
TRANSPORTATION….112
TRANSPORTATION PROCEDURE….112
LOADING AND UNLOADING WITH TRAILER….112
LIFTING MACHINE….114
SHIPPING MACHINE INFORMATION….116
COLD WEATHER OPERATION….117
COLD WEATHER OPERATION INFORMATION….117
AFTER DAILY WORK COMPLETION….119
AFTER COLD WEATHER SEASON….119
LONG TERM STORAGE….120
BEFORE STORAGE….120
DURING STORAGE….120
AFTER STORAGE….120
STARTING MACHINE AFTER LONG-TERM STORAGE….120
TROUBLES AND ACTIONS….121
RUNNING OUT OF FUEL….121
PHENOMENA THAT ARE NOT FAILURES….121
TOWING THE MACHINE….122
SEVERE JOB CONDITION….122
DISCHARGED BATTERY….123
OTHER TROUBLE….127
MAINTENANCE….131
MAINTENANCE INFORMATION….132
LUBRICANTS, COOLANT AND FILTERS….134
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….134
ELECTRIC SYSTEM MAINTENANCE….136
WEAR PARTS….137
WEAR PARTS LIST….137
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….138
PROPER SELECTION….138
TIGHTENING TORQUE SPECIFICATIONS….142
TIGHTENING TORQUE LIST….142
SAFETY CRITICAL PARTS….143
SAFETY CRITICAL PARTS LIST….143
MAINTENANCE SCHEDULE….144
MAINTENANCE SCHEDULE CHART….144
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….145
MAINTENANCE SCHEDULE….146
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….146
WHEN REQUIRED….147
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT….147
CLEAN INSIDE OF COOLING SYSTEM….149
CHECK LEVEL OF BATTERY ELECTROLYTE….152
CHECK RUBBER SHOES….155
CHECK AND ADJUST RUBBER SHOE TENSION….157
REPLACE RUBBER SHOES….159
DRAIN WATER AND SEDIMENT FROM FUEL TANK….162
CHECKS BEFORE STARTING….163
EVERY 100 HOURS MAINTENANCE….164
LUBRICATING….164
EVERY 250 HOURS MAINTENANCE….165
LUBRICATING….165
REPLACE ENGINE OIL IN ENGINE OIL PAN….166
CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL….167
REPLACE HYDRAULIC OIL FILTER CARTRIDGE….168
CHECK AND ADJUST COOLINE FAN BELT TENSION….169
EVERY 500 HOURS MAINTENANCE….170
LUBRICATING….170
REPLACE ENGINE OIL FILTER CARTRIDGE….171
REPLACE FUEL FILTER ELEMENT….172
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS….174
REPLACE FUEL FEED PUMP PRE-FILTER….175
EVERY 1000 HOURS MAINTENANCE….176
CHANGE OIL IN FINAL DRIVE CASE….176
EVERY 2000 HOURS MAINTENANCE….177
CHANGE OIL IN HYDRAULIC TANK,CLEAN STRAINER….177
CHECK ALTERNATOR,STARTING MOTOR….178
CHECK ENGINE VALVE CLEARANCE,ADJUST….178
SPECIFICATIONS….179
SPECIFICATIONS….180
ATTACHMENTS, OPTIONS….182
ATTACHMENTS AND OPTIONS-GENERAL INFORAMTION….183
SAFETY FIRST….183
ATTACHMENT INSTALLATION….184
BUCKET WITH HOOK….185
HOOK CONDITION….185
PROHIBITED OPERATIONS….185
ATTACHMENT GUIDE….186
ATTACHMENT COMBINATIONS….186
HANDLING ARM WITH BUILT-IN BREAKER….187
BUCKET POSTURE….187
REMOVING AND INSTALLING CHISEL….187
PROCEDURE FOR BREAKER OPERATIONS….188
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….189
STOWING CHISEL,DUMMY CHISEL….190
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….190
HANDLING DUMMY LINK….191
CHECK BEFORE STARTING….192
SPECIFICATIONS….193
HANDLING BUCKET COUPLER….194
PROCEDURE FOR REMOVING BUCKET….194
PROCEDURE FOR INSTALLING BUCKET….196
RECOMMENDED ATTACHMENT OPERATIONS….198
HYDRAULIC BREAKER….198
INDEX….202
SEAM044502 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual….205
COVER….205
FOREWARD….206
FOREWORD….207
SAFETY INFORMATION….210
INTRODUCTION….212
DIRECTIONS OF MACHINE….212
PRODUCT INFORMATION….213
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….213
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….213
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….214
SERVICE METER LOCATION….214
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….215
CONTENTS….216
SAFETY….220
SAFETY INFORMATION….221
SAFETY LABELS….223
LOCATION OF SAFETY LABELS….223
SAFETY LABELS….224
SAFETY INFORMATION….227
SAFETY RULES….227
IF ABNORMALITIES ARE FOUND….227
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….227
FIRE EXTINGUISHER AND FIRST AID KIT….227
SAFETY EQUIPMENT….227
KEEP MACHINE CLEAN….228
OPERATOR'S SEAT EQUIPMENT….228
LEAVING OPERATOR'S SEAT WITH LOCK….228
HANDRAILS AND STEPS….229
MOUNTING AND DISMOUNTING….229
NO PERSONS ON ATTACHMENTS….229
BURN PREVENTION….230
FIRE PREVENTION AND EXPLOSION PREVENTION….231
ACTION IF FIRE OCCURS….231
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….232
ATTACHMENT INSTALLATION….232
ATTACHMENT COMBINATIONS….232
UNAUTHORIZED MODIFICATIONS….232
SAFETY AT JOBSITE….233
WORKING ON LOOSE GROUND….233
DISTANCE TO HIGH VOLTAGE CABLES….233
ENSURE GOOD VISIBILITY….234
VENTILATION FOR ENCLOSED AREA….234
SIGNALMAN'S SIGNAL AND SIGNS….234
ASBESTOS DUST HAZARD PREVENTION….234
SAFETY MACHINE OPERATION….235
STARTING ENGINE….235
CHECKS BEFORE STARTING ENGINE….235
SAFETY RULES FOR STARTING ENGINE….235
STARTING ENGINE IN COLD WEATHER….235
OPERATION….236
CHECKS BEFORE OPERATION….236
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….236
SAFETY RULES FOR TRAVELING….237
TRAVELING ON SLOPES….238
OPERATIONS ON SLOPES ….239
PROHIBITED OPERATIONS….239
OPERATIONS ON SNOW….241
PARKING MACHINE….241
TRANSPORTATION….243
LOADING AND UNLOADING….243
SHIPPING THE MACHINE….243
BATTERY….244
BATTERY HAZARD PREVENTION….244
STARTING ENGINE WITH BOOSTER CABLES….245
TOWING….246
SAFETY RULES FOR TOWING….246
LIFTING OBJECTS WITH BUCKET….247
SAFETY RULES FOR LIFTING OBJECTS….247
SAFETY MAINTENANCE INFORMATION….248
WARNING TAG….248
KEEP WORK PLACE CLEAN AND TIDY….248
APPOINT LEADER WHEN WORKING WITH OTHERS….248
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….249
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….250
PROPER TOOLS….250
PERSONNEL….250
ATTACHMENTS….251
WORK UNDER THE MACHINE….251
NOISE….251
WHEN USING HAMMER….251
WELDING WORKS….251
REMOVING BATTERY TERMINALS….252
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….252
SAFETY RULES FOR HIGH-PRESSURE OIL….252
SAFETY HANDLING HIGH-PRESSURE HOSES….253
WASTE MATERIALS….253
COMPRESSED AIR….253
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….253
OPERATION….254
MACHINE VIEW ILLUSTRATIONS….255
OVERALL MACHINE VIEW….255
CONTROLS AND GAUGES….256
DETAILED CONTROLS AND GAUGES….257
METERS,LAMPS….257
SWITCHES….259
CONTROL LEVERS AND PEDALS….261
VARIABLE BLADE….268
ENGINE HOOD….268
FUSE….269
BLOCK FUSE….269
OPERATION MANUAL STORAGE….270
MACHINE OPERATIONS AND CONTROLS….271
BEFORE STARTING ENGINE….271
STARTING ENGINE….282
AFTER STARTING ENGINE….285
STOPPING THE ENGINE….288
CHECK AFTER SHUT OFF ENGINE….288
MACHINE OPERATION….289
STEERING THE MACHINE….293
SWINGING….295
WORK EQUIPMENT CONTROLS AND OPERATIONS….296
PROHIBITED OPERATIONS….298
GENERAL OPERATION INFORMATION….301
TRAVELING ON SLOPES….302
ESCAPE FROM MUD….304
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….305
BUCKET REPLACEMENT….307
PARKING MACHINE….309
MACHINE INSPECTION AFTER DAILY WORK….310
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)….311
TRANSPORTATION….316
TRANSPORTATION PROCEDURE….316
LOADING AND UNLOADING WITH TRAILER….316
LIFTING MACHINE….318
SHIPPING MACHINE INFORMATION….320
COLD WEATHER OPERATION….321
COLD WEATHER OPERATION INFORMATION….321
AFTER DAILY WORK COMPLETION….323
AFTER COLD WEATHER SEASON….323
LONG TERM STORAGE….324
BEFORE STORAGE….324
DURING STORAGE….324
AFTER STORAGE….324
STARTING MACHINE AFTER LONG-TERM STORAGE….324
TROUBLES AND ACTIONS….325
RUNNING OUT OF FUEL….325
PHENOMENA THAT ARE NOT FAILURES….325
TOWING THE MACHINE….326
SEVERE JOB CONDITION….326
DISCHARGED BATTERY….327
OTHER TROUBLE….331
MAINTENANCE….336
MAINTENANCE INFORMATION….337
LUBRICANTS, COOLANT AND FILTERS….339
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….339
ELECTRIC SYSTEM MAINTENANCE….341
WEAR PARTS….342
WEAR PARTS LIST….342
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….343
PROPER SELECTION….343
TIGHTENING TORQUE SPECIFICATIONS….347
TIGHTENING TORQUE LIST….347
SAFETY CRITICAL PARTS….348
SAFETY CRITICAL PARTS LIST….348
MAINTENANCE SCHEDULE….349
MAINTENANCE SCHEDULE CHART….349
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….350
MAINTENANCE PROCEDURE….351
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….351
REPLACE FUEL FILTER ELEMENT….376
REPLACE ENGINE OIL FILTER CARTRIDGE….375
CHECK ENGINE VALVE CLEARANCE, ADJUST….382
WHEN REQUIRED….352
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….352
CLEAN INSIDE OF COOLING SYSTEM….354
CHECK LEVEL OF BATTERY ELECTROLYTE….357
CHECK RUBBER SHOES….360
CHECK AND ADJUST RUBBER SHOE TENSION….362
REPLACE RUBBER SHOES….364
DRAIN WATER AND SEDIMENT FROM FUEL TANK….366
CHECK BEFORE STARTING….367
EVERY 100 HOURS MAINTENANCE….368
LUBRICATING….368
EVERY 250 HOURS MAINTENANCE….369
LUBRICATING….369
REPLACE ENGINE OIL IN ENGINE OIL PAN….370
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….371
REPLACE HYDRAULIC OIL FILTER CARTRIDGE….372
CHECK AND ADJUST COOLING FAN BELT TENSION….373
EVERY 500 HOURS MAINTENANCE….374
LUBRICATING….374
REPLACE ENGINE OIL FILTER CARTRIDGE….375
REPLACE FUEL FILTER ELEMENT….376
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS….378
REPLACE FUEL FEED PUMP PRE-FILTER….379
EVERY 1000 HOURS MAINTENANCE….380
CHANGE OIL IN FINAL DRIVE CASE….380
EVERY 2000 HOURS MAINTENANCE….381
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….381
CHECK ALTERNATOR, STARTING MOTOR….382
CHECK ENGINE VALVE CLEARANCE, ADJUST….382
SPECIFICATIONS….384
SPECIFICATIONS….385
ATTACHMENTS, OPTIONS….388
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….389
SAFETY FIRST….389
ATTACHMENT INSTALLATION….390
BUCKET WITH HOOK….391
HOOK CONDITION….391
PROHIBITED OPERATIONS….391
ATTACHMENT GUIDE….392
ATTACHMENT COMBINATIONS….392
HANDLING ARM WITH BUILT-IN BREAKER….393
BUCKET POSTURE….393
REMOVING AND INSTALLING CHISEL….393
PROCEDURE FOR BREAKER OPERATIONS….394
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….395
STOWING CHISEL, DUMMY CHISEL….396
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….396
HANDLING DUMMY LINK….397
CHECK BEFORE STARTING….398
SPECIFICATIONS….399
HANDLING BUCKET COUPLER….400
PROCEDURE FOR REMOVING BUCKET….400
PROCEDURE FOR INSTALLING BUCKET….402
RECOMMENDED ATTACHMENT OPERATIONS….404
HYDRAULIC BREAKER….404
INDEX….408
SEBM026105 – Hydraulic Excavator PC09-1 Shop Manual….412
COVER….412
CONTENTS….413
01 GENERAL….436
GENERAL ASSEMBLY DRAWING….437
SPECIFICATIONS….438
WEIGHT TABLE….444
LIST OF LUBRICANT AND WATER….446
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….447
RADIATOR….448
ENGINE CONTROL….450
PTO….452
POWER TRAIN DIAGRAM….453
SWING CIRCLE….454
TRACK FRAME….455
IDLER CUSHION….457
IDLER….458
TRACK ROLLER….459
TRACK SHOE….460
HYDRAULIC EQUIPMENT LAYOUT….461
VALVE CONTROL….462
HYDRAULIC TANK….463
HYDRAULIC PUMP….464
10-SPOOL CONTROL VALVE….466
CENTER SWIVEL JOINT….468
SWING MOTOR….469
TRAVEL MOTOR….470
HYDRAULIC CYLINDER….476
WORK EQUIPMENT….478
DIMENSION OF WORK EQUIPMENT….480
MACHINE MONITOR SYSTEM….484
20 TESTING AND ADJUSTING….486
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS….487
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS….489
TESTING AND ADJUSTING….497
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING….498
MEASUREMENT ENGINE SPEED….499
MASURING EXHAUST COLOR….501
ADJUSTMENT VALVE CLEARANCE….503
MEASURING COMPRESSION PRESSURE….504
MEASURING ENGINE OIL PRESSURE….505
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING….506
ADJUSTMENT OF FUEL CONTROL CABLE….508
BLEEDING AIR FROM FUEL CIRCUIT….510
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION….511
TESTING AND ADJUSTING TRACK SHOE TENSION….512
INSPECTION AND ADJUSTMENT OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS….513
IDENTIFICATION OF SPOT CAUSING WORK EQUIPMENT HYDRAULIC DRIFT….516
MEASUREMENT OF OIL LEAK AMOUNT INSIDE WORK EQUIPMENT CYLINDER….517
BLEEDING AIR FROM HYDRAULIC CIRCUITS….517
PRESSURIZING HYDRAULIC TANK….518
TROUBLESHOOTING….519
POINTS TO REMEMBER WHEN TROUBLESHOOTING….520
SEQUENCE OF EVENTS IN TROUBLESHOOTING….521
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ….522
CHECKS BEFORE TROUBLESHOOTING….530
METHOD OF USING TROUBLESHOOTING….531
CONNECTOR MOUNTING LOCATIONS AND ELECTRICAL CIRCUITS….532
CONNECTOR PIN ALLOCATION DRAWING….533
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START, STOP, PREHEATING AND CHARGING SYSTEMS (E CIRCUIT)….535
ELECTRICAL CIRCUIT DIAGRAM FOR PANEL SYSTEMS (P CIRCUIT)….536
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS….537
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….539
INFORMATION IN TROUBLESHOOTING TABLE….540
E-1 ENGINE DOES NOT START….541
E-2 ENGINE DOES NOT STOP….545
E-3 ENGINE OIL PRESSURE LAMP DOES NOT WORK PROPERLY….546
E-4 ENGINE COOLING WATER TEMPERATURE LAMP DOES NOT WORK PROPERLY….548
E-5 ENGINE PREHEATING SYSTEM DOES NOT WORK….550
E-6 SERVICE METER DOES NOT ADVANCE….552
E-7 HORN DOES NOT SOUND, OR DOES NOT STOP SOUNDING….553
E-8 WORKING LAMP DOES NOT LIGHT UP, OR DOES NOT GO OFF….555
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)….557
METHOD OF USING TROUBLESHOOTING CHARTS….558
H-1 ALL WORK EQUIPMENT, TRAVEL AND SWING SHOW SLOW SPEED OR LACK IN POWER….560
H-2 ENGINE RUNNING SPEED DROPS SHARPLY OR ENGINE STAALS.MOREOVER, ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE AT ALL OR MOVE EXTREMELY SLOWLY…..560
H-3 THERE IS NOISE FROM AROUND HYDRAULIC PUMP….561
H-4 CONTROL LEVERS AND PEDALS ARE HARD TO OPERATE….561
H-5 BOOM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….562
H-6 ARM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….562
H-7 BUCKET MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….563
H-8 SWING IS SLOW, LACKS IN POWER AND HAS BIG HYDRAULIC DRIFT….563
H-9 BLADE MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….563
H-10 MACHINE DEVIATES FROM TRAVEL PATH IN TRAVELING….564
a) THE MACHINE DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND IN REVERSE DIRECTIONS ….564
b) THE DEVIATION DIRECTION CHANGES DEPENDING ON FORWARD OR REVERSE TRAVEL….564
H-11 NO POWER OR SLOW IN TRAVELING….566
H-12 UNDERCARRIAGE DOES NOT MOVE (ONE SIDE ONLY)….566
H-13 TRAVEL SPEED CANNOT BE CHANGED….567
H-14 UPPER STRUCTURE DOES NOT SWING….567
H-15 SWING SPEED IS SLOW OR ACCELERATION IS POOR….568
H-16 OVERRUN WHEN STOPPING WING IS BIG….568
H-17 THERE IS BIG SHOCK WHEN STOPPING SWING….569
H-18 THERE IS BIG NOISE WHEN STOPPING SWING….569
H-19 HYDRAULIC DRIFT OF SWING IS BIG….570
H-20 TROUBLESHOOTING OF HYDRAULIC BREAKER….571
30 DISASSEMBLY AND ASSEMBLY….572
METHOD OF USING MANUAL….573
PRECAUTIONS WHEN CARRYING OUT OPERATION….574
SPECIAL TOOL LIST….576
SWING MOTOR….577
REMOVAL AND INSTALLATION….577
CENTER SWIVEL JOINT….578
REMOVAL AND INSTALLATION….577
DISASSEMBLY AND ASSEMBLY….579
ENGINE AND HYDRAULIC PUMP….580
REMOVAL….580
INSTALLATION….583
REVOLVING FRAME….584
REMOVAL ….584
INSTALLATION….585
SWING CIRCLE….586
REMOVAL AND INSTALLATION….586
IDLER….587
ASSEMBLY….587
TRACK ROLLER….588
ASSEMBLY….588
RUBBER SHOE….588
REMOVAL AND INSTALLATION….588
CONTROL VALVE….589
ASSEMBLY….589
HYDRAULIC CYLINDER….590
ASSEMBLY….590
HYDRAULIC BREAKER….593
DISASSEMBLY….594
ASSEMBLY….597
90 OTHERS….601
HYDRAULIC CIRCUIT DIAGRAM….602
FIXED GAUGE TYPE (STD)….602
VARIABLE GAUGE TYPE (IF EQUIPPED)….603
ELECTRICAL CIRCUIT DIAGRAM….604
STANDERD SPECIFICATION….604
TRAVEL ALREM SPECIFICATION (IF EQUIPPED)….605
TEN00062-04 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual….606
COVER….606
FOREWORD….607
FOREWORD….608
SAFETY INFORMATION….611
INTRODUCTION….613
DIRECTIONS OF MACHINE….613
PRODUCT INFORMATION….614
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….614
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….614
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….615
SERVICE METER LOCATION….615
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….616
CONTENTS….617
SAFETY….621
SAFETY….622
SAFETY LABELS….624
LOCATION OF SAFETY LABELS….624
SAFETY LABELS….625
GENERAL PRECAUTIONS….628
SAFETY MACHINE OPERATION….636
STARTING ENGINE….636
OPERATION….637
TRANSPORTATION….644
BATTERY….645
TOWING….647
LIFTING OBJECTS WITH BUCKET….648
SAFETY MAINTENANCE INFORMATION….649
OPERATION….655
MACHINE VIEW ILLUSTRATIONS….656
OVERALL MACHINE VIEW….656
CONTROLS AND GAUGES….657
DETAILED CONTROLS AND GAUGES….658
METERS, LAMPS….658
SWITCHES….660
CONTROL LEVERS AND PEDALS….662
VARIABLE BLADE….669
ENGINE HOOD….669
FUSE….670
BLOCK FUSE….670
OPERATION MANUAL STORAGE….671
MACHINE OPERATIONS AND CONTROLS….672
BEFORE STARTING ENGINE….672
STARTING ENGINE….683
AFTER STARTING ENGINE….686
STOPPING THE ENGINE….689
CHECK AFTER SHUT OFF ENGINE….689
MACHINE OPERATION….690
STEERING THE MACHINE….694
SWINGING….696
WORK EQUIPMENT CONTROLS AND OPERATIONS….697
PROHIBITED OPERATIONS….699
GENERAL OPERATION INFORMATION….702
TRAVELING ON SLOPES….703
ESCAPE FROM MUD….705
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….706
BUCKET REPLACEMENT….708
PARKING MACHINE….710
MACHINE INSPECTION AFTER DAILY WORK….711
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)….712
TRANSPORTATION….717
TRANSPORTATION PROCEDURE….717
LOADING AND UNLOADING WITH TRAILER….717
LIFTING MACHINE….719
SHIPPING MACHINE INFORMATION….721
COLD WEATHER OPERATION….722
COLD WEATHER OPERATION INFORMATION….722
AFTER DAILY WORK COMPLETION….724
AFTER COLD WEATHER SEASON….724
LONG TERM STORAGE….725
BEFORE STORAGE….725
DURING STORAGE….725
AFTER STORAGE….725
STARTING MACHINE AFTER LONG-TERM STORAGE….725
TROUBLES AND ACTIONS….726
RUNNING OUT OF FUEL….726
PHENOMENA THAT ARE NOT FAILURES….726
TOWING THE MACHINE….727
SEVERE JOB CONDITION….727
DISCHARGED BATTERY….728
OTHER TROUBLE….732
MAINTENANCE….737
MAINTENANCE INFORMATION….738
OUTLINE OF SERVICE….740
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….740
ELECTRIC SYSTEM MAINTENANCE….743
WEAR PARTS….744
WEAR PARTS LIST….744
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….745
PROPER SELECTION….745
TIGHTENING TORQUE SPECIFICATIONS….749
TIGHTENING TORQUE LIST….749
SAFETY CRITICAL PARTS….750
SAFETY CRITICAL PARTS LIST….750
MAINTENANCE SCHEDULE….751
MAINTENANCE SCHEDULE CHART….751
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….752
MAINTENANCE PROCEDURE….753
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….753
WHEN REQUIRED….754
CHECK BEFORE STARTING….769
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE….769
EVERY 100 HOURS MAINTENANCE….770
EVERY 250 HOURS MAINTENANCE….771
EVERY 500 HOURS MAINTENANCE….776
EVERY 1000 HOURS MAINTENANCE….783
EVERY 2000 HOURS MAINTENANCE….784
SPECIFICATIONS….787
SPECIFICATIONS….788
ATTACHMENTS, OPTIONS….791
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….792
SAFETY FIRST….792
ATTACHMENT INSTALLATION….793
BUCKET WITH HOOK….794
HOOK CONDITION….794
PROHIBITED OPERATIONS….794
ATTACHMENT GUIDE….795
ATTACHMENT COMBINATIONS….795
HANDLING ARM WITH BUILT-IN BREAKER….796
BUCKET POSTURE….796
REMOVING AND INSTALLING CHISEL….796
PROCEDURE FOR BREAKER OPERATIONS….797
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….798
STOWING CHISEL, DUMMY CHISEL….799
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….799
HANDLING DUMMY LINK….800
CHECK BEFORE STARTING….801
SPECIFICATIONS….802
HANDLING BUCKET COUPLER….803
PROCEDURE FOR REMOVING BUCKET….803
PROCEDURE FOR INSTALLING BUCKET….805
HANDLING FOLDING TOPS CANOPY….807
RECOMMENDED ATTACHMENT OPERATIONS….809
HYDRAULIC BREAKER….809
INDEX….813
TEN00555-00 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual….817
COVER….817
FOREWORD….818
FOREWORD….819
SAFETY INFORMATION….822
INTRODUCTION….824
DIRECTIONS OF MACHINE….824
PRODUCT INFORMATION….825
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….825
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….825
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….826
SERVICE METER LOCATION….826
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….827
CONTENTS….828
SAFETY….832
SAFETY….833
SAFETY LABELS….835
LOCATION OF SAFETY LABELS….835
SAFETY LABELS….836
GENERAL PRECAUTIONS….839
SAFETY MACHINE OPERATION….847
STARTING ENGINE….847
OPERATION….848
TRANSPORTATION….855
BATTERY….856
TOWING….858
LIFTING OBJECTS WITH BUCKET….859
SAFETY MAINTENANCE INFORMATION….860
OPERATION….866
MACHINE VIEW ILLUSTRATIONS….867
OVERALL MACHINE VIEW….867
CONTROLS AND GAUGES….868
DETAILED CONTROLS AND GAUGES….869
METERS, LAMPS….869
SWITCHES….871
CONTROL LEVERS AND PEDALS….873
VARIABLE BLADE….880
ENGINE HOOD….880
FUSE….881
BLOCK FUSE….881
OPERATION MANUAL STORAGE….882
MACHINE OPERATIONS AND CONTROLS….883
BEFORE STARTING ENGINE….883
STARTING ENGINE….894
AFTER STARTING ENGINE….897
STOPPING THE ENGINE….900
CHECK AFTER SHUT OFF ENGINE….900
MACHINE OPERATION….901
STEERING THE MACHINE….905
SWINGING….907
WORK EQUIPMENT CONTROLS AND OPERATIONS….908
PROHIBITED OPERATIONS….910
GENERAL OPERATION INFORMATION….913
TRAVELING ON SLOPES….914
ESCAPE FROM MUD….916
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….917
BUCKET REPLACEMENT….919
PARKING MACHINE….921
MACHINE INSPECTION AFTER DAILY WORK….922
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)….923
TRANSPORTATION….928
TRANSPORTATION PROCEDURE….928
LOADING AND UNLOADING WITH TRAILER….928
LIFTING MACHINE….930
SHIPPING MACHINE INFORMATION….932
COLD WEATHER OPERATION….933
COLD WEATHER OPERATION INFORMATION….933
AFTER DAILY WORK COMPLETION….935
AFTER COLD WEATHER SEASON….935
LONG TERM STORAGE….936
BEFORE STORAGE….936
DURING STORAGE….936
AFTER STORAGE….936
STARTING MACHINE AFTER LONG-TERM STORAGE….936
TROUBLES AND ACTIONS….937
RUNNING OUT OF FUEL….937
PHENOMENA THAT ARE NOT FAILURES….937
TOWING THE MACHINE….938
SEVERE JOB CONDITION….938
DISCHARGED BATTERY….939
OTHER TROUBLE….943
MAINTENANCE….948
MAINTENANCE INFORMATION….949
OUTLINE OF SERVICE….951
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….951
ELECTRIC SYSTEM MAINTENANCE….954
WEAR PARTS….955
WEAR PARTS LIST….955
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….956
PROPER SELECTION….956
TIGHTENING TORQUE SPECIFICATIONS….960
TIGHTENING TORQUE LIST….960
SAFETY CRITICAL PARTS….961
SAFETY CRITICAL PARTS LIST….961
MAINTENANCE SCHEDULE….962
MAINTENANCE SCHEDULE CHART….962
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….963
MAINTENANCE PROCEDURE….964
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….964
WHEN REQUIRED….965
CHECK BEFORE STARTING….980
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE….980
EVERY 100 HOURS MAINTENANCE….981
EVERY 250 HOURS MAINTENANCE….982
EVERY 500 HOURS MAINTENANCE….987
EVERY 1000 HOURS MAINTENANCE….994
EVERY 2000 HOURS MAINTENANCE….995
SPECIFICATIONS….998
SPECIFICATIONS….999
ATTACHMENTS, OPTIONS….1002
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….1003
SAFETY FIRST….1003
ATTACHMENT INSTALLATION….1004
BUCKET WITH HOOK….1005
HOOK CONDITION….1005
PROHIBITED OPERATIONS….1005
ATTACHMENT GUIDE….1006
ATTACHMENT COMBINATIONS….1006
HANDLING ARM WITH BUILT-IN BREAKER….1007
BUCKET POSTURE….1007
REMOVING AND INSTALLING CHISEL….1007
PROCEDURE FOR BREAKER OPERATIONS….1008
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….1009
STOWING CHISEL, DUMMY CHISEL….1010
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….1010
HANDLING DUMMY LINK….1011
CHECK BEFORE STARTING….1012
SPECIFICATIONS….1013
HANDLING BUCKET COUPLER….1014
PROCEDURE FOR REMOVING BUCKET….1014
PROCEDURE FOR INSTALLING BUCKET….1016
HANDLING FOLDING TOPS CANOPY….1018
RECOMMENDED ATTACHMENT OPERATIONS….1020
HYDRAULIC BREAKER….1020
INDEX….1024
Komatsu Hydraulic Excavator PC09 Repair Service Manuals