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KOMATSU EC SERIES AIR COMPRESSOR SHOP MANUAL SEBM0680A10 – PDF DOWNLOAD
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KOMATSU EC SERIES AIR COMPRESSOR SHOP MANUAL SEBM0680A10 – PDF DOWNLOAD
MACHINE MODEL | SERIAL No.
EC35V,VS | 1001 and up
EC50V,VS | 1001 and up
EC105V,VS | 1001 and up
EC170V | 1001 and up
EC260V | 1001 and up
MACHINE MODEL | SERIAL No.
EC25Z,ZS | 1001 and up
EC35Z,ZS | 1001 and up
EC50Z,ZS | 1001 and up
EC75Z,ZS | 1001 and up
EC105Z,ZS | 1001 and up
EC170Z,ZS | 1001 and up
EC210Z | 1001 and up
EC260Z | 1001 and up
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Description
KOMATSU EC SERIES AIR COMPRESSOR SHOP MANUAL SEBM0680A10 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU EC SERIES AIR COMPRESSOR SHOP MANUAL SEBM0680A10 – PDF DOWNLOAD
Language : English
Pages : 1050
Downloadable : Yes
File Type : PDF
MACHINE MODEL | SERIAL No.
EC35V,VS | 1001 and up
EC50V,VS | 1001 and up
EC105V,VS | 1001 and up
EC170V | 1001 and up
EC260V | 1001 and up
EC35V,VS | 1001 and up
EC50V,VS | 1001 and up
EC105V,VS | 1001 and up
EC170V | 1001 and up
EC260V | 1001 and up
EC25Z,ZS | 1001 and up
EC35Z,ZS | 1001 and up
EC50Z,ZS | 1001 and up
EC75Z,ZS | 1001 and up
EC105Z,ZS | 1001 and up
EC170Z,ZS | 1001 and up
EC210Z | 1001 and up
EC260Z | 1001 and up
EC35Z,ZS | 1001 and up
EC50Z,ZS | 1001 and up
EC75Z,ZS | 1001 and up
EC105Z,ZS | 1001 and up
EC170Z,ZS | 1001 and up
EC210Z | 1001 and up
EC260Z | 1001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU EC SERIES AIR COMPRESSOR SHOP MANUAL SEBM0680A10 – PDF DOWNLOAD
COVER................................................................................................................................................ 1 CONTENTS............................................................................................................................................. 2 01 GENERAL........................................................................................................................................... 22 01 GENERAL....................................................................................................................................... 22 GENERAL...................................................................................................................................... 23 GENERAL LOCATIONS........................................................................................................................ 24 SPECIFICATIONS........................................................................................................................... 44 ENGINE LOCATIONS......................................................................................................................... 49 ENGINE SPECIFICATIONS.................................................................................................................... 54 ENGINE DIMENSIONS........................................................................................................................ 57 GENERAL DIMENSIONS....................................................................................................................... 64 WEIGHT TABLE............................................................................................................................. 66 SERIAL NUMBERS, WATER AND OIL FILLING AND DRAINING POINT................................................................................. 72 10 ENGINE............................................................................................................................................ 90 12 TESTING AND ADJUSTING......................................................................................................................... 90 TESTING AND ADJUSTING........................................................................................................................ 91 STANDARD VALUES FOR TESTING AND ADJUSTING................................................................................................ 92 TESTING AND ADJUSTING TOOL LIST.......................................................................................................... 100 TESTING AND ADJUSTING.................................................................................................................... 102 MEASURING ENGINE SPEED............................................................................................................... 103 1. ENGINE WITH MECHANICAL SERVICE METER.......................................................................................... 103 2. ENGINE WITH ELECTRIC SERVICE METER............................................................................................ 103 3. MEASUREMENT USING PIEZO-ELECTRIC TACHOMETER................................................................................... 104 CRANKING METHOD...................................................................................................................... 105 1. BARRING METHOD................................................................................................................ 105 2. CRANKING KIT METHOD........................................................................................................... 105 INTAKE AND EXHAUST SYSTEM................................................................................................................ 106 CHECKING OF INTAKE AND EXHAUST SYSTEM................................................................................................ 107 1. CHECKING AND CLEANING OF PRECLEANER (WHEN USED)............................................................................... 107 2. CHECKING ,CLEANING AND REPLACEMENT OF AIR CLEANER ............................................................................ 107 3. CHECKING AND CLEANING OF INTAKE PIPE.......................................................................................... 110 4. CHECKING AND CLEANING OF TURBOCHARGER......................................................................................... 111 CHECKING AND ADJUSTING VALVE CLEARANCE............................................................................................... 114 1. 92, 94, 95, 105, 110, 125, 130 SERIES ENGINES................................................................................. 114 2. 3D94, 95 SERIES ENGINE........................................................................................................ 116 CHECKING AND ADJUSTING INJECTOR AND VALVE CLEARANCE (CUMMINS ENGINE)................................................................. 118 1. INJECTOR ADJUSTMENT........................................................................................................... 118 2. CHECKING AND ADJUSTING VALVE CLEARANCE........................................................................................ 120 MEASUREMENT OF EXHAUST COLOR (BOSCH TYPE)............................................................................................ 121 ENGINE BODY.............................................................................................................................. 122 BLOWBY MEASUREMENT................................................................................................................... 123 1. KOMATSU ENGINES............................................................................................................... 123 2. CUMMINS ENGINES............................................................................................................... 123 3. DETERMINATION OF RESULTS OF BLOWBY MEASUREMENTS AND REMEDY.................................................................... 124 MEASUREMENT OF COMPRESSION PRESSURE ................................................................................................. 125 1. KOMATSU ENGINES............................................................................................................... 125 2. CUMMINS ENGINES............................................................................................................... 125 3. PRECAUTIONS WHEN MEASURING COMPRESSION PRESSURE .............................................................................. 126 4. RESULTS OF COMPRESSION PRESSURE MEASUREMENTS.................................................................................. 126 CLEANING PISTON COOLING NOZZLE....................................................................................................... 127 CLEANING BREATHER ELEMENT............................................................................................................ 128 LUBRICATION SYSTEM...................................................................................................................... 129 CHECKING LUBRICATION SYSTEM.......................................................................................................... 130 1.CHECKING OIL LEVEL............................................................................................................. 130 2.CHECKING OIL FOR DIRT AND DEGRADATION.......................................................................................... 131 3.CHECKING OIL FOR INGRESS OF METAL DUST......................................................................................... 134 4.CHECKING OIL FOR INGRESS OF FUEL............................................................................................... 134 5.CHECKING OIL FOR INGRESS OF WATER.............................................................................................. 135 6.CHECKING AND MEASUREMENT OF OIL PRESSURE....................................................................................... 136 7.CHECKING AND MEASUREMENT OF OIL TEMPERATURE.................................................................................... 137 REPLACEMENT AND CLEANING OF LUBRICATION SYSTEM....................................................................................... 138 1.OIL REPLACEMENT................................................................................................................ 138 2.REPLACEMENT OF OIL FILTER ELEMENT.............................................................................................. 139 3.REPLACEMENT OF BYPASS FILTER ELEMENT........................................................................................... 141 MEASUREMENT OF OIL CONSUMPTION....................................................................................................... 144 KOMATSU ENGINE FUEL SYSTEM............................................................................................................... 146 CHECKING FUEL SYSTEM................................................................................................................. 147 1.CHECKING FUEL LEVEL............................................................................................................ 147 2.CHECKING FUEL FOR INGRESS OF WATER OR DIRT..................................................................................... 147 3.CHECKING FUEL FOR INGRESS OF AIR, AND AIR BLEED................................................................................ 148 REPLACEMENT AND CLEANING OF COMPONENTS OF FUEL SYSTEM................................................................................ 149 1.REPLACEMENT OF FUEL FILTER ELEMENT............................................................................................. 149 2.CLEANING FEED PUMP STRAINER.................................................................................................... 150 CHECKING FUEL INJECTION PUMP......................................................................................................... 151 1. CHECKING CONTROL LEVER POSITION............................................................................................... 151 2. CHECKING FUEL INJECTION PUMP DISCHARGE PERFORMANCE............................................................................ 151 3. OPERATING CHECKING FUEL INJECTION PUMP RACK................................................................................... 151 4. OPERATING CHECKING FUEL INJECTION PUMP PLUNGER................................................................................ 152 CHECKING AND ADJUSTMENT OF FUEL INJECTION NOZZLE..................................................................................... 153 1. CHECKING INJECTION PRESSURE AND SPRAY CONDITION............................................................................... 153 2. ADJUSTMENT OF INJECTION PRESSURE.............................................................................................. 154 3. WASHING THE NOZZLE............................................................................................................ 154 ADJUSTMENT OF FUEL INJECTION TIMING ................................................................................................. 155 1. ADJUSTMENT OF MATCH MARKS..................................................................................................... 155 2. DELIVERY ADJUSTMENT........................................................................................................... 157 CUMMINS ENGINE FUEL SYSTEM............................................................................................................... 162 CHECKING FUEL SYSTEM................................................................................................................. 163 1. CHECKING FUEL QUANTITY........................................................................................................ 163 2. CHECKING FUEL FOR INGRESS OF WATER OR DIRT.................................................................................... 163 3. CHECKING FUEL FOR INGRESS OF AIR.............................................................................................. 164 4. CHECKING VACUUM PRESSURE...................................................................................................... 164 REPLACEMENT AND CLEANING OF COMPONENTS OF FUEL SYSTEM................................................................................ 165 1. REPLACEMENT OF FUEL FILTER ELEMENT............................................................................................ 165 2. CHECKING AND CLEANING OF PT PUMP FILTER SCREEN................................................................................ 166 CHECKING PT PUMP..................................................................................................................... 167 1. CHECKING CONTROL LEVER POSITION............................................................................................... 167 2. CHECKING AND MEASUREMENT OF FUEL PRESSURE..................................................................................... 168 3. CHECKING OPERATION OF CHUT-OFF VALVE.......................................................................................... 169 CHECKING INJECTOR.................................................................................................................... 170 COOLING SYSTEM........................................................................................................................... 171 CHECKING COOLING SYSTEM.............................................................................................................. 172 1. CHECKING COOLING WATER QUANTITY............................................................................................... 172 2. CHECKING COOLING WATER FOR INGRESS OF DIRT.................................................................................... 172 3. CHECKING COOLING WATER FOR OIL INGRESS........................................................................................ 173 4. CHECKING AND MEASUREMENT OF WATER TEMPERATURE................................................................................. 173 5. CHECKING FREEZING TEMPERATURE OF COOLING WATER................................................................................ 174 REPLACEMENT AND CLEANING OF COMPONENTS OF COOLING SYSTEM............................................................................. 175 1. REPLENISHING OR REPLACING COOLING WATER....................................................................................... 175 2. WASHING THE COOLING SYSTEM.................................................................................................... 177 3. REPLACEMENT OF CORROSION RESISTOR ELEMENT..................................................................................... 179 CHECKING THERMOSTAT FUNCTION......................................................................................................... 181 CHECKING AND ADJUSTMENT OF V-BELT TENSION AND REPLACEMENT OF V-BELT.................................................................. 182 1. CHECKING V-BELT TENSION....................................................................................................... 182 2. ADJUSTMENT OF BELT TENSION OR REPLACEMENT OF BELT............................................................................. 182 13 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 184 DISASSEMBLY AND ASSEMBLY..................................................................................................................... 185 EC35Z, ZS.................................................................................................................................... 186 STARTING MOTOR ASSEMBLY.................................................................................................................. 187 DISMOUNTING.......................................................................................................................... 187 MOUNTING............................................................................................................................. 187 ALTERNATOR ASSEMBLY...................................................................................................................... 188 DISMOUNTING.......................................................................................................................... 188 MOUNTING............................................................................................................................. 188 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 189 DISMOUNTING.......................................................................................................................... 189 MOUNTING............................................................................................................................. 190 NOZZLE HOLDER ASSEMBLY................................................................................................................... 192 DISMOUNTING.......................................................................................................................... 192 MOUNTING............................................................................................................................. 192 WATER PUMP ASSEMBLY...................................................................................................................... 193 DISMOUNTING.......................................................................................................................... 193 MOUNTING............................................................................................................................. 194 CYLINDER HEAD ASSEMBLY................................................................................................................... 195 DISMOUNTING.......................................................................................................................... 195 MOUNTING............................................................................................................................. 200 RADIATOR, OIL COOLER ASSEMBLY............................................................................................................ 206 DISMOUNTING.......................................................................................................................... 206 MOUNTING............................................................................................................................. 209 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 212 DISMOUNTING.......................................................................................................................... 212 MOUNTING............................................................................................................................. 216 EC50Z, ZS-3.................................................................................................................................. 221 STARTING MOTOR ASSEMBLY.................................................................................................................. 222 DISMOUNTING.......................................................................................................................... 222 MOUNTING............................................................................................................................. 222 ALTERNATOR ASSEMBLY...................................................................................................................... 223 DISMOUNTING.......................................................................................................................... 223 MOUNTING............................................................................................................................. 223 OIL COOLER ASSEMBLY...................................................................................................................... 224 DISMOUNTING.......................................................................................................................... 224 MOUNTING............................................................................................................................. 224 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 225 DISMOUNTING.......................................................................................................................... 225 MOUNTING............................................................................................................................. 226 WATER PUMP ASSEMBLY...................................................................................................................... 228 DISMOUNTING.......................................................................................................................... 228 MOUNTING............................................................................................................................. 230 NOZZLE HOLDER ASSEMBLY................................................................................................................... 232 DISMOUNTING.......................................................................................................................... 232 MOUNTING............................................................................................................................. 232 CYLINDER HEAD ASSEMBLY................................................................................................................... 233 DISMOUNTING.......................................................................................................................... 233 MOUNTING............................................................................................................................. 238 RADIATOR AND COMPRESSOR OIL COOLER ASSEMBLY.............................................................................................. 244 DISMOUNTING.......................................................................................................................... 244 MOUNTING............................................................................................................................. 246 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 248 DISMOUNTING.......................................................................................................................... 248 MOUNTING............................................................................................................................. 253 ENGINE ASSEMBLY AND COMPRESSOR ASSEMBLY.................................................................................................. 258 DICONNECTING......................................................................................................................... 258 CONNECTING .......................................................................................................................... 258 COMPRESSOR ASSEMBLY...................................................................................................................... 259 DISMOUNTING.......................................................................................................................... 259 MOUNTING............................................................................................................................. 264 EC50Z, ZS-5.................................................................................................................................. 269 STARTING MOTOR ASSEMBLY.................................................................................................................. 270 REMOVAL.............................................................................................................................. 270 INSTALLATION......................................................................................................................... 270 ALTERNATOR ASSEMBLY...................................................................................................................... 271 REMOVAL.............................................................................................................................. 271 INSTALLATION......................................................................................................................... 271 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 272 REMOVAL.............................................................................................................................. 272 INSTALLATION......................................................................................................................... 273 WATER PUMP ASSEMBLY...................................................................................................................... 274 REMOVAL.............................................................................................................................. 274 INSTALLATION......................................................................................................................... 274 NOZZLE HOLDER ASSEMBLY................................................................................................................... 275 REMOVAL.............................................................................................................................. 275 INSTALLATION......................................................................................................................... 275 CYLINDER HEAD ASSEMBLY................................................................................................................... 276 REMOVAL.............................................................................................................................. 276 INSTALLATION......................................................................................................................... 278 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 281 REMOVAL.............................................................................................................................. 281 INSTALLATION......................................................................................................................... 284 ENGINE ASSEMBLY AND COMPRESSOR ASSEMBLY.................................................................................................. 287 DISCONNECTING........................................................................................................................ 287 CONNECTING........................................................................................................................... 287 RADIATOR, OIL COOLER ASSEMBLY............................................................................................................ 288 REMOVAL.............................................................................................................................. 288 INSTALLATION......................................................................................................................... 288 EC75Z, ZS-2.................................................................................................................................. 289 STARTING MOTOR ASSEMBLY.................................................................................................................. 290 DISMOUNTING.......................................................................................................................... 290 MOUNTING............................................................................................................................. 290 ALTERNATOR ASSEMBLY...................................................................................................................... 291 DISMOUNTING.......................................................................................................................... 291 MOUNTING............................................................................................................................. 291 OIL COOLER ASSEMBLY...................................................................................................................... 292 DISMOUNTING.......................................................................................................................... 292 MOUNTING............................................................................................................................. 292 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 293 DISMOUNTING.......................................................................................................................... 293 MOUNTING............................................................................................................................. 293 WATER PUMP ASSEMBLY...................................................................................................................... 294 DISMOUNTING.......................................................................................................................... 294 MOUNTING............................................................................................................................. 294 NOZZLE HOLDER ASSEMBLY................................................................................................................... 295 DISMOUNTING.......................................................................................................................... 295 MOUNTING............................................................................................................................. 295 CYLINDER HEAD ASSEMBLY................................................................................................................... 296 DISMOUNTING.......................................................................................................................... 296 MOUNTING............................................................................................................................. 299 RADIATOR AND OIL COOLER ASSEMBLY......................................................................................................... 303 DISMOUNTING.......................................................................................................................... 303 MOUNTING............................................................................................................................. 305 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 307 DISMOUNTING.......................................................................................................................... 307 MOUNTING............................................................................................................................. 312 EC105Z, ZS................................................................................................................................... 317 STARTING MOTOR ASSEMBLY.................................................................................................................. 318 DISMOUNTING.......................................................................................................................... 318 MOUNTING............................................................................................................................. 318 ALTERNATOR ASSEMBLY...................................................................................................................... 319 DISMOUNTING.......................................................................................................................... 319 MOUNTING............................................................................................................................. 319 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 320 DISMOUNTING.......................................................................................................................... 320 MOUNTING............................................................................................................................. 320 OIL COOLER ASSEMBLY...................................................................................................................... 321 DISMOUNTING.......................................................................................................................... 321 MOUNTING............................................................................................................................. 321 NOZZLE HOLDER ASSEMBLY................................................................................................................... 322 DISMOUNTING.......................................................................................................................... 322 MOUNTING............................................................................................................................. 322 TURBOCHARGER ASSEMBLY.................................................................................................................... 323 DISMOUNTING.......................................................................................................................... 323 MOUNTING............................................................................................................................. 323 WATER PUMP ASSEMBLY...................................................................................................................... 324 DISMOUNTING.......................................................................................................................... 324 MOUNTING............................................................................................................................. 325 CYLINDER HEAD ASSEMBLY................................................................................................................... 326 DISMOUNTING.......................................................................................................................... 326 MOUNTING............................................................................................................................. 331 RADIATOR, OIL COOLER ASSEMBLY............................................................................................................ 336 DISMOUNTING.......................................................................................................................... 336 MOUNTING............................................................................................................................. 337 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 338 DISMOUNTING.......................................................................................................................... 338 MOUNTING............................................................................................................................. 345 EC170V-1..................................................................................................................................... 352 STARTING MOTOR........................................................................................................................... 353 DISMOUNTING ......................................................................................................................... 353 MOUNTING ............................................................................................................................ 353 DYNAMO................................................................................................................................... 354 DISMOUNTING.......................................................................................................................... 354 MOUNTING ............................................................................................................................ 354 OIL COOLER............................................................................................................................... 355 DISMOUNTING.......................................................................................................................... 355 MOUNTING............................................................................................................................. 355 OIL PUMP................................................................................................................................. 356 DISMOUNTING ......................................................................................................................... 356 MOUNTING............................................................................................................................. 356 P.T. PUMP................................................................................................................................ 357 DISMOUNTING.......................................................................................................................... 357 MOUNTING............................................................................................................................. 357 WATER PUMP............................................................................................................................... 358 DISMOUNTING.......................................................................................................................... 358 MOUNTING............................................................................................................................. 358 CYLINDER HEAD............................................................................................................................ 360 DISMOUNTING.......................................................................................................................... 360 MOUNTING............................................................................................................................. 365 RADIATOR AND OIL COOLER.................................................................................................................. 371 DISMOUNTING.......................................................................................................................... 371 MOUNTING............................................................................................................................. 374 ENGINE ASSEMBLY.......................................................................................................................... 377 DISMOUNTING.......................................................................................................................... 377 MOUNTING ............................................................................................................................ 382 EC170Z, ZS-1 EC210Z-1........................................................................................................................ 387 STARTING MOTOR ASSEMBLY.................................................................................................................. 388 DISMOUNTING.......................................................................................................................... 388 MOUNTING............................................................................................................................. 388 ALTERNATOR ASSEMBLY...................................................................................................................... 389 DISMOUNTING.......................................................................................................................... 389 MOUNTING............................................................................................................................. 389 OIL COOLER ASSEMBLY...................................................................................................................... 390 DISMOUNTING.......................................................................................................................... 390 MOUNTING............................................................................................................................. 390 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 391 DISMOUNTING.......................................................................................................................... 391 MOUNTING............................................................................................................................. 391 WATER PUMP ASSEMBLY...................................................................................................................... 392 DISMOUNTING.......................................................................................................................... 392 MOUNTING............................................................................................................................. 392 NOZZLE HOLDER ASSEMBLY................................................................................................................... 393 DISMOUNTING.......................................................................................................................... 393 MOUNTING............................................................................................................................. 393 TURBOCHARGER ASSEMBLY (EC170Z, ZS-1)..................................................................................................... 394 DISMOUNTING.......................................................................................................................... 394 MOUNTING............................................................................................................................. 394 TURBOCHARGER ASSEMBLY (EC210Z-1)......................................................................................................... 395 DISMOUNTING.......................................................................................................................... 395 MOUNTING............................................................................................................................. 395 AFTER-COOLER ASSEMBLY.................................................................................................................... 396 DISMOUNTING.......................................................................................................................... 396 MOUNTING............................................................................................................................. 397 CYLINDER HEAD ASSEMBLY (EC170Z, ZS-1).................................................................................................... 398 DISMOUNTING.......................................................................................................................... 398 MOUNTING............................................................................................................................. 402 CYLINDER HEAD ASSEMBLY (EC210Z-1)........................................................................................................ 407 DISMOUNTING.......................................................................................................................... 407 MOUNTING............................................................................................................................. 411 RADIATOR AND OIL COOLER ASSEMBLY......................................................................................................... 416 DISMOUNTING.......................................................................................................................... 416 MOUNTING............................................................................................................................. 418 GATE ROTOR ASSEMBLY...................................................................................................................... 420 DISMOUNTING.......................................................................................................................... 420 MOUNTING............................................................................................................................. 421 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 422 DISMOUNTING.......................................................................................................................... 422 MOUNTING............................................................................................................................. 426 EC260Z-1..................................................................................................................................... 430 STARTING MOTOR ASSEMBLY.................................................................................................................. 431 DISMOUNTING.......................................................................................................................... 431 MOUNTING............................................................................................................................. 431 ALTERNATOR ASSEMBLY...................................................................................................................... 432 DISMOUNTING.......................................................................................................................... 432 MOUNTING............................................................................................................................. 432 OIL COOLER ASSEMBLY...................................................................................................................... 433 DISMOUNTING.......................................................................................................................... 433 MOUNTING............................................................................................................................. 433 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 434 DISMOUNTING.......................................................................................................................... 434 MOUNTING............................................................................................................................. 435 WATER PUMP ASSEMBLY...................................................................................................................... 436 DISMOUNTING.......................................................................................................................... 436 MOUNTING............................................................................................................................. 436 NOZZLE HOLDER ASSEMBLY................................................................................................................... 437 DISMOUNTING.......................................................................................................................... 437 MOUNTING............................................................................................................................. 437 TURBOCHARGER ASSEMBLY.................................................................................................................... 438 DISMOUNTING.......................................................................................................................... 438 MOUNTING............................................................................................................................. 438 CYLINDER HEAD ASSEMBLY................................................................................................................... 439 DISMOUNTING.......................................................................................................................... 439 MOUNTING............................................................................................................................. 446 RADIATOR, OIL COOLER ASSEMBLY............................................................................................................ 454 DISMOUNTING.......................................................................................................................... 454 MOUNTING............................................................................................................................. 459 GATE ROTOR ASSEMBLY...................................................................................................................... 464 DISMOUNTING.......................................................................................................................... 464 MOUNTING............................................................................................................................. 465 ENGINE, COMPRESSOR ASSEMBLY.............................................................................................................. 466 DISMOUNTING.......................................................................................................................... 466 MOUNTING............................................................................................................................. 472 20 COMPRESSOR........................................................................................................................................ 478 21 STRUCTURE AND FUNCTION........................................................................................................................ 478 STRUCTURE AND FUNCTION....................................................................................................................... 479 GENERAL.................................................................................................................................. 480 ROTARY COMPRESSOR........................................................................................................................ 503 Z-SCREW COMPRESSOR....................................................................................................................... 508 22 TESTING AND ADJUSTING......................................................................................................................... 521 TESTING AND ADJUSTING........................................................................................................................ 522 ROTARY COMPRESSOR........................................................................................................................ 523 Z-SCREW COMPRESSOR....................................................................................................................... 526 ADJUSTING A Z-SCREW TYPE (ONE-UNIT TYPE) COMPRESSOR...................................................................................... 530 23 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 531 DISASSEMBLY AND ASSEMBLY..................................................................................................................... 532 EC35Z, ZS................................................................................................................................ 533 COMPRESSOR ASSEMBLY.................................................................................................................. 534 DISMOUNTING...................................................................................................................... 534 MOUNTING......................................................................................................................... 536 DISASSEMBLY...................................................................................................................... 538 ASSEMBLY......................................................................................................................... 544 EC35V, VS................................................................................................................................ 550 COMPRESSOR ASSEMBLY.................................................................................................................. 551 DISMOUNTING...................................................................................................................... 551 MOUNTING......................................................................................................................... 555 DISASSEMBLING.................................................................................................................... 559 ASSEMBLING....................................................................................................................... 562 EC50Z, ZS-1, 2........................................................................................................................... 565 COMPRESSOR ASSEMBLY.................................................................................................................. 566 DISMOUNTING...................................................................................................................... 566 MOUNTING......................................................................................................................... 570 EC50Z-3 10001๏ฝ15652 EC50ZS-3 10001๏ฝ10561................................................................................................. 574 COMPRESSOR ASSEMBLY.................................................................................................................. 574 DISASSEMBLY...................................................................................................................... 574 ASSEMBLY......................................................................................................................... 580 EC50Z-3 15653๏ฝ EC50ZS-3 10362๏ฝ.......................................................................................................... 586 COMPRESSOR ASSEMBLY.................................................................................................................. 586 DISMOUNTING ..................................................................................................................... 586 MOUNTING......................................................................................................................... 590 DISASSEMBLING.................................................................................................................... 594 ASSEMBLING....................................................................................................................... 600 GATE ROTOR........................................................................................................................... 607 DISMOUNTING...................................................................................................................... 607 MOUNTING......................................................................................................................... 609 EC50V, VS................................................................................................................................ 611 COMPRESSOR ASSEMBLY.................................................................................................................. 612 DISMOUNTING ..................................................................................................................... 612 MOUNTING......................................................................................................................... 614 DISASSEMBLING.................................................................................................................... 616 ASSEMBLING....................................................................................................................... 620 EC75Z, ZS................................................................................................................................ 623 COMPRESSOR ASSEMBLY.................................................................................................................. 624 DISMOUNTING ..................................................................................................................... 624 MOUNTING......................................................................................................................... 627 DISASSEMBLING.................................................................................................................... 629 ASSEMBLING ...................................................................................................................... 633 EC105Z, ZS............................................................................................................................... 638 GATE ROTOR .......................................................................................................................... 639 DISMOUNTING...................................................................................................................... 639 MOUNTING......................................................................................................................... 640 COMPRESSOR ASSEMBLY.................................................................................................................. 641 DISMOUNTING...................................................................................................................... 641 MOUNTING......................................................................................................................... 647 DISASSEMBLY...................................................................................................................... 653 ASSEMBLY......................................................................................................................... 657 EC SERIES................................................................................................................................ 661 VOLUME REGULATOR..................................................................................................................... 662 DISASSEMBLING.................................................................................................................... 662 ASSEMBLING....................................................................................................................... 663 OIL RECLAIMER (EC35, VS, EC50Z, ZS).................................................................................................. 664 DISMOUNTING...................................................................................................................... 664 MOUNTING......................................................................................................................... 666 RECEIVER TANK (EC50V TO 260V, VS, EC75Z, ZS)......................................................................................... 668 DISMOUNTING...................................................................................................................... 668 MOUNTING......................................................................................................................... 670 EC75Z, ZS-2.............................................................................................................................. 671 GATE ROTOR ASSEMBLY.................................................................................................................. 672 DISMOUNTING...................................................................................................................... 672 MOUNTING......................................................................................................................... 674 COMPRESSOR ASSEMBLY.................................................................................................................. 676 DISMOUNTING...................................................................................................................... 676 MOUNTING......................................................................................................................... 680 DISASSEMBLY...................................................................................................................... 684 ASSEMBLY......................................................................................................................... 689 EC170V................................................................................................................................... 695 RECEIVER TANK ....................................................................................................................... 696 DISMOUNTING ..................................................................................................................... 696 MOUNTING......................................................................................................................... 698 VOLUME REGULATOR..................................................................................................................... 700 DISMOUNTING...................................................................................................................... 700 MOUNTING ........................................................................................................................ 702 DISASSEMBLING.................................................................................................................... 704 ASSEMBLING....................................................................................................................... 706 COMPRESSOR ASSEMBLY.................................................................................................................. 708 DISMOUNTING...................................................................................................................... 708 MOUNTING......................................................................................................................... 711 HIGH PRESSURE CYLINDER............................................................................................................... 716 DISASSEMBLING.................................................................................................................... 716 ASSEMBLING....................................................................................................................... 718 LOW PRESSURE CYLINDER................................................................................................................ 720 DISASSEMBLING.................................................................................................................... 720 ASSEMBLING....................................................................................................................... 725 EC170Z, ZS-1 EC210Z-1.................................................................................................................... 729 COMPRESSOR ASSEMBLY.................................................................................................................. 730 DISMOUNTING...................................................................................................................... 730 MOUNTING......................................................................................................................... 733 DISASSEMBLY...................................................................................................................... 736 ASSEMBLY......................................................................................................................... 740 EC260Z-1................................................................................................................................. 744 COMPRESSOR ASSEMBLY.................................................................................................................. 745 DISMOUNTING...................................................................................................................... 745 MOUNTING......................................................................................................................... 750 DISASSEMBLY...................................................................................................................... 755 ASSEMBLY......................................................................................................................... 759 24 MAINTENANCE STANDARD.......................................................................................................................... 763 MAINTENANCE STANDARD......................................................................................................................... 764 ROTARY TYPE COMPRESSOR................................................................................................................... 765 OIL PUMP................................................................................................................................. 775 Z-SCREW TYPE COMPRESSOR.................................................................................................................. 783 30 REGULATOR......................................................................................................................................... 787 31 STRUCTURE AND FUNCTION........................................................................................................................ 787 STRUCTURE AND FUNCTION....................................................................................................................... 788 OPERATION OF REGULATOR....................................................................................................................... 789 VOLUME REGULATOR............................................................................................................................. 792 SPEED REGULATOR.............................................................................................................................. 803 STRUCTURE AND FUNCTION VOLUME REGULATOR...................................................................................................... 807 SPEED REGULATOR.............................................................................................................................. 810 LOADING VALVE................................................................................................................................ 812 MAGNETIC VALVE (OPTION )..................................................................................................................... 813 THREE-WAY COCK (OPTION )..................................................................................................................... 814 OPERATION DIAGRAM OF REGULATORS.............................................................................................................. 815 32 TESTING AND ADJUSTING......................................................................................................................... 831 TESTING AND ADJUSTING........................................................................................................................ 832 TESTING AND ADJUSTING TABLE.............................................................................................................. 833 ADJUSTING OF REGULATOR................................................................................................................... 835 CHECKING THE SAFETY VALVE AND TESTING THE MINIMUM PRESSURE VALVE AND AUTOMATIC BLOW-OFF VALVE............................................ 841 TROUBLE SHOOTING............................................................................................................................. 842 GENERAL.................................................................................................................................. 843 TESTING.................................................................................................................................. 845 ROTRAY COMPRESSOR ....................................................................................................................... 846 Z-SCREW COMPRESSOR....................................................................................................................... 849 REGULATOR................................................................................................................................ 851 34 MAINTENANCE STANDARD.......................................................................................................................... 855 MAINTENANCE STANDARD......................................................................................................................... 856 VOLUME REGULATOR......................................................................................................................... 857 40 LUBRICATION SYSTEM................................................................................................................................ 860 41 STRUCTURE AND FUNCTION........................................................................................................................ 860 STRUCTURE AND FUNCTION....................................................................................................................... 861 GENERAL.................................................................................................................................. 862 RECEIVER TANK............................................................................................................................ 877 OIL RECLAIMER............................................................................................................................ 883 OIL FILTER .............................................................................................................................. 884 THERMOSTAT VALVE......................................................................................................................... 885 OIL MANIFOLD............................................................................................................................. 887 SLUICE VALVE............................................................................................................................. 888 LUBRICATION OIL PIPING................................................................................................................... 894 42 TESTING AND ADJUSTING......................................................................................................................... 918 TESTING AND ADJUSTING........................................................................................................................ 919 TESTING THERMOSTAT VALVE................................................................................................................. 920 CHANGING OIL AND CLEANING COMPRESSOR..................................................................................................... 922 TROUBLE SHOOTING............................................................................................................................. 925 LUBRICATION OIL (MAIN CAUSES AND CHECKING)............................................................................................... 926 44 MAINTENANCE STANDARD......................................................................................................................... 929 MAINTENANCE STANDARD......................................................................................................................... 930 OIL MANIFOLD............................................................................................................................. 931 50 AIR SYSTEM........................................................................................................................................ 932 51 STRUCTURE AND FUNCTION........................................................................................................................ 932 STRUCTURE AND FUNCTION....................................................................................................................... 933 GENERAL.................................................................................................................................. 934 MINIMUM PRESSURE VALVE................................................................................................................... 935 SAFETY VALVE............................................................................................................................. 937 AUTOMATIC BLOW-OFF VALVE................................................................................................................. 939 AIR PIPING............................................................................................................................... 943 52 TESTING AND ADJUSTING......................................................................................................................... 952 TESTING AND ADJUSTING........................................................................................................................ 953 CHECKING SAFETY VALVE AND MINIMUM PRESSURE VALVE AND AUTOMATIC BLOW-OFF VALVE TESTS...................................................... 954 70 OTHERS............................................................................................................................................ 955 71 STRUCTURE AND FUNCTION........................................................................................................................ 955 STRUCTURE AND FUNCTION....................................................................................................................... 956 EXPLANATION OF COMPONENT PARTS (EMERGENCY STOP, MONITORING DEVICES)...................................................................... 957 EMERGENCY STOP MONITORING DEVICES........................................................................................................ 959 EXPLANATION OF COMPONENT PARTS (AUTOMATIC START, EMERGENCY STOP AND MONITORING DEVICES).................................................. 969 ELECTRICAL CIRCUIT DIAGRAM............................................................................................................... 973 CHASSIS...................................................................................................................................... 998 CASTER WHEEL............................................................................................................................. 999 REAR AXLE................................................................................................................................1000 FRONT AXLE...............................................................................................................................1004 BRAKE LINKAGE............................................................................................................................1005 BRAKE....................................................................................................................................1006 FUEL TANK................................................................................................................................1008 TROUBLESHOOTING..............................................................................................................................1013 GENERAL..................................................................................................................................1014 PRECAUTIONS IN TROUBLESHOOTING...........................................................................................................1015 EMERGENCY STOP MONITORING DEVICES (EC35Z, ZS-1)..........................................................................................1016 EMERGENCY STOP MONITORING DEVICES (EC75Z, ZS-2, EC105Z,ZS-1, EC170Z, ZS-1, EC210Z-1).....................................................1022 AUTOMATIC STARTING, EMERGENCY STOP AND MONITORING DEVICES (OPTION: EC75ZS-2, EC105ZS-1,EC170ZS-1)........................................1028 TROUBLESHOOTING TABLE CLASSIFIED BY AUTOMATIC STARTING, EMERGENCY STOP AND MONITORING DEVICES (OPTION: EC75ZS-2, EC105ZS-1,EC170ZS-1)....1039 72 TESTING AND ADJUSTING.........................................................................................................................1044 TESTING AND ADJUSTING........................................................................................................................1045 TABLE OF EMERGENCY SYSTEMS...............................................................................................................1046 FUEL CUT SOLENOID........................................................................................................................1047 TESTING CIRCUIT OF EMERGENCY SYSTEM......................................................................................................1048 CHECKING SENSORS.........................................................................................................................1049
DESCRIPTION:
KOMATSU EC SERIES AIR COMPRESSOR SHOP MANUAL SEBM0680A10 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality at repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure. but also serves as reference material for Troubleshooting .
TESTING AND ADJUSTING
This section explains checks to be made before and alter performing repairs. as well as adjustments to be made at completion of the checks and Repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken For these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 29/12/24
