Komatsu PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual
Description:
Komatsu PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac- curate 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.The manual is divided into chapters on 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 under- standing of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections explains checks to be made before and after 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.
Table of Contents:
Komatsu PC12R-8 PC15R-8 Hydraulic Excavator Service Repair Manual
COVER............................................................................................ 1 CONTENTS..................................................................................... 3 LIST OF REVISED PAGES........................................................................ 5 SAFETY....................................................................................... 7 FOREWORD..................................................................................... 9 HOW TO READ THE SHOP MANUAL.................................................................. 10 HOISTING INSTRUCTIONS........................................................................ 11 STANDARD TIGHTENING TORQUE................................................................... 12 COATING MATERIALS............................................................................ 13 ELECTRIC WIRE CODE........................................................................... 14 WEIGHT TABLE................................................................................. 15 TABLE OF OIL AND COOLANT QUANTITIES.......................................................... 16 10.STRUCTURE AND FUNCTION.................................................................... 19 POWER TRAIN.............................................................................. 20 SWING CIRCLE............................................................................. 22 SWING MOTOR.............................................................................. 23 FINAL DRIVE.............................................................................. 24 TRACK FRAME AND RECOIL SPRING............................................................ 25 VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING............................................. 27 CARRIER ROLLER........................................................................... 28 STEEL SHOE............................................................................... 29 HYDRAULIC SYSTEM PC12R-8................................................................. 31 HYDRAULIC SYSTEM PC15R-8................................................................. 33 HYDRAULIC CIRCUIT DIAGRAM PC12R-8........................................................ 35 HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL................................................ 37 HYDRAULIC CIRCUIT DIAGRAM PC12R-8 HS..................................................... 39 HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL HS............................................. 41 HYDRAULIC CIRCUIT DIAGRAM PC15R-8........................................................ 43 HYDRAULIC CIRCUIT DIAGRAM PC15R-8 HS..................................................... 45 HYDRAULIC CIRCUIT DIAGRAM................................................................ 46 HYDRAULIC PUMP........................................................................... 47 CONTROL VALVE PC12R-8 PC12R-8 MISTRAL.................................................... 52 CONTROL VALVE PC12R-8 HS PC12R-8 MISTRAL HS.............................................. 54 CLSS..................................................................................... 62 CONTROL VALVE PC15R-8.................................................................... 80 CLSS..................................................................................... 90 SWIVEL JOINT.............................................................................107 TRAVEL MOTOR.............................................................................110 CYLINDERS................................................................................113 VALVE CONTROL............................................................................117 ACCUMULATOR..............................................................................118 PPC VALVE................................................................................119 PPC VALVE................................................................................121 SOLENOID VALVE...........................................................................124 VARIABLE GAUGE UNDERCARRIAGE SERVOCONTROL................................................127 SAFETY VALVE.............................................................................128 CUTTING SHOVEL CONTROL VALVE.............................................................129 ELECTRICAL CIRCUIT DIAGRAM...............................................................131 20.TESTING AND ADJUSTMENTS...................................................................135 NORMAL OR STANDARD TECHNICAL DATA........................................................136 SPECIAL TOOLS............................................................................157 CHECKING THE ENGINE SPEED................................................................159 ADJUSTMENT OF VALVE CLEARANCE............................................................160 MEASUREMENT OF THE COMPRESSION PRESSURE..................................................161 CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....................................162 CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...........................................163 CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE.........................................165 ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER......................................166 CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER.................................167 CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL.....................................168 ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT.........169 CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION.........................................170 CONTROL AND REGULATION OF THE PRESSURE IN THE HYDRAULIC CIRCUITS (PC12R).................171 CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS (PC15R)................174 CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....177 REGULATION OF THE PC VALVE...............................................................179 CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC12R).........................180 CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC15R).........................181 ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...........................182 BLEEDING AIR FROM THE HYDRAULIC CIRCUITS.................................................183 CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT..........................185 CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS.........................191 CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR.........................................192 METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT.................................193 30.REMOVAL AND INSTALLATION..................................................................201 HOW TO READ THE MANUAL...................................................................203 PRECAUTIONS TO BE TAKEN WHILE WORKING....................................................204 SPECIAL TOOLS............................................................................205 STARTER MOTOR............................................................................207 ALTERNATOR...............................................................................208 PUMP GROUP...............................................................................209 INJECTION NOZZLES........................................................................210 CYLINDER HEAD............................................................................211 OIL COOLER...............................................................................215 RADIATOR.................................................................................216 ENGINE HOOD..............................................................................217 CAB AND CANOPY...........................................................................218 HEATING FAN..............................................................................220 REAR COUNTERWEIGHT.......................................................................221 TOP COVER AND SIDE PANELS................................................................222 HYDRAULIC OIL TANK.......................................................................224 FUEL TANK................................................................................227 ENGINE-PUMP GROUP........................................................................228 PUMP.....................................................................................231 ENGINE-PUMP COUPLING.....................................................................232 CONTROL VALVE............................................................................233 RIGHT-HAND PPC VALVE (BOOM-BUCKET).......................................................235 LEFT-HAND PPC VALVE (ARM-BUCKET).........................................................236 SERVOCONTROL SOLENOID GROUP (PC12 WITHOUT TRAVEL INCREMENT)..............................237 SERVOCONTROL SOLENOID GROUP (PC12 WITH TRAVEL INCREMENT - PC15R).........................238 SWIVEL JOINT.............................................................................239 SWING MOTOR..............................................................................240 REVOLVING FRAME..........................................................................241 SWING CIRCLE.............................................................................243 TRAVEL MOTOR.............................................................................244 RUBBER TRACK SHOES.......................................................................245 TRACK-SHOES..............................................................................246 SPROCKET WHEEL...........................................................................247 COMPLETE FINAL DRIVE.....................................................................248 FINAL DRIVE..............................................................................249 IDLER AND RECOIL SPRING ASSEMBLY.........................................................259 IDLER....................................................................................260 SPRING RECOIL AND THRUST CYLINDER GROUPS.................................................261 TRACK ROLLERS............................................................................262 BOOM CYLINDER............................................................................263 ARM CYLINDER.............................................................................264 BUCKET CYLINDER..........................................................................265 BOOM SWING CYLINDER......................................................................266 BLADE CYLINDER...........................................................................267 WORKING EQUIPMENT CYLINDER...............................................................268 UPPER WORKING EQUIPMENT..................................................................274 BUCKET...................................................................................276 ARM......................................................................................277 BOOM.....................................................................................279 BOOM SWING SUPPORT.......................................................................281 BLADE....................................................................................282 40.STANDARD MAINTENANCE......................................................................285 SWING CIRCLE.............................................................................286 TRACK FRAME AND RECOIL SPRING............................................................287 VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING.............................................288 IDLER....................................................................................289 FINAL DRIVE..............................................................................290 SPROCKET.................................................................................291 TRACK ROLLER.............................................................................292 TRACK SHOE...............................................................................293 HYDRAULIC PUMP...........................................................................295 CONTROL VALVE............................................................................297 SWIVEL JOINT.............................................................................309 SWING MOTOR..............................................................................311 TRAVEL MOTOR.............................................................................312 CYLINDERS PC12R-8........................................................................318 CYLINDERS PC15R-8........................................................................319 WORK EQUIPMENT PC12R-8...................................................................320 WORK EQUIPMENT PC15R-8...................................................................322
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