Komatsu PC09-1 Hydraulic Excavator Shop Manual SEBM026105

Description

• Model List:
  • PC09-1 Hydraulic Excavator

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND WATER
• 4. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 4.1. RADIATOR
• 4.2. ENGINE CONTROL
• 4.4. POWER TRAIN DIAGRAM
• 4.5. HYDRAULIC EQUIPMENT LAYOUT
• 4.6. VALVE CONTROL
• 4.7. HYDRAULIC TANK
• 4.8. HYDRAULIC PUMP
• 4.9. SPOOL CONTROL VALVE
• 4.10. CENTER SWIVEL JOINT
• 4.11. SWING MOTOR
• 4.12. TRAVEL MOTOR
• 4.13. HYDRAULIC CYLINDER
• 4.14. WORK EQUIPMENT
• 4.15. DIMENSION OF WORK EQUIPMENT
• 4.16. MACHINE MONITOR SYSTEM
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
• 5.2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• 5.3. TESTING AND ADJUSTING
• 5.3.1. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.3.2. MEASUREMENT ENGINE SPEED
• 5.3.3. MASURING EXHAUST COLOR
• 5.3.4. ADJUSTMENT VALVE CLEARANCE
• 5.3.5. MEASURING COMPRESSION PRESSURE
• 5.3.6. MEASURING ENGINE OIL PRESSURE
• 5.3.7. INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
• 5.3.8. ADJUSTMENT OF FUEL CONTROL CABLE
• 5.3.9. BLEEDING AIR FROM FUEL CIRCUIT
• 5.3.10. TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION
• 5.3.11. TESTING AND ADJUSTING TRACK SHOE TENSION
• 5.3.12. INSPECTION AND ADJUSTMENT OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS
• 5.3.13. IDENTIFICATION OF SPOT CAUSING WORK EQUIPMENT HYDRAULIC DRIFT
• 5.3.14. MEASUREMENT OF OIL LEAK AMOUNT INSIDE WORK EQUIPMENT CYLINDER
• 5.3.15. BLEEDING AIR FROM HYDRAULIC CIRCUITS
• 5.3.16. PRESSURIZING HYDRAULIC TANK
• 5.4. TROUBLESHOOTING
• 5.4.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.4.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.4.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.4.4. CHECKS BEFORE TROUBLESHOOTING
• 5.4.5. METHOD OF USING TROUBLESHOOTING
• 5.4.6. CONNECTOR MOUNTING LOCATIONS AND ELECTRICAL CIRCUITS
• 5.4.7. CONNECTOR PIN ALLOCATION DRAWING
• 5.4.8. ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START, STOP, PREHEATING AND CHARGING SYSTEMS (E CIRCUIT)
• 5.4.9. ELECTRICAL CIRCUIT DIAGRAM FOR PANEL SYSTEMS (P CIRCUIT)
• 5.4.10. CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS
• 5.4.11. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.4.11.1. INFORMATION IN TROUBLESHOOTING TABLE
• 5.4.11.2. E1 ENGINE DOES NOT START
• 5.4.11.3. E2 ENGINE DOES NOT STOP
• 5.4.11.4. E3 ENGINE OIL PRESSURE LAMP DOES NOT WORK PROPERLY
• 5.4.11.5. E4 ENGINE COOLING WATER TEMPERATURE LAMP DOES NOT WORK PROPERLY
• 5.4.11.6. E5 ENGINE PREHEATING SYSTEM DOES NOT WORK
• 5.4.11.7. E6 SERVICE METER DOES NOT ADVANCE
• 5.4.11.8. E7 HORN DOES NOT SOUND, OR DOES NOT STOP SOUNDING
• 5.4.11.9. E8 WORKING LAMP DOES NOT LIGHT UP, OR DOES NOT GO OFF
• 5.4.12. TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (HMODE)
• 5.4.12.1. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.4.12.2. H1 ALL WORK EQUIPMENT, TRAVEL AND SWING SHOW SLOW SPEED OR LACK IN POWER
• 5.4.12.3. H2 ENGINE RUNNING SPEED DROPS SHARPLY OR ENGINE STAALS.MOREOVER, ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE AT ALL OR MOVE EXTREMELY SLOWLY.
• 5.4.12.4. H3 THERE IS NOISE FROM AROUND HYDRAULIC PUMP
• 5.4.12.5. H4 CONTROL LEVERS AND PEDALS ARE HARD TO OPERATE
• 5.4.12.6. H5 BOOM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
• 5.4.12.7. H6 ARM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
• 5.4.12.8. H7 BUCKET MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
• 5.4.12.9. H8 SWING IS SLOW, LACKS IN POWER AND HAS BIG HYDRAULIC DRIFT
• 5.4.12.10. H9 BLADE MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
• 5.4.12.11. H10 MACHINE DEVIATES FROM TRAVEL PATH IN TRAVELING
• 5.4.12.11.1. THE MACHINE DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND IN REVERSE DIRECTIONS
• 5.4.12.11.2. THE DEVIATION DIRECTION CHANGES DEPENDING ON FORWARD OR REVERSE TRAVEL
• 5.4.12.12. H11 NO POWER OR SLOW IN TRAVELING
• 5.4.12.13. H12 UNDERCARRIAGE DOES NOT MOVE (ONE SIDE ONLY)
• 5.4.12.14. H13 TRAVEL SPEED CANNOT BE CHANGED
• 5.4.12.15. H14 UPPER STRUCTURE DOES NOT SWING
• 5.4.12.16. H15 SWING SPEED IS SLOW OR ACCELERATION IS POOR
• 5.4.12.17. H16 OVERRUN WHEN STOPPING WING IS BIG
• 5.4.12.18. H17 THERE IS BIG SHOCK WHEN STOPPING SWING
• 5.4.12.19. H18 THERE IS BIG NOISE WHEN STOPPING SWING
• 5.4.12.20. H19 HYDRAULIC DRIFT OF SWING IS BIG
• 5.4.12.21. H20 TROUBLESHOOTING OF HYDRAULIC BREAKER
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. SWING MOTOR
• 6.4.1. REMOVAL AND INSTALLATION
• 6.5. CENTER SWIVEL JOINT
• 6.5.1. REMOVAL AND INSTALLATION
• 6.5.2. DISASSEMBLY AND ASSEMBLY
• 6.6. ENGINE AND HYDRAULIC PUMP
• 6.6.1. REMOVAL
• 6.6.2. INSTALLATION
• 6.7. REVOLVING FRAME
• 6.7.1. REMOVAL
• 6.7.2. INSTALLATION
• 6.8. SWING CIRCLE
• 6.8.1. REMOVAL AND INSTALLATION
• 6.8.2. REMOVAL AND INSTALLATION
• 6.9. CONTROL VALVE
• 6.9.1. ASSEMBLY
• 6.10. HYDRAULIC CYLINDER
• 6.10.1. ASSEMBLY
• 6.11. HYDRAULIC BREAKER
• 6.11.1. DISASSEMBLY
• 6.11.2. ASSEMBLY
• 7. OTHERS
• 7.1. HYDRAULIC CIRCUIT DIAGRAM
• 7.1.1. FIXED GAUGE TYPE (STD)
• 7.1.2. VARIABLE GAUGE TYPE (IF EQUIPPED)
• 7.2. ELECTRICAL CIRCUIT DIAGRAM
• 7.2.1. STANDERD SPECIFICATION
• 7.2.2. TRAVEL ALREM SPECIFICATION (IF EQUIPPED)