This complete service repair workshop manual PDF download for the PC09-1 Komatsu Mini Excavator (S/N: 10001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Machine Model : Komatsu PC09-1
Serial Number : 10001 and up
Engine : 2D68E-N3C and 2D70E-5SBA
TABLE OF CONTENTS :
– GENERAL
– STRUCTURE AND FUNCTION
– MAINTENANCE STANDARD
– TESTING AND ADJUSTING
– DISASSEMBLY AND ASSEMBLY
– OTHERS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM026105
Total Pages : 194
Komatsu PC09-1 mount the 2D68E-N3C and 2D70E-5SBA engine.
For details of the engine, see the 68E-88E Series and 70E, 76E-5 Series Engine Shop
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
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01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RADIATOR
ENGINE CONTROL
PTO
POWER TRAIN DIAGRAM
SWING CIRCLE
TRACK FRAME
IDLER CUSHION
IDLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC EQUIPMENT LAYOUT
VALVE CONTROL
HYDRAULIC TANK
HYDRAULIC PUMP
10-SPOOL CONTROL VALVE
CENTER SWIVEL JOINT
SWING MOTOR
TRAVEL MOTOR
HYDRAULIC CYLINDER
WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT
MACHINE MONITOR SYSTEM
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASUREMENT ENGINE SPEED
MASURING EXHAUST COLOR
ADJUSTMENT VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING ENGINE OIL PRESSURE
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
ADJUSTMENT OF FUEL CONTROL CABLE
BLEEDING AIR FROM FUEL CIRCUIT
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION
INSPECTION AND ADJUSTMENT OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS
IDENTIFICATION OF SPOT CAUSING WORK EQUIPMENT HYDRAULIC DRIFT
MEASUREMENT OF OIL LEAK AMOUNT INSIDE WORK EQUIPMENT CYLINDER
BLEEDING AIR FROM HYDRAULIC CIRCUITS
PRESSURIZING HYDRAULIC TANK
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CONNECTOR MOUNTING LOCATIONS AND ELECTRICAL CIRCUITS
CONNECTOR PIN ALLOCATION DRAWING
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START, STOP, PREHEATING AND CHARGING SYSTEMS (E CIRCUIT)
ELECTRICAL CIRCUIT DIAGRAM FOR PANEL SYSTEMS (P CIRCUIT)
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
INFORMATION IN TROUBLESHOOTING TABLE
E-1 ENGINE DOES NOT START
E-2 ENGINE DOES NOT STOP
E-3 ENGINE OIL PRESSURE LAMP DOES NOT WORK PROPERLY
E-4 ENGINE COOLING WATER TEMPERATURE LAMP DOES NOT WORK PROPERLY
E-5 ENGINE PREHEATING SYSTEM DOES NOT WORK
E-6 SERVICE METER DOES NOT ADVANCE
E-7 HORN DOES NOT SOUND, OR DOES NOT STOP SOUNDING
E-8 WORKING LAMP DOES NOT LIGHT UP, OR DOES NOT GO OFF
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
H-1 ALL WORK EQUIPMENT, TRAVEL AND SWING SHOW SLOW SPEED OR LACK IN POWER
H-2 ENGINE RUNNING SPEED DROPS SHARPLY OR ENGINE STAALS.MOREOVER, ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE AT ALL OR MOVE EXTREMELY SLOWLY.
H-3 THERE IS NOISE FROM AROUND HYDRAULIC PUMP
H-4 CONTROL LEVERS AND PEDALS ARE HARD TO OPERATE
H-5 BOOM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
H-6 ARM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
H-7 BUCKET MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
H-8 SWING IS SLOW, LACKS IN POWER AND HAS BIG HYDRAULIC DRIFT
H-9 BLADE MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT
H-10 MACHINE DEVIATES FROM TRAVEL PATH IN TRAVELING
a) THE MACHINE DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND IN REVERSE DIRECTIONS
b) THE DEVIATION DIRECTION CHANGES DEPENDING ON FORWARD OR REVERSE TRAVEL
H-11 NO POWER OR SLOW IN TRAVELING
H-12 UNDERCARRIAGE DOES NOT MOVE (ONE SIDE ONLY)
H-13 TRAVEL SPEED CANNOT BE CHANGED
H-14 UPPER STRUCTURE DOES NOT SWING
H-15 SWING SPEED IS SLOW OR ACCELERATION IS POOR
H-16 OVERRUN WHEN STOPPING WING IS BIG
H-17 THERE IS BIG SHOCK WHEN STOPPING SWING
H-18 THERE IS BIG NOISE WHEN STOPPING SWING
H-19 HYDRAULIC DRIFT OF SWING IS BIG
H-20 TROUBLESHOOTING OF HYDRAULIC BREAKER
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SWING MOTOR
REMOVAL AND INSTALLATION
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
REMOVAL
INSTALLATION
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING CIRCLE
REMOVAL AND INSTALLATION
IDLER
ASSEMBLY
TRACK ROLLER
ASSEMBLY
RUBBER SHOE
REMOVAL AND INSTALLATION
CONTROL VALVE
ASSEMBLY
HYDRAULIC CYLINDER
ASSEMBLY
HYDRAULIC BREAKER
DISASSEMBLY
ASSEMBLY
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM
FIXED GAUGE TYPE (STD)
VARIABLE GAUGE TYPE (IF EQUIPPED)
ELECTRICAL CIRCUIT DIAGRAM
STANDERD SPECIFICATION
TRAVEL ALREM SPECIFICATION (IF EQUIPPED)
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Komatsu PC09-1 Mini Excavator Service Repair Shop Manual (10001 and up) – SEBM026105.pdf
