Pc20mr-3 Shop Manual

SEN04767-02
HYDRAULIC PC20MR -3
EXCAVATOR
SERIAL NUMBERS 20001 and up
SEN04769-02
HYDRAULIC EXCAVATOR
PC20MR-3
Machine model Serial number

PC20MR-3 20001 and up
00 Index and foreword 00

100 Index
Composition of shop manual .......................................................................................................................... 2

Table of contents ............................................................................................................................................. 3
PC20MR-3 00-100 1
100 Index
SEN04769-02 Composition of shop manual
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04767-02
00 Index and foreword .................................................................................................................... SEN04768-02

100 Index .................................................................................................................................. SEN04769-02 q
200 Foreword and general information ..................................................................................... SEN04770-00
01 Specification ............................................................................................................................... SEN04771-00

100 Specification and technical data......................................................................................... SEN04772-00
10 Structure, function and maintenance standard........................................................................... SEN04773-00

100 Engine and cooling system ................................................................................................ SEN04774-00
200 Power train......................................................................................................................... SEN04775-00
300 Undercarriage and frame ................................................................................................... SEN04776-00
410 Hydraulic system, Part 1 .................................................................................................... SEN04777-00
500 Work equipment................................................................................................................. SEN04780-00
600 Cab and its attachments .................................................................................................... SEN04781-00
700 Electrical system ................................................................................................................ SEN04782-00
20 Standard value table................................................................................................................... SEN04783-01

100 Standard service value table.............................................................................................. SEN04867-01 q
30 Testing and adjusting ................................................................................................................. SEN04784-00

100 Testing and adjusting ......................................................................................................... SEN04868-00
40 Troubleshooting.......................................................................................................................... SEN04785-00
100 General information on troubleshooting............................................................................. SEN04869-00
200 Troubleshooting of electrical system (E-mode).................................................................. SEN04870-00
300 Troubleshooting of hydraulic and mechanical system (H-mode) ....................................... SEN04871-00
400 Troubleshooting of engine (S-mode).................................................................................. SEN04872-00
500 Troubleshooting of Machine monitor System(M-mode) ...................................................... SEN04873-00
50 Disassembly and assembly........................................................................................................ SEN04786-00

100 General information on disassembly and assembly .......................................................... SEN04874-00
200 Engine and cooling system ................................................................................................ SEN04875-00
00-100 2 PC20MR-3
100 Index
Composition of shop manual SEN04769-02
300 Power train .........................................................................................................................SEN04876-00

400 Undercarriage and frame ...................................................................................................SEN04877-00
500 Hydraulic system ................................................................................................................SEN04878-00
600 Work equipment .................................................................................................................SEN04879-00
700 Cab and its attachments.....................................................................................................SEN04880-00
800 Electrical system ................................................................................................................SEN04881-00
90 Diagrams and drawings ..............................................................................................................SEN04787-01

100 Hydraulic diagrams and drawings ......................................................................................SEN04788-00
200 Electrical diagrams and drawings.......................................................................................SEN04789-01
PC20MR-3 00-100 3
100 Index
SEN04769-02 Table of contents
Table of contents 1
00 Index and foreword
100 Index SEN04769-02
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN04770-00
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN04772-00
Specification dimension drawing ................................................................................................................... 2
Working range drawing ................................................................................................................................. 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 7
Table of fuel, coolant and lubricants.............................................................................................................. 9
10 Structure, function and maintenance standard

100 Engine and cooling system SEN04774-00
PTO ............................................................................................................................................................... 2
Cooling system.............................................................................................................................................. 4
200 Power train SEN04775-00
Power train .................................................................................................................................................... 2
Swing circle ................................................................................................................................................... 3
300 Undercarriage and frame SEN04776-00
Track frame ................................................................................................................................................... 2
Idler cushion.................................................................................................................................................. 3
Idler ............................................................................................................................................................... 4
Track roller .................................................................................................................................................... 5
Sprocket ........................................................................................................................................................ 14
Track shoe..................................................................................................................................................... 17
401 Hydraulic system, Part 1 SEN04777-00
Hydraulic components layout drawing .......................................................................................................... 2
Hydraulic tank and filter................................................................................................................................. 3
Center swivel joint ......................................................................................................................................... 4
Travel motor .................................................................................................................................................. 5
Hydraulic cylinder.......................................................................................................................................... 14
Solenoid valve............................................................................................................................................... 17
Hydraulic pump ............................................................................................................................................. 2
Control valve ................................................................................................................................................. 8
00-100 4 PC20MR-3
100 Index
Table of contents SEN04769-02

CLSS ............................................................................................................................................................. 2
Operation for each function and valve........................................................................................................... 6
Swing motor................................................................................................................................................... 26
PPC valve...................................................................................................................................................... 37
500 Work equipment SEN04780-00
Work equipment ............................................................................................................................................ 3
Dimensions of each part of work equipment ................................................................................................. 6
600 Cab and its attachments SEN04781-00
Floor .............................................................................................................................................................. 2
700 Electrical system SEN04782-00
Engine control system ................................................................................................................................... 2
Electric control system................................................................................................................................... 4
KOMTRAX system ........................................................................................................................................ 9
Component parts of system........................................................................................................................... 12
Monitor system .............................................................................................................................................. 13
Sensors ......................................................................................................................................................... 16
20 Standard value table

100 Standard service value table SEN04867-01
Standard value table for engine related parts ................................................................................................ 2
Standard value table for chassis related parts............................................................................................... 3
30 Testing and adjusting

100 Testing and adjusting SEN04868-00
List of testing, adjusting, and troubleshooting tools....................................................................................... 3
Measuring engine speed ............................................................................................................................... 6
Adjusting valve clearance.............................................................................................................................. 7
Measuring compression pressure ................................................................................................................. 8
Measuring engine oil pressure ...................................................................................................................... 9
Testing and adjusting fuel injection timing ..................................................................................................... 10
Bleeding air from fuel circuit .......................................................................................................................... 12
Testing and adjusting fan belt tension ........................................................................................................... 13
Adjusting fuel control lever linkage ................................................................................................................ 14
Measurement of clearance in swing circle bearings...................................................................................... 15
Testing and adjusting track shoe tension....................................................................................................... 16
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits ............................. 18
Measuring control circuit basic pressure ....................................................................................................... 21
Testing and adjusting pump LS differential pressure..................................................................................... 22
Measuring solenoid valve output pressure .................................................................................................... 24
Measuring PPC valve output pressure .......................................................................................................... 26
Adjusting play of work equipment and swing PPC valves ............................................................................. 28
Measuring swing holding brake release pressure ......................................................................................... 28
Measurement of oil leakage from cylinder..................................................................................................... 30
Releasing residual pressure from hydraulic circuit ........................................................................................ 32
Bleeding air from cylinder .............................................................................................................................. 32
Pressurizing hydraulic tank............................................................................................................................ 33
How to open and close (tilt) floor ................................................................................................................... 34
Inspection procedures for diode .................................................................................................................... 38
How to start operation of KOMTRAX terminal ............................................................................................... 39
Lamp display of KOMTRAX terminal............................................................................................................. 43
Preparation work for troubleshooting of electrical system ............................................................................. 46
PC20MR-3 00-100 5
100 Index
SEN04769-02 Table of contents
40 Troubleshooting
100 General information on troubleshooting SEN04869-00
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Check before troubleshooting ....................................................................................................................... 4
Classification and troubleshooting steps....................................................................................................... 5
Probable problems and troubleshooting No.................................................................................................. 6
Connection table for connector pin numbers ................................................................................................ 9
T- branch box and T- branch adapter table ................................................................................................... 45
200 Troubleshooting of electrical system (E-mode) SEN04870-00
Before starting E-mode troubleshooting........................................................................................................ 2
Information contained in troubleshooting table ............................................................................................. 4
E-1 Engine does not start.............................................................................................................................. 5
E-2 Engine does not stop.............................................................................................................................. 11
E- 3 When lock lever is in FREE position, whole work equipment, travel, swing, and blade systems do not work
...................................................................................................................................................................... 13
E- 4 When lock lever is in LOCK position, whole work equipment, travel, swing, and blade systems work . 16
E- 5 When machine starts traveling, travel alarm does not sound ................................................................ 18
E- 6 When machine stops traveling, travel alarm does not stop sounding ................................................... 21
E- 7 Windshield wiper does not operate [Cab specification] ......................................................................... 23
E- 8 Windshield washer does not operate [Cab specification] ...................................................................... 25
E- 9 Heater does not operate........................................................................................................................ 27
300 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04871-00
H-1 Speed or power of whole work equipment, travel, swing, and blade is low............................................ 4
H-2 Engine speed lowers extremely or engine stalls .................................................................................... 7
H-3 Whole work equipment, travel system, swing system, and blade do not work....................................... 8
H-4 Abnormal sound comes out from around hydraulic pump...................................................................... 11
H-5 Fine control performance or response is low ......................................................................................... 11
H-6 Speed or power of boom is low .............................................................................................................. 12
H-7 Speed or power of arm is low ................................................................................................................. 13
H-8 Speed or power of bucket is low............................................................................................................. 14
H-9 Speed or power of boom swing is low .................................................................................................... 15
H-10 Work equipment does not move in its single operation ........................................................................ 16
H-11 Work equipment hydraulic drift is large................................................................................................. 16
H-12 Time lag of work equipment is large..................................................................................................... 17
H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 17
H-14 Machine deviates during travel............................................................................................................. 18
H-15 Travel speed or travel power is low ...................................................................................................... 20
H-16 Machine is not steered well or steering power is low ........................................................................... 20
H-17 Travel speed does not change ............................................................................................................. 21
H-18 Travel motor does not work (one side only) ......................................................................................... 21
H-19 Speed or power of swing is low ............................................................................................................ 22
H-20 Machine does not swing....................................................................................................................... 24
H-21 Swing acceleration performance is low ................................................................................................ 26
H-22 Machine overruns when it stops swinging............................................................................................ 27
H-23 Large shock is made when machine stops swinging ........................................................................... 28
H-24 When upper structure stops swinging, it makes large sound ............................................................... 28
H-25 Hydraulic drift of swing is large............................................................................................................. 29
H-26 Speed or power of blade is low ............................................................................................................ 30
H-27 Blade does not move............................................................................................................................ 31
H-28 Hydraulic drift of blade is large ............................................................................................................. 31
400 Troubleshooting of engine (S-mode) SEN04872-00
Troubleshooting charts.................................................................................................................................. 2
500 Troubleshooting of Machine monitor System(M-mode) SEN04873-00
Before starting M-mode troubleshooting ....................................................................................................... 2
00-100 6 PC20MR-3
100 Index
Table of contents SEN04769-02
M- 1 When starting switch is turned ON, no monitor/gauge operates ........................................................... 5

M- 2 When starting switch is turned ON, some monitors/gauges do not operate ......................................... 7
M- 3 Caution buzzer does not sound or does not stop sounding .................................................................. 8
M- 4 While engine is running, engine oil pressure monitor flashes ............................................................... 10
M- 5 While engine is running, charge level monitor flashes .......................................................................... 11
M- 6 Preheating system does not operate..................................................................................................... 13
M- 7 Coolant temperature gauge does not indicate normally........................................................................ 15
M- 8 Fuel level gauge does not indicate normally ......................................................................................... 18
M- 9 Service meter does not operate while engine is running....................................................................... 20
M-10 Travel speed shifting system does not operate normally ..................................................................... 21
M-11 Machine monitor night lamp and working lamp do not right up ............................................................ 24
50 Disassembly and assembly

100 General information on disassembly and assembly SEN04874-00
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
200 Engine and cooling system SEN04875-00
Removal and installation of fuel injection pump assembly ............................................................................ 2
Removal and installation of radiator and hydraulic oil cooler assembly ........................................................ 4
Removal and installation of engine and hydraulic pump assembly ............................................................... 8
300 Power train SEN04876-00
Removal and installation of swing circle assembly........................................................................................ 2
400 Undercarriage and frame SEN04877-00
Removal and installation of track shoe assembly.......................................................................................... 2
Disassembly and assembly of idler assembly ............................................................................................... 3
Disassembly and assembly of recoil spring................................................................................................... 5
Disassembly and assembly of track roller assembly ..................................................................................... 8
Removal and installation of floor frame assembly ......................................................................................... 9
Removal and installation of revolving frame assembly.................................................................................. 13
500 Hydraulic system SEN04878-00
Disassembly and assembly of control valve assembly.................................................................................. 2
Removal and installation of center swivel joint assembly.............................................................................. 6
Disassembly and assembly of center swivel joint assembly ......................................................................... 8
Removal and installation of swing motor and swing machinery assembly .................................................... 10
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 11
600 Work equipment SEN04879-00
Removal and installation of work equipment assembly................................................................................. 2
700 Cab and its attachments SEN04880-00
Removal and installation of front window assembly ...................................................................................... 2
Removal and installation of operator's cab glass (stuck glass) ..................................................................... 3
800 Electric system SEN04881-00
Removal and installation of KOMTRAX terminal ........................................................................................... 2
90 Diagrams and drawings

100 Hydraulic diagrams and drawings SEN04788-00
Hydraulic circuit diagram ............................................................................................................................... 3
200 Electrical diagrams and drawings SEN04789-01
Electrical circuit diagram (1/2) ....................................................................................................................... 3
Electrical circuit diagram (2/2) ....................................................................................................................... 5
Conector list and stereogram ........................................................................................................................ 7
PC20MR-3 00-100 7
SEN04769-02
PC20MR-3 Hydraulic excavator

Form No. SEN04769-02
2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10
00-100 8
SEN04770-00
HYDRAULIC EXCAVATOR
PC20MR-3

00 Index and foreword 00
200 Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC20MR-3 00-200 1
SEN04770-00 Safety notice
Safety notice (Rev. 2008/08)1

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 PC20MR-3
Safety notice SEN04770-00
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative () terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
PC20MR-3 00-200 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00-200 4 PC20MR-3
Safety notice SEN04770-00
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard Z twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC20MR-3 00-200 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00-200 6 PC20MR-3
How to read the shop manual SEN04770-00
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC20MR-3 00-200 7
SEN04770-00 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 PC20MR-3
Explanation of terms for maintenance standard SEN04770-00
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the standard size and the range of differ-
ence from the standard size is called the
tolerance.
q The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
0.022
120
0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
PC20MR-3 00-200 9
SEN04770-00 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the standard clear- between them is increased to a certain
ance, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the clearance limit.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
standard value, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value interference limit.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 PC20MR-3
Handling of electric equipment and hydraulic component SEN04770-00
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC20MR-3 00-200 11
SEN04770-00 Handling of electric equipment and hydraulic component
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 PC20MR-3
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC20MR-3 00-200 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 PC20MR-3
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC20MR-3 00-200 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 PC20MR-3
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC20MR-3 00-200 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-200 18 PC20MR-3
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC20MR-3 00-200 19
SEN04770-00 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 PC20MR-3
Handling of connectors newly used for engines SEN04770-00
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC20MR-3 00-200 21
SEN04770-00 Handling of connectors newly used for engines
q 95, 125 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 PC20MR-3
How to read electric wire code SEN04770-00
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
tor tric appliance General wiring in extremely
tant low-volt-
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC20MR-3 00-200 23
SEN04770-00 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
f of nominal No. denotes flexible.
00-200 24 PC20MR-3
How to read electric wire code SEN04770-00
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
PC20MR-3 00-200 25
SEN04770-00 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00-200 26 PC20MR-3
Precautions when carrying out operation SEN04770-00
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC20MR-3 00-200 27
SEN04770-00 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
00-200 28 PC20MR-3
Method of disassembling and connecting push-pull type coupler SEN04770-00
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC20MR-3 00-200 29
SEN04770-00 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00-200 30 PC20MR-3
Method of disassembling and connecting push-pull type coupler SEN04770-00
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
PC20MR-3 00-200 31
SEN04770-00 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5
8 13 27 34 2.8 3.5
10 17 59 74 6.0 7.5
12 19 98 123 10.0 12.5
14 22 157 196 16 20
16 24 245 309 25 31.5
18 27 343 427 35 43.5
20 30 490 608 50 62
22 32 662 829 67.5 84.5
24 36 824 1,030 84 105
27 41 1,180 1,470 120 150
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 12 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 17 74.5 90.2 7.6 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-200 32 PC20MR-3
Standard tightening torque table SEN04770-00
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 63 { 3.5 6.5} 44 { 4.5}
03,04 20 Varies depending 84 132 { 8.5 13.5} 103 {10.5}
05,06 24 on type of connec- 128 186 {13.0 19.0} 157 {16.0}
10,12 33 tor. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.81 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 { 9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
PC20MR-3 00-200 33
SEN04770-00 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No.
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 54 { 3.5 5.5} 9/16-18UN 14.3
02 19 44 { 4.5}
34 63 { 3.5 6.5} 14
22 54 93 { 5.5 9.5} 74 { 7.5} 11/16-16UN 17.5
03
24 59 98 { 6.0 10.0} 78 { 8.0} 18
04 27 84 132 { 8.5 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 16 {1.4 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 27 {2.4 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 47 {4.4 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 68 {6.1 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 95 {9.2 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
00-200 34 PC20MR-3
Standard tightening torque table SEN04770-00
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51
PC20MR-3 00-200 35
SEN04770-00 Conversion table
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-200 36 PC20MR-3
Conversion table SEN04770-00
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC20MR-3 00-200 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-200 38 PC20MR-3
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC20MR-3 00-200 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 40 PC20MR-3
PC20MR-3 00-200 41
SEN04770-00

2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09 (01)
00-200 42
SEN04772-00
HYDRAULIC EXCAVATOR
PC20MR-3

01 Specification 1
100 Specification and technical data
Specification dimension drawing..................................................................................................................... 2
Working range drawing ................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 7
Table of fuel, coolant and lubricants................................................................................................................ 9
PC20MR-3 01-100 1
SEN04772-00 Specification dimension drawing
Specification dimension drawing1
Item Unit PC20MR-3
Canopy specification 2,155

Machine weight kg
Cab specification 2,330
3
Bucket capacity m 0.066
Komatsu 3D76E-6
Engine model
Diesel engine
Rated engine output kW{HP}/rpm 15.5 {20.8} / 2,500
A Overall length mm 3,750
B Overall height mm 2,520
C Overall width mm 1,450
D Shoe width mm 250
Canopy specification 800
E Tail swing radius mm
Cab specification 865
F Overall length of track mm 1,880
G Distance between tumbler centers mm 1,440
Minimum ground clearance mm 285
Travel speed (Low / High) km/h 2.8 / 4.6
Continuous swing speed rpm 8.9
01-100 2 PC20MR-3
Working range drawing SEN04772-00
Working range drawing 1
Working range (mm) PC20MR-3
A Max. digging radius 4,150

B Max. digging depth 2,280
C Max. digging height 4,000
D Max. vertical wall depth 1,860
E Max. dumping height 2,760
Swing radius of work equipment 1,790
F
<Values in ( ) are boom swing radii> (1,450)
G Max. reach at ground level 4,000
H Blade lifting height 340
I Blade lowering depth 240
PC20MR-3 01-100 3
SEN04772-00 Specifications
Specifications 1
PC20MR-3
Machine model
Canopy specification Cab specification
Serial number 20001 and up
Bucket capacity m3 0.066 0.066

2,155 2,330
Operating weight kg
[2,265] [2,440]
Max. digging depth 2,280 2,280
Max. vertical wall depth 1,860 1,860
Max. digging reach 4,150 4,150
Working ranges
Max. reach at ground level 4,000 4,000

Max. digging height mm 4,000 4,000
Max. dumping height 2,720 2,720
Bucket offset (L.H./R.H.) 510 / 760 510 / 760
Performance
Max. blade lifting height 340 340

Max. blade lowering depth 240 240
Max. digging force (bucket) kN {kg} 18.8 {1,920} 18.8 {1,920}
Continuous swing speed rpm 8.9 8.9
Swing max. slope angle deg. 19.0 19.0
Travel speed km/h 2.8 / 4.6 2.8 / 4.6
Gradeability deg. 30 30
2
Ground pressure kPa {kg/cm } 27.0 {0.28} 29.8 {0.30}
[28.4 {0.29}] [31.2 {0.31}]
Overall length (for transport) 3,750 3,750
Overall width 1,450 1,450
Overall height (for transport) 2,520 [2,515] 2,520 [2,515]
Ground clearance of counterweight 530 [525] 530 [525]
Min. ground clearance 285 [280] 285 [280]
Tail swing radius 800 865
Dimensions
Min. swing radius of work equipment 1,790 (1,450) 1,790 (1,450)

(at boom swing)
mm
Height of work equipment at min. 2,990 2,990
swing radius
Overall width (crawler) 1,450 1,450
Overall length (crawler) 1,880 1,880
Length of track on ground 1,440 1,440
Track gauge 1,200 1,200
Machine cab height 1,380 1,380
Blade width x height 1,450 300 1,450 300
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe
specification are shown.)
a Values in [ ] are for the steel shoe specification.
a Operating weight of machine with full tank of fuel and a 75 kg operator (ISO 6016).
01-100 4 PC20MR-3
Specifications SEN04772-00
1
PC20MR-3
Machine model
Model 3D76E-6
Type 4-cycle, water cooled, in-line direct injection type,
swirl chamber type
No. of cylinders bore x stroke mm 3 76 82
Piston displacement l {cc} 1.115 {1,115}
Flywheel horsepower kW {HP}/rpm 15.5 {20.8} / 2,500
Performance
Maximum torque Nm {kgm}/rpm 66.7 {6.8} / 1,600

Engine
High idle speed rpm 2,680

Low idle speed rpm 1,450
Min. fuel consumption ratio g/kWh {g/HPh} 265 {198}
Starting motor 12 V, 1.4 kW
Alternator 12 V, 40 A
Battery (*1) 12 V, 45 Ah 1 (50B24L)
Radiator
AL louver type fin
Core type
Undercarriage
Carrier plate 2 on each side

Track roller 3 on each side
Track shoe (Rubber shoe) Unit-type rubber crawler
Track shoe (Steel shoe) Assembly-type double grouser: 44 each side
Type x No. Variable displacement piston type x 1, gear type x 1

Hydraulic pump
3
Theoretical capacity cm /rev 22 + 6.4
Set pressure
For travel, work equipment MPa {kg/cm2} 24.5 {250}
For swing MPa {kg/cm } 2 21.1 {215}
For blade 2 21.1 {215}
Hydraulic system
MPa {kg/cm }
Control
Type x No. 8-spool type x 1

valve
Control method Hydraulic assist type
Variable-displacement piston motor

Hydraulic
Travel motor
motor
(with counterbalance valve, parking brake) x 2

Fixed-displacement piston motor
Swing motor (with brake valve, swing shaft brake) x 1
Hydraulic tank Box-shaped, open type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (Drawn-cup)
PC20MR-3 01-100 5
SEN04772-00 Specifications
PC20MR-3
Machine model
Cylinder type Double acting piston

Boom cylinder
Inside diameter of cylinder 70

Outside diameter of piston rod 40
mm
Stroke 453.5
Max. distance between pins 1,186.5
Min. distance between pins 733
Arm cylinder

mm
Stroke 451
Max. distance between pins 1,165
Work equipment cylinder

Hydraulic system
Bucket cylinder

mm
Stroke 469.5
Min. distance between pins 705.5
Boom swing cylinder

mm
Stroke 429.5
Min. distance between pins 701.5

Blade cylinder

mm
Stroke 135
Max. distance between pins 545
*1: The battery capacity (Ah) is based on 5-hour rate.
01-100 6 PC20MR-3
Weight table SEN04772-00
Weight table 1
k This weight table is a guide for use when transporting or handing components.
Unit: kg
PC20MR-3
Machine model
Engine assembly (without oil, coolant) 155 155

Engine 115 115
Engine mount 9 9
PTO 10 10
Hydraulic pump 21 21
Cooling assembly (excluding coolant and oil) 24 24
Battery 12 12
Revolving frame 201 201
Floor frame 128
Canopy assembly 66
Handrail 6
Operator's cab (with floor frame) 356
Operator's seat 12 12
Fuel tank (without fuel) 3 3
Hydraulic tank (without hydraulic oil) 28 28
Control valve 33 33
Counterweight 76 76
X-weight (Additional counterweight) 190 190
Swing motor (with brake valve and machinery) 24 24
Track frame assembly (without track shoe) 466 466
Track frame 201 201
Idler assembly 25 2 25 2
Recoil spring assembly 14 2 14 2
Carrier plate 14 14
Track roller assembly 68 68
Travel motor (with reduction gear) 27 2 27 2
Sprocket 10 2 10 2
Swing circle 27 27
Center swivel joint 13 13
PC20MR-3 01-100 7
SEN04772-00 Weight table
1
Unit: kg
PC20MR-3
Machine model
Track shoe assembly

Rubber shoe (250 mm) 73 2 73 2
Double grouser shoe (250 mm) 129 2 129 2
Boom swing bracket assembly 34 34
Boom assembly 64 64
Arm assembly 30 30
Bucket link assembly 9 9
Bucket assembly (with side cutter) 48 48
Blade assembly 93 93
Boom cylinder assembly 18 18
Arm cylinder assembly 16 16
Bucket cylinder assembly 10 10
Boom swing cylinder assembly 17 17
Blade cylinder assembly 9 9
01-100 8 PC20MR-3
Table of fuel, coolant and lubricants SEN04772-00
Table of fuel, coolant and lubricants 1

a For details of notes (Notes 1 and 2 ...) in the table, see Operation and Maintenance Manual.
Unit: l
PC20MR-3
Reservoir
Specified capacity Refill capacity
Engine oil pan 3.7 3.4
Final drive case (each) 0.6 0.6
Hydraulic system 29 19
Fuel tank 27
Cooling system 3.0
PC20MR-3 01-100 9
SEN04772-00

2009 KOMATSU
All Rights Reserved
01-100 10
SEN04774-00
HYDRAULIC EXCAVATOR
PC20MR-3

10 Structure, function and

maintenance standard 1
100 Engine and cooling system
PTO................................................................................................................................................................. 2
Cooling system ............................................................................................................................................... 4
PC20MR-3 10-100 1
SEN04774-00 PTO
PTO 1
1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump
10-100 2 PC20MR-3
PTO SEN04774-00
PC20MR-3 10-100 3
SEN04774-00 Cooling system
Cooling system 1
1. Oil cooler inlet 7. Shroud

2. Oil cooler outlet 8. Radiator cap
3. Oil cooler 9. Radiator inlet hose
4. Drain valve 10. Reservoir tank
5. Radiator 11. Radiator outlet hose
6. Fan guard
10-100 4 PC20MR-3
Cooling system SEN04774-00
Specifications
Radiator Oil cooler
Core type AL louver type fin AL drawn-cup
Fin pitch mm 3.5 / 2 4.0 / 2
Total heat dissipation surface m2 2.832 2.29
88.3 14.7
Pressure valve cracking pressure kPa {kg/cm2} {0.9 0.15}
4.9
Vacuum valve cracking pressure kPa {kg/cm2} {0.05}
PC20MR-3 10-100 5
SEN04774-00

2009 KOMATSU
All Rights Reserved
10-100 6
SEN04775-00
HYDRAULIC EXCAVATOR
PC20MR-3


200 Power train
Power train...................................................................................................................................................... 2
Swing circle..................................................................................................................................................... 3
PC20MR-3 10-200 1
200 Power train
SEN04775-00 Power train
Power train 1
1. Idler 7. Hydraulic pump (For PPC control)

2. Swing motor 8. Left travel motor
3. Center swivel joint 9. Control valve
4. Right travel motor 10. Travel Hi-Lo speed selector valve
5. Engine 11. PPC lock solenoid valve
6. Hydraulic pump (For work equipment, travel, 12. Swing machinery
swing, blade and variable gauge) 13. Swing circle
10-200 2 PC20MR-3
200 Power train
Swing circle SEN04775-00
Swing circle 1
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

1 Clearance between bearing Replace
0.03 0.13 0.23
2. Swing circle bearing lubricator Specifications

3. Swing circle pinion lubricator
Reduction ratio 87 / 11 = 7.90
4. Outer race
5. Inner race Grease G2-LI
6. Ball
7. Seal
a. Inner race soft zone position

b. Outer race soft zone position
PC20MR-3 10-200 3
SEN04775-00

2009 KOMATSU
All Rights Reserved
10-200 4
SEN04776-00
HYDRAULIC EXCAVATOR
PC20MR-3


300 Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Idler cushion.................................................................................................................................................... 3
Idler ................................................................................................................................................................. 4
Track roller ...................................................................................................................................................... 6
Sprocket .......................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC20MR-3 10-300 1
SEN04776-00 Track frame
Track frame 1
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier plate 8. Idler cushion
4. Travel motor 9. Idler guard
5. Sprocket (Steel shoe and road liner spec.)
10-300 2 PC20MR-3
Idler cushion SEN04776-00
Idler cushion 1
a The following figure shows with the rubber shoe specification.
Unit: mm
Standard size Repair limit

Installed Installed Installed
Recoil spring Free length Free length
length load load
(Rubber shoe spec.)
1 30.9 kN 28.5 kN Replace
257 188 251
{3,153 kg} {2,901 kg}
Recoil spring
19.7 kN 17.6 kN
(Steel shoe spec.) 257 213 251
{2,012 kg} {1,791 kg}
(Road liner spec.)
2. Rod Specifications
3. Cylinder
Grease G2-LI
4. Recoil spring
5. Rear support Amount of grease 120 cc
6. Nut
7. Lubricator
PC20MR-3 10-300 3
SEN04776-00 Idler
Idler 1
10-300 4 PC20MR-3
Idler SEN04776-00
Unit: mm

Outside diameter of projec-
1
tion 338
2 Outside diameter of tread 300 292

Repair by
3 Depth of tread 19 23 overlaying
welding or
replace
4 Thickness of tread 8.7 4.7
5 Width of tread 18 22
6 Total width 64
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
7
bushing
0.025 +0.142 0.105
35
0.064 +0.080 0.206
Clearance between shaft and 0.025 +0.060 0.025 Replace
8 35
support 0.064 +0.030 0.124
9 Play of shaft in axial direction
0.25
Track frame 95.5 100 Repair by

10 Height of idler guide overlaying
Idler support 94 90 welding
Track frame 161.5 165 Repair by

overlaying
11 Width of idler guide
welding or
Idler support 160 155 replace
PC20MR-3 10-300 5
SEN04776-00 Track roller
Track roller 1
Unit: mm

1 Outside diameter of flange
108
2 Outside diameter of tread 85 77

Repair by
3 Thickness of tread 26.5 22.5 overlaying
welding or
replace
4 Width of flange 30.3 24.3
5 Width of tread 31.85
6 Total width 94
Tolerance Standard Clearance

Standard size
Clearance between shaft Shaft Hole clearance limit
7
and bushing
0.025 +0.183 0.144
25
0.013 +0.144 0.196
Clearance between shaft 0.025 +0.033 Replace
8 25 0 0.046
and collar 0.013 +0.030

Play of roller in axial direc-
9
tion
0.15 0..32
10-300 6 PC20MR-3
Sprocket SEN04776-00
Sprocket 1
Unit: mm
Standard size Tolerance Repair limit

1 Wear of root circle diameter +1.0
344.3 332
2.0
2 Wear of tip circle diameter 386.2 1.5 374 Repair by

overlaying
3 Wear of tip width 20 18 welding or
replace
+0.5
4 Wear of bottom width 27 24
1.0
+0.475
5 Thickness of bottom 77.15 71
1.061
PC20MR-3 10-300 7
SEN04776-00 Track shoe
Track shoe 1
Rubber shoe
Unit: mm

1 Wear of lug height
18 5
2 Wear of roller guide 34 42

Replace
Wear of meshing parts of
3 3 2
sprocket
4 Wear of roller tread height 27 19
10-300 8 PC20MR-3
Track shoe SEN04776-00
PC20MR-3 10-300 9
SEN04776-00

2009 KOMATSU
All Rights Reserved
10-300 10
SEN04777-00
HYDRAULIC EXCAVATOR
PC20MR-3


401 Hydraulic system, Part 1
Hydraulic components layout drawing ............................................................................................................ 2
Hydraulic tank and filter .................................................................................................................................. 3
Center swivel joint........................................................................................................................................... 4
Travel motor .................................................................................................................................................... 5
Hydraulic cylinder.......................................................................................................................................... 14
Solenoid valve............................................................................................................................................... 17
PC20MR-3 10-401 1
SEN04777-00 Hydraulic components layout drawing
Hydraulic components layout drawing 1
1. Boom swing PPC valve 12. Control valve

2. Swing motor 13. Multi-control valve (If equipped)
3. Boom swing cylinder 14. Attachment PPC valve (If equipped)
4. Right work equipment PPC valve 15. Accumulator
5. Hydraulic tank 16. Travel PPC valve
6. Blade PPC valve 17. Arm cylinder
7. Oil cooler 18. Boom cylinder
8. Right travel motor 19. Center swivel joint
9. Left travel motor 20. 2-spool solenoid valve
10. Hydraulic pump 21. Blade cylinder
11. Left work equipment PPC valve 22. Bucket cylinder
10-401 2 PC20MR-3
Hydraulic tank and filter SEN04777-00
Hydraulic tank and filter 1
1. Filler cap Specifications

2. Hydraulic tank
Tank capacity l 27
3. Sight gauge
4. Drain plug Oil amount l 19
5. Bypass valve Bypass valve set 150 30
6. Filter element kPa {kg/cm2}
pressure {1.53 0.31}
7. Strainer Pressure valve 70 15
kPa {kg/cm2}
cracking pressure {0.71 0.15}
Vacuum valve 05
kPa {kg/cm2}
cracking pressure {0 0.05}
PC20MR-3 10-401 3
SEN04777-00 Center swivel joint
Center swivel joint 1
A1 : From R.H. travel control valve 1. Shaft

A2 : To R.H. travel motor 2. Rotor
B1 : From L.H. travel control valve 3. Slipper seal
B2 : To L.H. travel motor 4. Cover
C1 : From R.H. travel control valve
C2 : To R.H. travel motor
D1 : From L.H. travel control valve
D2 : To L.H. travel motor
E1 : From blade control valve
E2 : To blade cylinder head
F1 : From blade control valve
F2 : To blade cylinder bottom
G1 : From travel Hi-Lo speed selector solenoid valve
G2 : To travel Hi-Lo speed selector valve
T1 : To hydraulic tank
T2 : From travel motor drain port
Unit: mm
Standard size Standard clearance Clearance limit

Clearance between rotor and
5 Replace
shaft 60 0.055 0.085 0.090
10-401 4 PC20MR-3
Travel motor SEN04777-00
Travel motor 1
Model: PHV-2B-20B-PT-8435A
A : From travel control valve Specifications

B : From travel control valve Model: PHV-2B-20B-PT-8435A
PP : From travel speed Hi-Lo selector solenoid valve Delivery of motor: (1st) 16.1 / (2nd) 9.1 cm3/rev
DR : To tank Max. output speed: (1st) 1,394 / (2nd) 2,466 rpm
Max. flow rate: 22.9 l/min
PC20MR-3 10-401 5
SEN04777-00 Travel motor
1. Oil filler plug 14. Disc

2. Cover 15. Shaft
3. No. 2 planetary gear 16. Rocker cam
4. No. 2 sun gear 17. Control piston
5. Ring gear 18. No. 1 planetary gear
6. Ball 19. No. 1 sun gear
7. Housing 20. No. 2 planetary carrier
8. Piston 21. Drain plug
9. Cylinder 22. Oil level plug
10. Valve plate 23. Check valve
11. Brake valve 24. Counterbalance valve
12. Brake piston 25. Check valve
13. Plate 26. Automatic speed changing valve
10-401 6 PC20MR-3
Principle of operation
q The PVH Series travel motor consists of the fixed
part which consists of hydraulic motor (2) and
hydraulic valve and the rotary part which consists
of simple planetary reduction gear unit (1).
a (b1) consists of 4 planetary gears and (b2) 1. Simple planetary reduction gear unit
consists of 3 planetary gears. (Double reduction)
2. Hydraulic motor
3. Automatic 1st valve
4. Counterbalance valve
5. Carrier 2
PC20MR-3 10-401 7
Reduction gear unit q The reduction ratio of the 2 stages of the sim-
ple planetary gears is generally given by the
Function following expression.
q The reduction gear unit consists of 2 stages of R = Zs1 (Zs1 + Za1) x Zs2 (Zs2 + Za2)
simple planetary gears. It converts the high- Zs1, Zs2: Number of teeth of gears (s1) and (s2)
speed revolution from the hydraulic motor into Za1, Za2: Number of teeth of gears (a1) and (a2)
low-speed higher torque to obtain revolution of
the case. q Since the body of the PHV Series travel motor
revolves, the above reduction ratio is given by
the following expression.
Operation
R' = 1/(1-1/R)
q In the following figure, gear (s2) is coupled with
the hydraulic motor output shaft by spline (or
by a shaft). The revolution of gear (s2) is
reduced through gears (s2), (b2), and (a2).
q The reduced revolution is further reduced
through gears (s1), (b1), and (a1) coupled with
carrier 2 (5) by spline.
q This revolution is transmitted through internal
gears (a1) and (a2) to the rotary part and used
for travel.
10-401 8 PC20MR-3
Hydraulic motor
Function
q This hydraulic motor is an axial piston motor
(rotary cylinder swash plate type). It converts
the hydraulic energy from the pump into rotary
movement.
Operation
q The hydraulic oil flowing in through the hydrau-
lic valve is supplied to valve plate (3).
q The hydraulic oil supplied to port (A) flows into
the cylinder port in cylinder barrel (2) corre-
sponding to port (A) and pushes piston (1).
q The pushing force of the above hydraulic oil is
converted through rocker cam (4) into rotary
force and output to shaft (5) coupled with cylin-
der barrel (2).
q The return oil in the cylinder port flows out
through port (B) of valve plate (3).
q When the motor revolves in reverse, the
hydraulic oil flows in through port (B) and the
return oil flows out through port (A).
PC20MR-3 10-401 9
Operation of 2nd motor q If the 2nd gear lever is set, hydraulic oil (P) is
q Rocker cam (4) has 2 faces of (A) and (B) on led through the 2nd spool into control chamber
the opposite side to the face on which shoe (6) (10).
slides. It is supported on 2 balls (7) fixed to q Control piston (11) moves until face (B) of
body (8). rocker cam (4) reaches body (8), and then
q Balls (7) are installed a little higher than the rocker cam (4) is fixed at swash plate angle
axis. Accordingly, in the 1st gear speed, face (b). At this time, the delivery of the motor is
(A) is pressed against body (8) by the hydraulic reduced.
force applied to piston (1) and the force of
spring (9), and swash plate angle is set to (a)
and the delivery of the motor is increased.
q While the engine is stopped, control chamber

(10) is connected through the 2nd spool to the
drain port.
q As a result, rocker cam (4) is returned to the
1st gear speed position by spring (9), thus the
1st gear speed is always selected when the
machine starts travel.
10-401 10 PC20MR-3
Hydraulic valve
Counterbalance valve
Operation q Even if the hydraulic oil from port (A) is

q If the hydraulic oil is supplied through port (A), stopped, the hydraulic motor continues revolu-
it pushes check valve (2) open and flows in tion by inertia.
port (A') on the inlet side of the hydraulic motor. q At this time, the return oil is controlled gradu-
q On the other hand, the hydraulic oil flows ally by the changing speed and shape of the
through choke (C) into chamber (D) and cut of spool (3) to stop the hydraulic motor
moves spool (3) to the right against spring (4). smoothly.
q As a result, the oil on the return side of the
hydraulic motor flows in through port (B') and
returns through body (1) and opening (E) of
spool (3) to port (B) to rotate the hydraulic
motor.
q If the hydraulic oil is supplied through port (B),
each part operates in the opposite direction
and the hydraulic motor revolves in reverse.
q If the hydraulic oil from port (A) is stopped,
spool (3) moved to the right is returned to the
left by the force of spring (4).
q At this time, the oil in chamber (D) controls the
speed of spool (3) returning to the left with
choke (C).
PC20MR-3 10-401 11
Automatic 1st valve
Operation q If the drive pressure is increased from the 2nd

q If the 2nd pilot switch is turned ON, the 2nd gear speed level to the set pressure of the 1st
pilot pressure is led through port (PP) into gear speed, the total of rightward forces (F1)
hydraulic pressure pilot (1) and force (F1) is and (F2) applied to automatic 1st valve (5)
generated. increases the total of leftward forces (F3) and
q Force (F1) moves automatic 1st valve (5) to (F4). As a result, automatic 1st valve (5)
the right against force (F4) and sets the system moves to the left and sets the system in the 1st
in the 2nd gear speed. gear speed.
q On the other hand, the drive pressure is led q If the drive pressure lowers from the 1st gear
into pilots (2) and (3) to generate forces (F2) speed level to the set pressure of the 2nd gear
and (F3). speed, the total of rightward forces (F1) and
q Since the pressure receiving area of hydraulic (F2) ap pl i ed t o au to ma ti c 1 s t v al v e (5)
pilot (3) is larger than that of (2), force (F3) is decreases the total of leftward forces (F3) and
larger than force (F2). As the drive pressure is (F4). As a result, automatic 1st valve (5)
increased, the difference between forces (F2) moves to the right and set the system in the
and (F3) is increased. 2nd gear speed.
10-401 12 PC20MR-3
Parking brake q If the hydraulic oil is supplied to port (A) or (B),

Function hydraulic oil (P) is led into chamber (6).
q When the travel motor is stopped, the parking Hydraulic oil (P) moves brake piston (7) to the
brake fixes the hydraulic motor output shaft right against the force of spring (8).
mechanically. q As a result, disc plate (4) and steel plates (3)
and (5) are released and the friction force is
lost and cylinder barrel (1) can revolve.
Operation
q While the hydraulic oil is not supplied to port
(A) or (B), spring (8) presses brake piston (7)
to the left.
q At this time, disc plate (4) fixed by the semi
lunar groove of cylinder barrel (1) is fixed
between steel plates (3) and (5) which are also
fixed to body (2).
q As a result, cylinder barrel (1) cannot revolve
because of the friction force of disc plate (4)
and steel plates (3) and (5) and the hydraulic
motor output shaft is fixed.
PC20MR-3 10-401 13
SEN04777-00 Hydraulic cylinder
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
10-401 14 PC20MR-3
Hydraulic cylinder SEN04777-00
Boom swing cylinder
Blade cylinder
PC20MR-3 10-401 15
SEN04777-00 Hydraulic cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance

name size Shaft Hole clearance limit Replace cyl-
inder head
0.025 +0.039 0.025
Boom 40 0.403
0.064 +0.080 0.103
Clearance 0.025 +0.132 0.031
Arm 40 0.496
between piston 0.064 +0.006 0.196
1
rod and bush-
0.020 +0.133 0.013
ing Bucket 30 0.486
0.053 0.007 0.186 Replace
0.025 +0.132 0.031 bushing
Boom swing 40 0.496
0.064 +0.006 0.196
0.025 +0.132 0.031
Blade 35 0.496
0.064 +0.006 0.196
0.090 +0.142 0.089
Boom 35 1.0
0.130 +0.080 0.272
0.025 +0.142 0.105
Arm 35 1.0
Clearance 0.064 +0.080 0.206
between piston
0.090 +0.070 0.100
2 rod supporting Bucket 30 1.0
0.130 +0.010 0.200
shaft and bush-
ing 0.010 +0.134 0.082
Boom swing 40 1.0
0.050 +0.072 0.184
0.070 +0.142 0.150
Blade 35 1.0
0.130 +0.080 0.272 Replace pin
0.025 +0.142 0.105 and bushing
Boom 35 1.0
0.064 +0.080 0.206
0.090 +0.142 0.089
Arm 35 1.0
Clearance 0.130 +0.080 0.272
between cylin-
0.025 +0.117 0.105
3 der bottom sup- Bucket 30 1.0
0.087 +0.080 0.204
porting shaft
and bushing 0.010 +0.134 0.082
Boom swing 40 1.0
0.050 +0.072 0.184
0.025 +0.142 0.105
Blade 35 1.0
0.087 +0.080 0.229
Boom 539 54.0 Nm {55 5.5 kgm}
Arm 677 67.5 Nm {69 6.9 kgm}

Tightening
4 torque of cylin- Bucket 539 54.0 Nm {55 5.5 kgm}
der head
Boom swing 539 54.0 Nm {55 5.5 kgm}
Blade 490 49.0 Nm {50 5.0 kgm}

Retighten
Boom 618 62 Nm {63 6.3 kgm} (Width across flats: 41 mm)
Arm 784 78.4 Nm {80 8.0 kgm} (Width across flats: 46 mm)
Tightening
torque of cylin-
5 Bucket 343 34.0 Nm {35 3.5 kgm} (Width across flats: 32 mm)
der piston fixing
bolt
Boom swing 784 78.4 Nm {80 8.0 kgm} (Width across flats: 46 mm)
Blade 618 62 Nm {63 6.3 kgm} (Width across flats: 41 mm)
10-401 16 PC20MR-3
Solenoid valve SEN04777-00
Solenoid valve 1
A : To PPC valve
B : To 2nd travel speed selector valve
P : From hydraulic pump
T : To hydraulic tank
1. PPC lock solenoid valve

2. To travel Hi-Lo speed selector valve
Solenoid valve
3. Coil (ON/OFF type)
4. Push pin
5. Valve spool
6. Return spring
7. Valve body
PC20MR-3 10-401 17
SEN04777-00 Solenoid valve
2nd travel speed selector solenoid valve

PPC lock solenoid valve
Operation
When solenoid is turned OFF When solenoid is turned ON
(When circuit is shut off) (When circuit is connected)
q While the signal current is not flowing from the q While the signal current is flowing from the
PPC lock switch or travel speed selector PPC lock switch or travel speed selector
switch, solenoid (1) is turned OFF. switch to solenoid (1), solenoid (1) is turned
Accordingly, spool (2) is pressed up by spring ON.
(3). q Accordingly, spool (2) is pressed down by push
q As a result, ports (P) and (A) are shut off from pin (4).
each other and the pilot pressure does not flow q As a result, ports (P) and (A) are connected to
into the actuator. each other and the pilot pressure flows into the
At the same time, the oil from the actuator actuator.
flows through ports (A) and (T) to the hydraulic At the same time, port (T) is closed and the oil
tank. does not flow to the hydraulic tank.
10-401 18 PC20MR-3
Solenoid valve SEN04777-00
PC20MR-3 10-401 19
SEN04777-00

2009 KOMATSU
All Rights Reserved
10-401 20
SEN04778-00
HYDRAULIC EXCAVATOR
PC20MR-3


Hydraulic pump ............................................................................................................................................... 2
Control valve ................................................................................................................................................... 8
PC20MR-3 10-402 1
SEN04778-00 Hydraulic pump
Hydraulic pump 1
Model: PVK-OB-226G-PK-4220A
P1 : Pump discharge 1. Main pump (piston pump)

P2 : Gear pump discharge 2. Gear pump
PLS : LS pressure inlet 3. LS valve
PP : Pump pressure inlet
S1 : Pump suction
10-402 2 PC20MR-3
Hydraulic pump SEN04778-00
Function Operation
q This pump converts the engine torque trans- q As shaft (5) revolves, cylinder block (1)
mitted to its shaft into hydraulic pressure and revolves and pistons (2) in it reciprocate
supplies the hydraulic oil according to the load. according to the movement of rocker cam (4)
q The delivery can be changed by changing the to suck and discharge the oil.
swash plate angle. q Accordingly, 9 pistons (2) perform 1 cycle of
q This pump has the constant-horsepower con- suction and discharge each time cylinder block
trol function and the load-sensitive control (1) revolves. If shaft (5) revolves continuously,
function. the oil is sucked and discharged continuously.
q Since the displacement of pistons (2) depends
Structure on the inclination of rocker cam (4), the dis-
q Cylinder block (1) has 9 pistons (2) in it and its charge can be changed by changing the incli-
end is in contact with valve plate (3). Valve nation of rocker cam (4).
plate (3) has suction port (A) and discharge
port (B).
q Rocker cam (4) is fixed to body (S) at a certain
angle. Piston (2) revolves along rocker cam
(4).
a: Suction stroke
b: Discharge stroke
c: Suction
d: Discharge
PC20MR-3 10-402 3
Constant-horsepower control q If the discharge pressure increases further, the

q Rocker pin (6) is installed to rocker cam (4) inclination of rocker cam (4) is decreased.
and they are so installed to body (S) that the q At this time, the length of the arm receiving
angle of rocker cam (4) can be changed. combined force (F1) of the pistons is reduced
q Spring (7) and pistons (2) of cylinder block are from (a) to (a'). Accordingly, larger force (F1) is
so arranged that they will be against each necessary for the inclination of rocker cam (4).
other through rocker cam (4). Discharge pres- q As a result, the (P) (Q) curve is so changed
sure (P1) is applied to pistons (2). that the engine horsepower will be used effi-
q While discharge pressure (P1) is lower than ciently (constant-horsepower control).
the set value of spring (7), the inclination of
rocker cam (4) is fixed to the maximum posi-
tion by spring (7).
q If discharge pressure (P1) is larger than the set
value of spring (7), the inclination of rocker
cam (4) is reduced by combined force (F1) x
(a) of the pistons and fixed to the point where
discharge pressure (P1) is balanced with the
spring force.
10-402 4 PC20MR-3
Load-sensitive control All-horsepower control

q In the load-sensitive control mode, the signal q Rod (8) is arranged in the position against
pressure from the LS valve is transmitted to spring (7) and discharge pressure (P2) is
control piston (9), which presses rocker cam applied to it.
(4). q As discharge pressure (P2) is increased, the
q Rocker cam (4) is slanted to change the dis- inclination of rocker cam (4) is reduced.
charge until the above pressure, spring force, q Accordingly, the horsepower used by the
and combined force of the pistons are bal- whole pump is kept constant, even if pressure
anced. (P2) rises.
q Since the load-sensitive control gives the con-
stant-horsepower control priority, the discharge
is controlled within the flow range of the con-
stant-horsepower control.
PC20MR-3 10-402 5
LS valve
q The LS valve controls the pump discharge
according to the stroke of the control lever, or
the demand flow for the actuator.
q The LS valve detects the demand flow for the
actuator from differential pressure (dPLS)
between pump discharge pressure (P1L) and
control valve outlet pressure (PLS) and con-
trols pump discharge (Q) [(P1L) is called the
pump discharge pressure, (PLS) the LS pres-
sure, and (dPLS) the LS differential pressure].
q In other words, the pressure loss caused by
flowing of oil through the opening of the control
valve spool (= LS differential pressure (dPLS))
is detected, and then pump discharge (Q) is
controlled to keep that pressure loss constant
and supply the pump discharge according to
the demand of flow for the actuator.
10-402 6 PC20MR-3
PC20MR-3 10-402 7
SEN04778-00 Control valve
Control valve 1
Outline
a The control valve is an add-on type where one
service valve each can be added, so it is possi-
ble to add valves or remove valves if neces-
sary.
a The service valve is installed additionally
between the top cover and lower valve.
a As for the 9-spool valve, only the parts different
from the 8-spool valve are shown.
A1 : To R.H. travel motor

A2 : To L.H. travel motor
A3 : To boom cylinder head
A4 : To arm cylinder head
A5 : To bucket cylinder head
A6 : To boom swing cylinder head
A7 : To blade cylinder head
A8 : To swing motor port (MA)
B1 : To R.H. travel motor
B2 : To L.H. travel motor
B3 : To boom cylinder bottom
B4 : To arm cylinder bottom
B5 : To bucket cylinder bottom
B6 : To boom swing cylinder bottom
B7 : To blade cylinder bottom
B8 : To swing motor port (MB)
C : To oil cooler
LS : To pump LS valve
P1 : From main pump (Variable pump)
P2 : From main pump (Gear pump)
PA1 : From R.H. travel FORWARD PPC valve
PA2 : From L.H. travel FORWARD PPC valve
PA3 : From boom LOWER PPC valve
PA4 : From arm OUT PPC valve
PA5 : From bucket DUMP PPC valve
PA6 : From boom swing PPC valve
PA7 : From blade PPC valve
PA8 : From swing L.H. PPC valve
PB1 : From R.H. travel REVERSE PPC valve
PB2 : From L.H. travel REVERSE PPC valve
PB3 : From boom RAISE PPC valve
PB4 : From arm IN PPC valve
PB5 : From bucket CURL PPC valve
PB6 : From boom swing PPC valve
PB7 : From blade PPC valve
PB8 : From swing R.H. PPC valve
PP : To pump LS valve
PPPC : To solenoid valve port (P)
PS : To swing motor port (B)
S1 : To swing motor port (S)
T : To tank
TS : To tank
10-402 8 PC20MR-3
Control valve SEN04778-00
8-spool valve
General view
PC20MR-3 10-402 9
Sectional view
(1/4)
10-402 10 PC20MR-3
1. Suction valve (Boom bottom)

2. Suction valve (Arm bottom)
3. Suction valve (Bucket bottom)
4. Suction valve (Blade bottom)
5. Safety valve
6. Suction valve (Boom swing head)
7. Suction valve (Bucket head)
8. Suction valve (Boom head)
9. Spool (Swing)
10. Spool (Blade)
11. Spool (Boom swing)
12. Spool (Bucket)
13. Spool (Arm)
14. Spool (Boom)
15. Spool (L.H. travel)
16. Spool (R.H. travel)
17. Main relief valve
Unit: mm

Free length
Installed Installed Free Installed
18 Suction valve spring Outside
length load length load
diameter
Replace spring
2.65 N 2.16 N
36.3 4.45 33.3 if damaged or
{0.27 kg} {0.22 kg}
deformed
5.10 N 4.12 N
19 Suction valve spring 39.2 4.45 33.5
{0.52 kg} {0.42 kg}
22.6 N 18.1 N
20 Spool return spring 29 17.5 28.5
{2.3 kg} {1.80 kg}
PC20MR-3 10-402 11
(2/4)
10-402 12 PC20MR-3
1. Back pressure check valve 11. Pressure compensation valve R

2. Self pressure reducing sequence valve (Boom swing)
3. Pressure compensation valve F 12. Pressure compensation valve R
(R.H. travel) (Bucket)
(L.H. travel) (Arm)
(Boom) (Boom)
(Arm) (L.H. travel)
(Bucket) (R.H. travel)
8. Pressure compensation valve F 17. LS bypass valve
(Boom swing) 18. Unload valve
9. Filter 19. Spool (travel)
10. Swing relief valve (for gear pump)
F: Flow control valve
R: Pressure reducing valve
Unit: mm

Free length
20 Unload valve spring Outside
diameter
172 N 137 N
28.57 19.2 16.5
{17.5 kg} {14 kg}
Replace spring
Back pressure check valve 15.3 N 12.3 N
21 29 13.3 21 if damaged or
spring {1.56 kg} {1.25 kg}
deformed
Self pressure reducing 88.3 N 70.6 N
22 40.5 14.3 35.5
sequence valve spring {9.0 kg} {7.2 kg}
Pressure compensation 6.86 N 5.49 N
23 20.0 8.40 12.0
valve spring {0.70 kg} {0.56 kg}
24 22.51 8.4 18.2
PC20MR-3 10-402 13
(3/4)
10-402 14 PC20MR-3
1. Self pressure reducing spool 15. Spool (Arm)

2. Self pressure reducing sequence valve 16. Suction valve
3. Main relief valve 17. Check valve
4. LS bypass valve 18. Pressure compensation valve R (Arm)
5. Unload valve 19. Pressure compensation valve F (Bucket)
6. Self pressure reducing valve 20. Spool (Bucket)
7. Pressure compensation valve F (Boom) 21. Suction valve
8. Spool (Boom) 22. Check valve
9. Suction valve 23. Suction valve
10. Check valve 24. Pressure compensation valve R (Bucket)
11. Suction valve
12. Pressure compensation valve R (Boom) F: Flow control valve
13. Pressure compensation valve F (Arm) R: Pressure reducing valve
14. Pilot check valve
Unit: mm

Free length Replace spring
25 Check valve spring Outside if damaged or
diameter deformed
1.96 N 1.57 N
21.9 5 15.8
{0.2 kg} {0.16 kg}
PC20MR-3 10-402 15
(4/4)
10-402 16 PC20MR-3
1. Pressure compensation valve F (Boom swing)

2. Spool (Boom swing)
3. Check valve
4. Suction valve
5. Pressure compensation valve R (Boom swing)
6. Spool (Blade)
7. Suction valve
8. Check valve
9. Pilot pressure check valve
10. Spool (Swing)
11. Swing relief valve (For gear pump)
13. Safety valve
14. Pressure release plug

Unit: mm

Free length Replace spring
15 Check valve spring Outside if damaged or
diameter deformed
1.96 N 1.57 N
21.9 5 15.8
{0.2 kg} {0.16 kg}
PC20MR-3 10-402 17
9-spool valve
10-402 18 PC20MR-3
A9 : To stop valve
B9 : To stop valve
PA9 : To attachment PPC valve
PB9 : To attachment PPC valve
1. Pressure compensation valve F (Attachment)

2. Pressure compensation valve R (Attachment)
3. Spool (Attachment)
4. Port relief valve

Unit: mm

Free length
5 Spool return spring Outside
diameter
Replace spring
181.0 N 145.0 N
29 17.5 25 if damaged or
{18.42 kg} {14.74 kg}
deformed
6 20.0 8.4 12.0
7 15.4 6 8
PC20MR-3 10-402 19
SEN04778-00

2009 KOMATSU
All Rights Reserved
10-402 20
SEN04779-00
HYDRAULIC EXCAVATOR
PC20MR-3


CLSS............................................................................................................................................................... 2
Operation for each function and valve ............................................................................................................ 6
Swing motor .................................................................................................................................................. 26
PPC valve ..................................................................................................................................................... 37
PC20MR-3 10-403 1
SEN04779-00 CLSS
CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a variable capacity sin-
tem, and has the following features. gle piston pump, control valve, and actuators.
q Fine control not influenced by load q The pump body consists of the main pump, PC
q Control enabling digging even with fine control valve and LS valve.
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
10-403 2 PC20MR-3
CLSS SEN04779-00
Basic principle
Control of pump swash plate angle
q The pump swash plate angle (pump delivery) q If LS differential pressure (dPLS) becomes
is controlled so that LS differential pressure lower than the set pressure of the LS valve
(dPLS) [the difference between pump dis- (when the actuator load pressure is high), the
charge pressure (PP) and control valve outlet pump swash plate moves towards the maxi-
port LS pressure (PLS) (load pressure of actu- mum position.
ator)] is constant. q If the set pressure becomes higher than the set
q [LS differential pressure (dPLS) = Pump dis- pressure of the LS valve (when the actuator
charge pressure (PP) LS pressure (PLS)] load pressure is low), the pump swash plate
moves towards the minimum position.
LS differential pressure (dPLS) and pump

swash plate angle
a For details of the operation, see Hydraulic

pump.
PC20MR-3 10-403 3
SEN04779-00 CLSS
Pressure compensation control
q A pressure compensation valve is

installed to the outlet port side of the con-
trol valve spool to balance the load.
q When two actuators are operated together,
this valve acts to make pressure difference
(dP) between the upstream (inlet port) and
downstream (outlet port) the same, regard-
less of the size of the load (pressure).
q The flow of oil from the pump is divided
(compensated) in proportion to the area of
openings (S1) and (S2) of each valve
when it is operated.
10-403 4 PC20MR-3
CLSS SEN04779-00
PC20MR-3 10-403 5
SEN04779-00 Operation for each function and valve
Operation for each function and valve 1

Hydraulic circuit diagram and name of valve
8-spool valve
10-403 6 PC20MR-3
Operation for each function and valve SEN04779-00
1. Unload valve
Set pressure: LS pressure + 3.4 MPa
{35.0 kg/cm2}
2. Safety valve
Set pressure: 27.9 MPa {285 kg/cm2}
3. Main relief valve
4. Self pressure reducing valve
5. Pilot relief valve
Set pressure: 2.90 MPa {30.0 kg/cm2}
6. Self pressure sequence valve
Set pressure:
2.90 to 3.40 MPa {30.0 to 35.0 kg/cm2}
7. Pressure compensation valve
8. Suction valve
10. Check valve
11. Back pressure check valve
Set pressure: 0.34 MPa {3.5 kg/cm2}
12. Swing relief valve (for gear pump)
9-spool valve
13. Port relief valve

PC20MR-3 10-403 7
Unload valve
When control valve is at neutral
PP : Pump circuit
PLS : LS circuit
T : Tank circuit
1. Spool
2. Spring
Function
q When the control valve is at neutral, pump
delivery (Q) discharged by the minimum swash
plate angle is released to the tank circuit.
When this happens, pump discharge pressure
(PP) is set at 3.43 MPa {35 kg/cm2} by spring
(2) inside the valve. [LS pressure (PLS): 0 MPa
{0 kg/cm2}.]
Operation
q Pump discharge pressure (PP) is acting on the
left end of spool (1), and LS pressure (PLS) is
acting on the right end.
q When the control valve is at neutral, LS pres-
sure (PLS) is 0, so only pump discharge pres-
sure (PP) has any effect, and (PP) is set only
by the load of spring (2).
q As pump discharge pressure (PP) rises and
reaches the load of spring (2) (3.43 MPa {35
kg/cm2}), spool (1) is moved to the right in the
direction of the arrow. Pump discharge pres-
sure (PP) then passes through the notch (a) of
spool (1) and is connected to tank circuit (T).
q In this way, pump discharge pressure (PP) is
set to 3.43 MPa {35 kg/cm2}.
10-403 8 PC20MR-3
When control valve is in fine control
PP : Pump circuit
PLS : LS circuit
T : Tank circuit
1. Spool
2. Spring
Function Operation
q When the control valve is in the fine control q When fine control is carried out on the control
mode, if the demand flow for actuator is less valve, LS pressure (PLS) is generated and
than the value corresponding to the minimum acts on the right end of spool (1).
swash plate angle of the pump, pump pressure When this happens, the area of the opening of
(PP) is set to LS pressure (PLS) + 3.43 MPa the control valve spool is small, so there is a
{35.0 kg/cm 2 }. If the differential pressure big difference between LS pressure (PLS) and
between pump pressure (PP) and LS pressure pump discharge pressure (PP).
(PLS) becomes equal to the load of spring (2) q When the differential pressure between pump
(3.43 MPa {35.0 kg/cm 2 }), the unload valve discharge pressure (PP) and LS pressure
opens. Accordingly, LS differential pressure (PLS) reaches the load of spring (2) (3.43MPa
(dPLS) is (3.43 MPa {35.0 kg/cm 2 }) at this {35 kg/cm2}), spool (1) moves to the right in the
time. direction of the arrow, and pump circuit (PP)
and tank circuit (T) are connected.
q In other words, pump discharge pressure (PP)
is set to a pressure equal to the spring force
(3.43 MPa {35 kg/cm2}) + LS pressure (PLS),
and LS differential pressure (dPLS) becomes
3.43 MPa {35 kg/cm2}.
PC20MR-3 10-403 9
When control valve is being operated (work equipment)
PP : Pump circuit
PLS : LS circuit
T : Tank circuit
1. Spool
2. Spring
3. Actuator circuit
Function
q When the control valve is operated, if the
demand flow for actuator exceeds the value
corresponding to the minimum swash plate
angle of the pump, the outflow to tank circuit
(T) is shut off and all of pump delivery (Q) is
sent to the actuator circuit.
Operation
q When the control valve is operated to a bigger
stroke, LS pressure (PLS) is generated and
acts on the right end of spool (1). When this
happens, the area of the opening of the control
valve spool is large, so the difference between
LS pressure (PLS) and pump discharge pres-
sure (PP) is small.
q For this reason, the differential pressure
between pump discharge pressure (PP) and
LS pressure (PLS) does not reach the load of
spring (2) (3.43 MPa {35 kg/cm2}), so spool (1)
is pushed to the left by spring (2).
q As a result, pump circuit (PP) and tank circuit
(T) are shut off, and all the pump delivery (Q)
flows to the actuator circuit (3).
10-403 10 PC20MR-3
Introduction of LS pressure
Work equipment valve (Boom, arm, bucket, boom swing, travel)
Function Operation
q The LS pressure is the actuator load pressure q When spool (1) is operated, pump pressure
at the outlet port end of the control valve. (PP) flows from flow control valve (2) and
q With the control valve, it actually reduces notch (a) in the spool through bridge passage
pump pressure (PP) at reducing valve (3) of (b) to actuator circuit (A).
the pressure compensation valve to the same q At the same time, reducing valve (3) also
pressure as actuation circuit pressure (A), and moves to the right, so pump pressure (PP) is
sends it to the LS circuit (PLS). reduced by the pressure loss at notch (c), and
then applied through LS circuit (PLS) to spring
chamber (PLS1).
q When this happens, LS circuit (PLS) is con-
nected to tank circuit (T) from LS bypass valve
(4) (see the section on the LS bypass valve).
q The actuator circuit pressure (A) acts on the
left end of reducing valve (3). The reduced
pump pressure (PP) acts on at the other end.
q As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure (A)
and the pressure of spring chamber (PLS1)
are the same. Pump pressure (PP) reduced at
notch (a) becomes actuator circuit pressure (A)
and is taken to LS circuit (PLS).
PC20MR-3 10-403 11
LS bypass valve
PLS : LS circuit
T : Tank circuit
1. LS bypass valve
2. Valve cover
Function
q This valve releases the residual pressure of LS
pressure (PLS).
q It makes the speed of the rise in pressure of LS
pressure (PLS) more gentle. In addition, with
this discarded throttled flow, it creates a pres-
sure loss in the throttled flow of the spool or
shuttle valve, and increases the stability by
lowering the effective LS differential pressure.
Operation
q The pressurized oil for LS circuit (PLS) passes
from filter (a) of LS bypass valve (1) through
orifice (b) and flows to the tank circuit (T).
10-403 12 PC20MR-3
Pressure compensation valve
Function q Flow control valve (2) and reducing valve (1)

q During compound operations, if the load pres- are balanced in position where the difference
sure becomes lower than the other actuator in pressure between (PLS) and (PA) acting on
and the oil flow tries to increase, compensation both ends of reducing valve (1) and the pres-
is received. sure loss between (PP) and (PPA) on both
[When this happens, the other actuator being sides of flow control valve (2) are the same.
used for compound operation (right side) is at q In this way, the pressure difference between
a higher load than the actuator on this side (left upstream pressure (PPA) and downstream
side).] pressure (PA) of both spools used during com-
pound operations is the same, so the pump
Operation flow is divided in proportion to the area of
q If the load pressure of the other actuator (right opening of notch (a) of each spool.
side) becomes higher during compound opera-
tions, the oil flow in actuator circuit (A) on this
side (left side) tries to increase.
q If this happens, the LS pressure (PLS) of the
other actuator acts on spring chamber (PLS'),
and reducing valve (1) and flow control valve
(2) are pushed to the left.
q Flow control valve (2) throttles the area of
opening between pump circuit (PP) and spool
upstream (PPA), and pressure loss is gener-
ated between (PP) and (PPA).
PC20MR-3 10-403 13
Area ratio of pressure compensation valve
Function Area ratio (S2) : (S1) and compensation charac-

q The pressure compensation valve determines teristics
the compensation characteristics by carrying q When ratio is 1.00:
out fine adjustment of the area ratio (S2) : (S1) [Pump pressure (PP) spool notch upstream
between area (right side) (S2) of reducing pressure (PPB)] C [LS circuit pressure (PLS)
valve (1) and area (left side) (S1) of flow con- actuator circuit pressure (PA) = (A)], and oil
trol valve (2) to match the characteristics of flow is divided in proportion to area of opening
each actuator. of spool.
q When ratio is more than 1.00:
S1: Area of flow control valve (2) (PP) (PPB) > (PLS) (PA) = (A), and oil flow
area of piston (3) is divided in a proportion less than area of
S2: Area of reducing valve (1) opening of spool.
area of piston (3) q When ratio is less than 1.00:
(PP) (PPB) < (PLS) (PA) = (A), and oil flow
is divided in a proportion more than area of
opening of spool.
10-403 14 PC20MR-3
LS receiving throttle of pressure compensation valve
Function Operation
q If the other actuator is relieved during com- q If the other actuator (right side) is relieved dur-
pound operations, LS introduction throttle (b) ing compound operations, each circuit pres-
of reducing valve (1) divides the flow and sure (PPA), (PA) of the other actuator becomes
sends more oil to the side receiving compen- the same as the pump circuit pressure [(PP) =
sation. relief pressure].
q In this case, spring chamber (PLSA) of the
other actuator becomes the same as pump cir-
cuit pressure (PP) because of the balance of
reducing valve (1).
q (PLSB) passes through LS introduction throttle
(b) of reducing valve (1) and becomes (PLS).
(PLS) is connected to the tank circuit (T) from
LS bypass valve (4), so pressure loss is gener-
ated at LS introduction throttle (b) [the condi-
tion becomes (PLS) < (PLSB)].
q As a result, even if the other actuator is
relieved, a pressure difference is created
between (PP) and (PLS), so more oil flows to
actuator circuit (A) on this side (left side).
PC20MR-3 10-403 15
L.H., R.H. Travel junction circuit
When traveling in a straight line
Function Operation
q To compensate for any difference in the oil flow q When left and right travel spools (1) are oper-
in the left and right travel circuits when travel- ated, the pump discharge flows from pump cir-
ing in a straight line, the junction circuit opens cuit (PP) and circuits (PA) to actuator circuits
when the left and right travel spools are oper- (B).
ated. q When traveling in a straight line, to make actu-
q In this way, the flow of oil to the left and right ator circuits (PA) equal, left and right reducing
travel motors is almost the same when travel- valves (2) are pushed to the right by the same
ing in a straight line, so there is no travel devia- amount, and notch (a) and the travel junction
tion. circuit are opened.
q When steering the machine, the difference in q In this way, the left and right travel actuator cir-
the load pressure returns the reducing valve of cuits are interconnected by the travel junction
the travel valve on the inside of the turn and circuit, so if any difference occurs in the flow of
the opening of the notch in the travel junction oil to the left and right travel motors, the com-
circuit becomes smaller, so the machine can pensation is carried out to prevent any devia-
be steered. tion in travel.
10-403 16 PC20MR-3
Steering when traveling
Operation
q When traveling in a straight line, if left travel
spool (Left 1) is returned to the neutral position
and the steering is operated, a difference
(Right B) > (Left B) is generated in the load
pressure of left and right travel actuator circuits
(PA), and LS pressure (PLS) becomes the
same pressure as (Right B).
q As a result, flow control valve (3) on the left
travel side is pushed to the left by LS circuit
(PLS). Because of this, the opening of the left
notch (a) is made smaller, so it becomes possi-
ble to operate the steering when traveling.
q Damper (b) is provided in the circuit to damper
any excessive characteristics in the opening or
closing of the travel junction circuit if the spool
is operated suddenly.
PC20MR-3 10-403 17
Self pressure reducing valve
When the control valve is held
Function Operation
q This valve reduces pump discharge pressure q Unload spool (1) moves and pump discharge
(PP) and supplies the pilot main pressure of pressure (PP) is set to 2.90 MPa {30.0 kg/cm2}.
2.90 MPa {30.0 kg/cm2} to the PPC valve. (See the explanation of the unload valve.)
q When the actuator circuit pressure is low, the q Pump discharge pressure (PP) is reduced to
self pressure sequence valve is closed to raise 2.90 MPa {30.0 kg/cm 2 } by self pressure
pump discharge pressure (PP) to secure the reducing spool (2) and self pressure reducing
pilot main pressure. pilot relief valve (3), and the main pressure oil
is supplied through the port (PC) to the PPC
valve.
10-403 18 PC20MR-3
When the control valve is operated
Operation
q Unload spool (1) moves to the left and pump
discharge pressure (PP) becomes higher than
the LS pressure by the LS differential pressure.
(See the explanation of unload valve.)
q When pump discharge pressure (PP) is higher
than 2.90 MPa {30.0 kg/cm2}, it is reduced to
2.90 MPa {30.0 kg/cm 2 } by self pressure
reducing spool (2) and self pressure reducing
pilot relief valve (3), and the pressure oil is
supplied through the port (PC) to the PPC
valve.
q At this time, self pressure sequence valve (4)
is kept open.
PC20MR-3 10-403 19
Operation
q When pump discharge pressure (PP) is below
2 . 9 0 M P a {3 0 . 0 k g / c m 2 } , s e l f p r e s s u r e
sequence valve (4) moves to the right to
reduce the opening area between (PP) and
actuator circuit (5).
q As a result, differential pressure is made
between (PP) and actuator circuit (5) and (PP)
is raised to above 2.90 MPa {30.0 kg/cm 2 },
then it is reduced to 2.90 MPa {30.0 kg/cm2} by
self pressure reducing spool (2) and self pres-
sure reducing pilot relief valve (3), and the
pressure oil is supplied through the port (PC)
to the PPC valve.
10-403 20 PC20MR-3
PC20MR-3 10-403 21
Swing and blade valve
10-403 22 PC20MR-3
Structure
q The swing and blade sections are the open
center valves of the gear pump. They are
arranged tandem, with the swing section
ahead of the blade section.
Operation
Swing section
q If pressure is applied from the PPC valve to the
port (PA8), the spool moves to the left and oil
flows in the port (A8).
port (PB8), the spool moves to the right and oil
flows in the port (B8).
q Load check valve (2) is installed in each spool,
corresponding to ports (A) and (B) of each
valve.
q Relief valve (1) for the gear pump is installed to
the swing section.
Blade section
port (PA7), the spool moves to the left and oil
flows in the port (A7).
port (PB7), the spool moves to the right and oil
flows in the port (B7).
q Load check valve (2) is installed in each spool,
corresponding to ports (A) and (B) of each
valve.
PC20MR-3 10-403 23
Swing holding brake cancel system
Function
q This system resets the swing holding brake by
using both swing PPC pressures and arm IN
PPC pressure as signals.
10-403 24 PC20MR-3
PC20MR-3 10-403 25
SEN04779-00 Swing motor
Swing motor 1
Model: PCR-1B-05A-FP-8436A
A : From control valve Specifications

B : From control valve Model : PCR-1B-05A-FP-8436A
T : To tank Delivery of motor : 23.6 cm3/rev
DR : To tank Max. using speed : 604 rpm
PB : From PPC basic pressure Max. using flow rate : 14.7 l/min
PP : From control valve (PPC valve pressure sig- Relief valve set pressure: 15.2 MPa {155 kg/cm2}
nal) Check valve cracking pressure:
0.02 MPa {0.2 kg/cm2}
10-403 26 PC20MR-3
Swing motor SEN04779-00
1. Pinion shaft 9. Brake piston

2. Carrier 10. Swash plate
3. Shaft 11. b1 gear
4. Plate 12. Body
5. Shoe 13. Brake timer valve
6. Piston 14. Relief valve
7. Cylinder barrel 15. Check valve
8. Valve plate
PC20MR-3 10-403 27
Principle of operation
q The PCR Series swing motor consists of sim-
ple planetary reduction gear unit (1), hydraulic
motor (2), and hydraulic valve.
1. Simple planetary reduction gear unit 6. b1 gear

(Single reduction) 7. s1 gear
2. Hydraulic motor 8. Carrier 1
3. Shockless relief valve 9. Pinion shaft
4. Parking brake timer
5. a1 gear
10-403 28 PC20MR-3
Reduction gear unit
Function
q The reduction gear unit consists of 1 stage of
simple planetary gears. It converts the high-
speed revolution from the hydraulic motor into
low-speed higher torque to obtain revolution of
pinion shaft (9).
Operation
q In the following figure, the hydraulic motor has
gear (s1), the revolution of which is reduced by
gears (s1), (b1), and (a1).
q This revolution is transmitted to pinion shaft (9)
coupled with carrier 1 (8) by spline and used
for swinging.
q The reduction ratio of the 1 stage of the simple

planetary gears is generally given by the fol-
lowing expression.
R = Zs1 / (Zs1 + Za1)
Zs1: Number of teeth of gears s1
Za1: Number of teeth of gears a1
PC20MR-3 10-403 29
Hydraulic motor
Function
q This hydraulic motor is an axial piston motor
(rotary cylinder swash plate type). It converts
the hydraulic energy from the pump into rotary
movement.
Operation
q The hydraulic oil flowing in through the hydrau-
lic valve is supplied to valve plate (3).
q The hydraulic oil supplied to port (A) flows into
the cylinder port in cylinder barrel (2) corre-
sponding to port (A) and pushes piston (1).
q The pushing force of the above hydraulic oil is
converted through swash plate (4) into rotary
force and output to shaft (5) coupled with cylin-
der barrel (2).
q The return oil in the cylinder port flows out
through port (B) of valve plate (3).
q When the motor revolves in reverse, the
hydraulic oil flows in through port (B) and the
return oil flows out through port (A).
10-403 30 PC20MR-3
Swing holding brake When brake release pressure is turned ON

q When the brake release pressure is turned
Function ON, the hydraulic oil is led into chamber (3).
q When the swing motor is stopped, the swing q This hydraulic oil moves brake piston (2) to the
holding brake fixes the swing motor output left against the force of spring (1).
shaft mechanically. q As a result, disc plate (5) is released and the
friction force is lost and cylinder barrel (6) can
When brake release pressure is turned OFF revolve.
q When the brake release pressure is turned
OFF, brake piston (2) is pressed to the right by
spring (1).
q At this time, disc plate (5) fixed by the semilu-
nar groove of cylinder barrel (6) is fixed
between body (4) and brake piston (2).
q Cylinder barrel (6) cannot revolve because of
the friction force and the swing motor output
shaft is fixed.
PC20MR-3 10-403 31
Hydraulic valve 2nd stage

Shockless relief valve q The hydraulic pressure of (P1) flows through
orifices (a) and (b) into secondary chamber (c)
Function to move piston (1) to the right stroke end.
q As a result, the installed length of spring (2) is
q The shockless relief valve consists of a direct
reduced and the force is increased, and then
relief valve (poppet) and a 2-stage selector pis-
pressure of (P1) increases to set pressure
ton to which a spring force is applied.
(PS).
q When the hydraulic motor is stopped, the
motor continues revolution by inertia, even
after ports IN and OUT of the hydraulic motor
are closed.
q As a result, pressure (brake pressure) is gen-
erated on the port OUT side by the pumping
action of the motor.
q The shockless relief valve relieves this pres-
sure by the following 2-stage operation to
reduce the stopping shock and prevent dam-
age of the motor.
q The shockless relief valve also reduces the
starting shock of the motor.
Operation
1st stage
q If pressure (P1) rises high, the pressure equiv-
alent to force (F1) of spring (2) opens poppet
(3).
10-403 32 PC20MR-3
Check valve
q When the upper structure is accelerated and
decelerated with the control lever, the oil sup-
ply from the pump to port (A) is reduced.
q If the upper structure has been swinging at rel-
ative high speed, it rotates the swing motor,
which works as a pump. Since the pressure in
part (C) becomes negative at this time, oil must
be supplied.
q If the pressure in port (B) is lower than the
operating pressure of the relief valve, however,
all of the oil flowing through port (A) to part (C)
is discharged through port (B) into the control
valve.
q Accordingly, the oil from the control valve is
insufficient for part (C).
q To prevent cavitation at this time, the oil in the
tank is supplied through port (T) and check
valve to part (C).
PC20MR-3 10-403 33
Swing holding brake timer valve
Function
q When the swing motor stops, the swing hold-
ing brake timer valve delays the operation of
the brake for a certain time to prevent damage
of the motor parts caused by sudden operation
of the brake.
Operation
When swing holding brake is released
q If the brake pilot pressure of port (PP) is turned

ON, it moves spool (1) to the right against the
force of spring (2).
q At this time, the brake release pressure in port
(PB) is led through the route indicated by the
arrows to the brake piston chamber to release
the brake.
10-403 34 PC20MR-3
When swing holding brake is applied
q If the brake pilot pressure of port (PP) is turned

OFF, spool (1) is pushed back to the left by the
force of spring (2).
q The brake release pressure in port (PB) is
stopped by spool (1) and not led to the brake
piston chamber.
q Accordingly, the hydraulic oil in the brake pis-
ton chamber is pushed out by the spring in the
brake, and then it flows through the route indi-
cated by the arrows into port (DR).
q At this time, the oil flow to port (DR) is reduced
by piston (3) to delay the operation of the
brake for a certain time.
PC20MR-3 10-403 35
10-403 36 PC20MR-3
PPC valve SEN04779-00
PPC valve 1
For work equipment and swing
P : From pilot pump P4 : L.H. PPC valve: swing LEFT port/

P1 : L.H. PPC valve: arm IN port/ R.H. PPC valve: bucket CURL port
R.H. PPC valve: boom RAISE port T : To tank
P2 : L.H. PPC valve: arm OUT port/
R.H. PPC valve: boom LOWER port
P3 : L.H. PPC valve: swing RIGHT port/
R.H. PPC valve: bucket DUMP port
PC20MR-3 10-403 37
SEN04779-00 PPC valve
10-403 38 PC20MR-3
1. Spool 6. Plate
2. Piston 7. Retainer
3. Disc 8. Body
4. Nut (for connecting lever) 9. Filter
5. Joint
Unit: mm

Free length
Centering spring Outside
10 length load length load
[For ports (P3) and (P4)] diameter
Replace spring
9.81 N 7.85 N
38.71 15.5 34 if damaged or
{1 kg} {0.8 kg}
deformed
Centering spring 17.7 N 14.1 N
11 42.48 15.5 34
[For ports (P1) and (P2)] {1.8 kg} {1.44 kg}
16.7 N 13.3 N
12 Metering spring 26.53 8.15 24.9
{1.7 kg} {1.36 kg}
PC20MR-3 10-403 39
Operation q The relationship in the position of spool (1) and

At neutral body (10) [fine control hole (f) is at a point mid-
q Ports (A) and (B) of the control valve and ports way between drain chamber (D) and pump
(P1) and (P2) of the PPC valve are connected pressure chamber (PP)] does not change until
to drain chamber (D) through fine control hole retainer (9) contacts spool (1).
(f) in spool (1). q Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever.
q So the pressure at port (P1) also rises in pro-
portion to the travel of the control lever.
q In this way, the control valve spool moves to a
position where the pressure in chamber (A)
[the same as the pressure at port (P1)] and the
force of the control valve spool return spring
are balanced.
During fine control

(neutral o fine control)
q When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
q When this happens, fine control hole (f) is shut
off from drain chamber (D), and at almost the
same time, it is connected to pump pressure
chamber (PP).
q So pilot pressure oil from the control pump
passes through fine control hole (f) and goes
from port (P1) to port (A).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP).
At almost the same time, it is connected to
drain chamber (D) to release the pressure at
port (P1).
q When this happens, spool (1) moves up or
down so that the force of metering spring (2) is
balanced with the pressure at port (P1).
10-403 40 PC20MR-3
During fine control At full stroke

(when control lever is returned) q When disc (5) pushes down piston (4), and
q When disc (5) starts to be returned, spool (1) is retainer (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is connected with pump
q When this happens, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D) and the pressure q Therefore, the pilot pressure from the solenoid
oil at port (P1) is released. valve passes through fine control hole (f) and
q If the pressure at port (P1) drops too far, spool flows to chamber (A) from port (P1), and
(1) is pushed down by metering spring (2). pushes the control valve spool.
q Fine control hole (f) is shut off from drain q The oil returning from chamber (B) passes
chamber (D). At almost the same time, it is from port (P2) through fine control hole (f') and
connected to pump pressure chamber (PP). flows to drain chamber (D).
q The pump pressure is supplied until the pres-
sure at port (P1) recovers to a pressure that
corresponds to the lever position.
q When the spool of the control valve returns, oil
in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not
working. The oil passes through port (P2) and
enters chamber (B) to fill the chamber with oil.
PC20MR-3 10-403 41
Travel PPC valve
a For operation, see the sections of the Work

equipment and swing PPC valve.
P : From solenoid valve

P1 : R.H. travel FORWARD port
P2 : R.H. travel REVERSE port
P3 : L.H. travel FORWARD port
P4 : L.H. travel REVERSE port
T : To tank
10-403 42 PC20MR-3
1. Piston
2. Plate
3. Collar
4. Body
5. Valve
6. Metering spring
7. Centering spring
8. Bolt
PC20MR-3 10-403 43
Blade, boom swing and attachment PPC valve
a For operation, see the sections of the Work equipment and swing PPC valve.
10-403 44 PC20MR-3
P : From solenoid valve

P1 : To blade, boom swing and attachment valve
P2 : To blade, boom swing and attachment valve
T : To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm

Free length
8 Centering spring Outside
length load length load Replace spring
diameter
if damaged or
125 N 100 N deformed
33.88 15.3 28.4
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
9 Metering spring 22.73 8.1 22
{1.7 kg} {1.36 kg}
PC20MR-3 10-403 45
SEN04779-00

2009 KOMATSU
All Rights Reserved
10-403 46
SEN04780-00
HYDRAULIC EXCAVATOR
PC20MR-3


500 Work equipment
Work equipment .............................................................................................................................................. 3
Dimensions of each part of work equipment................................................................................................... 6
PC20MR-3 10-500 1
500 Work equipment
SEN04780-00
10-500 2 PC20MR-3
500 Work equipment
Work equipment SEN04780-00
Work equipment 1
PC20MR-3 10-500 3
500 Work equipment
SEN04780-00 Work equipment
10-500 4 PC20MR-3
500 Work equipment
Work equipment SEN04780-00
Unit: mm
Standard Tolerance Standard Clearance

Clearance between mounting size clearance limit
Shaft Hole
1 pin of revolving frame and
swing bracket and bushing 0.030 +0.136 0.095
75 1.0
0.076 +0.065 0.212
Clearance between mounting
0.025 +0.083 0.052
2 pin of swing bracket and 35 1.0
0.064 +0.027 0.147
boom and bushing
0.090 +0.142 0.170
3 pin of boom and arm and 35 1.0
0.130 +0.080 0.272
bushing
0.090 +0.070 0.100 Replace pin
4 pin of arm and bucket and 30 1.0
0.130 +0.010 0.200 and bushing
bushing
0.090 +0.070 0.100
5 pin of link and bucket and 30 1.0
0.130 +0.010 0.200
bushing
Clearance between mounting 0.090 +0.070 0.100
6 30 1.0
pin of links and bushing 0.130 +0.010 0.200
0.090 +0.070 0.100
7 pin of arm and link and bush- 30 1.0
0.130 +0.010 0.200
ing
0.025 +0.142 0.105
8 pin of track frame and blade 35 1.0
0.087 +0.080 0.229
and bushing
PC20MR-3 10-500 5
500 Work equipment
SEN04780-00 Dimensions of each part of work equipment
Dimensions of each part of work equipment 1

Arm section
10-500 6 PC20MR-3
500 Work equipment
Dimensions of each part of work equipment SEN04780-00
Unit: mm
Tolerance
No. Measuring point Standard size
Shaft Hole
0.025 +0.039
1 35
0.064 +0.000
Arm side 46 1
2
0.5
Cylinder head side 45
0.5
0.09 +0.142
3 35
0.13 +0.080
+1.0
Boom side 124
+0.5
4
+0.0
Arm side 122.5
0.5
5 234.3 0.5
+1.0
6 143.2
0.5
+1.0
7 217
0.5
8 1,100.6 3
9 102.6 0.5
10 130.6 1
11 6 1
12 280 0.5
13 256 0.5
14 190 0.2
15 640.4
0.090 +0.09
16 30
0.130 + 0.000
0.
Link side 131
0.5
17
+2
Bucket side 132
0
0.090 +0.09
18 30
0.130 +0.000
0.
Arm side 131
0.5
19
+2
Bucket side 132
0
Min. 705.5 1
20
Max. 1,175
PC20MR-3 10-500 7
500 Work equipment
SEN04780-00 Dimensions of each part of work equipment
Bucket section
Unit: mm
No. Measuring point Standard size Tolerance
1 188.8
2 21.3
3 553
4 38
5 38
6 15
7 50
8 12.5
+2
9 132
+ 0.009
10 46
11 31
12 198 1
13 55
14 55
+0.009
15 30
+0.009
10-500 8 PC20MR-3
500 Work equipment
Dimensions of each part of work equipment SEN04780-00
PC20MR-3 10-500 9
SEN04780-00

2009 KOMATSU
All Rights Reserved
10-500 10
SEN04781-00
HYDRAULIC EXCAVATOR
PC20MR-3


600 Cab and its attachments
Floor................................................................................................................................................................ 2
PC20MR-3 10-600 1
SEN04781-00 Floor
Floor 1
Tilt floor
1. Hinge pin Outline

2. Torsion bar q The tilt floor can be tilted open for the ease of
3. Lock pin adjusting of the fan belt, inspection and main-
4. Wire tenance such as replacement of the hydraulic
5. Gas spring hoses, etc.
6. Reset lever Tilt open angle (a): Approx. 35
7. Tilt lock bracket
8. Floor assembly
10-600 2 PC20MR-3
Floor SEN04781-00
PC20MR-3 10-600 3
SEN04781-00

2009 KOMATSU
All Rights Reserved
10-600 4
SEN04782-00
HYDRAULIC EXCAVATOR
PC20MR-3


700 Electrical system
Engine control system..................................................................................................................................... 2
Electric control system .................................................................................................................................... 4
KOMTRAX system.......................................................................................................................................... 9
Component parts of system .......................................................................................................................... 12
Monitor system.............................................................................................................................................. 13
Sensors......................................................................................................................................................... 16
PC20MR-3 10-700 1
SEN04782-00 Engine control system
Engine control system 1
1. Battery
2. Starting switch
3. Fuse box
4. Engine stop solenoid
5. Lock lever
6. PPC lock switch
7. Neutral engine start relay
8. Safety relay
9. Starting motor
10. Fuel control lever
11. KOMTRAX terminal
12. KOMTRAX engine cut relay
10-700 2 PC20MR-3
Engine control system SEN04782-00
Starting engine
q If starting switch (2) is set to the ON position,
engine stop solenoid (4) sets the governor stop
lever to the RUN position. Accordingly, if the
electric system has a failure, the engine stops,
that is, a fail-safe mechanism is formed.
q If starting switch (2) is set to the START posi-
tion while lock lever (5) is in the LOCK posi-
tion, the start signal flows in starting motor (9)
and the engine starts. If lock lever (5) is in the
FREE position, neutral engine start relay (7)
operates to shut off the start signal to starting
motor (9), thus the engine does not start.
q If the machine is equipped with the KOMTRAX
terminal system and receives an engine cut-
out command generated by an external opera-
t i o n , K O M T R A X c o n t r o l l e r ( 11 ) t u r n s
KOMTRAX engine cut-out relay (12) ON to
shut off the current to starting motor (9), thus
the engine cannot start.
Engine speed control

q If fuel control lever (10) is operated, the cable
is extended or retracted to control the engine
speed.
Stopping engine
q If starting switch (2) is set to the OFF posi-
tion, engine stop solenoid (4) sets the governor
stop lever to the STOP position to stop the
engine.
PC20MR-3 10-700 3
SEN04782-00 Electric control system
Electric control system 1

General system drawing
10-700 4 PC20MR-3
Electric control system SEN04782-00
1. Battery
2. Starting switch
3. Fuse box
4. Machine monitor
5. 2nd travel speed selection solenoid relay
6. Lock lever
7. PPC lock switch
8. PPC lock solenoid relay
9. 2nd travel speed selection solenoid valve
10. PPC lock solenoid valve
11. Right work equipment PPC valve
12. Travel PPC valve
13. Left work equipment PPC valve
14. Boom swing PPC valve
15. Blade PPC valve
16. Travel motor
17. Travel pressure switch
18. Travel alarm
19. Engine
20. Hydraulic pump
20a. Servo valve
20b. LS valve
20c. PC valve
21. Control valve
21a. Self pressure reducing valve
PC20MR-3 10-700 5
Travel control function
1. Battery Input and output signals

2. Starting switch a. Monitor panel power supply
3. Fuse box b. Solenoid power supply
4. Machine monitor c. 2nd travel speed selection signal
5. 2nd travel speed selection solenoid relay d. Solenoid valve drive signal
7. Left travel motor
8. Right travel motor
9. Control valve
10. Engine
11. Hydraulic pump
12. Travel pressure switch
13. Travel alarm
10-700 6 PC20MR-3
Electric control system SEN04782-00
Function
Changing travel speed
2nd travel speed selection Low High
q If the travel speed selection switch of the switch speed speed
machine monitor is operated, the motor capac-
2nd travel speed selection
ity changes, thus the travel speed changes. OFF ON
monitor
2nd travel speed selection
a Even while the machine is traveling at the high OFF ON
solenoid valve
speed (High), if the load changes largely on a
soft ground or on a slope, the travel speed is Motor capacity (cm3/rev) 16.1 9.1
set to the low speed (Low) automatically. At
this time, the 2nd travel speed selection moni- Travel speed (km/h) 2.8 4.6
tor keeps lighting up.
Travel motor swash plate
Max. Min.
angle
19.2 MPa
A
{196 kg/cm2}
20.7 MPa
B
{211 kg/cm2}
PC20MR-3 10-700 7
PPC lock function
1. Battery Function
2. Starting switch q The PPC lock switch is interlocked with the
3. Fuse box lock lever. If the lock lever is set in the LOCK
4. Lock lever position, the PPC lock switch is turned OFF.
5. PPC lock lever q If the PPC lock switch is turned OFF, the cur-
6. PPC lock solenoid relay rent flowing to the PPC lock solenoid valve is
7. PPC lock solenoid valve shut off. T hen, the work equipment and
8. Left PPC valve machine unit do not move even if any control
9. Right PPC valve lever or pedal is operated.
10. Travel PPC valve
11. Boom swing PPC valve
12. Blade PPC valve
13. Engine
14. Hydraulic pump
15. Control valve
Input and output signals

a. PPC lock signal
b. Solenoid power supply
c. Solenoid valve drive signal
10-700 8 PC20MR-3
KOMTRAX system SEN04782-00
KOMTRAX system 1
q The KOMTRAX terminal transmits various

kinds of machine information wirelessly. The
KOMTRAX operator can refer to the informa-
tion at the office to provide various kinds of ser-
vices for customers.
a To provide the services, a separate arrange-

ment for setting up the KOMTRAX terminal is
required.
Information transmittable from the KOMTRAX

terminal includes the following.
1. Operation information
2. Service meter
3. Position information
4. Fuel level
PC20MR-3 10-700 9
SEN04782-00 KOMTRAX system
KOMTRAX terminal
Model: TC310
q The KOMTRAX system uses satellite communication technology.
1. GPS antenna connection

2. Connector (A)
3. Connector (B)
4. Connector (C)
5. Communication antenna connection
Outline
q The KOMTRAX terminal can obtain various
kinds of information from network signals or
input signals in the machine and transmit them
through the wireless communication antenna.
It has a CPU (Central Processing Unit) in it and
also has wireless communication function and
GPS (Global Positioning System) function.
q This terminal has LED lamps and 7-segment
indicator lamps used for inspection and trou-
bleshooting on its unit.
q Use of KOMTRAX terminal must be limited to
the countries where such communication is
allowed.
a When using the system outside the countries
which had been already registered, notification
of using the system in the new country is nec-
essary to be given when starting operation in
the country.
10-700 10 PC20MR-3
KOMTRAX system SEN04782-00

174480-1 AMP (18 + 12 + 12 pins)
Input/ Input/ Input/

Pin Pin Pin
Signal name Output Signal name Output Signal name Output
No. No. No.
signal signal signal
1 NC (*) 1 NC (*) 1 GND
2 NC (*) 2 NC (*) 2 GND
3 NC (*) 3 NC (*) 3 ACC input Input
4 NC (*) 4 NC (*) 4 R terminal input Input
5 NC (*) 5 NC (*) 5 NC (*)
6 NC (*) 6 NC (*) 6 Constant power supply Input
B C
7 NC (*) 7 NC (*) 7 Constant power supply Input
8 NC (*) 8 NC (*) 8 Relay output Output
9 NC (*) 9 NC (*) 9 Inspection mode selection signal Input
A Input/
10 CAN (H) Output 10 NC (*) 10 NC (*)
Input/
11 CAN (L) Output 11 NC (*) 11 C terminal input Input
12 NC (*) 12 NC (*) 12 NC (*)
13 NC (*) *: Never connect to NC or malfunctions or *: Never connect to NC or malfunctions or
failures will occur. failures will occur.
14 NC (*)
15 NC (*)
16 NC (*)
17 NC (*)
18 NC (*)
*: Never connect to NC or malfunctions or
failures will occur.
PC20MR-3 10-700 11
SEN04782-00 Component parts of system
Component parts of system 1

PPC lock solenoid valve
2nd travel speed selection solenoid valve

a See Solenoid valve.
Monitor panel
a See Monitor system.
10-700 12 PC20MR-3
Monitor system SEN04782-00
Monitor system 1
1. Machine monitor Outline

2. Battery q The machine monitor system uses the net-
3. Each sensor work circuit between the controllers and sensor
4. Alarm buzzer installed to all parts of the machine to observe
the condition of the machine. It processes this
Input and output signals information, and display it on a panel to inform
a. Power supply the operator of condition of the machine.
b. Sensor signal
c. Alarm buzzer signal
PC20MR-3 10-700 13
SEN04782-00 Monitor system
Machine monitor
Outline
q The machine monitor has the monitor display function, gauge display function and service meter func-
tion.
q The machine monitor has a CPU (Central Processing Unit) in it to process, display and output informa-
tion.
q If there is a trouble in the machine monitor unit, the monitor does not display normally.

AMP070-20P [CN-F15]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 GND Input 11 Buzzer output Output
2 NC (*) 12 Working lamp switch Input
3 NC (*) 13 Fuel level sensor Input
4 Wake up switch Input 14 CAN+ Input/Output
5 CAN Input/Output 15 Speed increase solenoid relay output Output
6 Speed increase Input 16 Engine coolant temperature sensor Input
7 Engine oil pressure switch Input 17 Battery charge level Input
8 Preheating switch Input 18 NC (*)
9 Key input Input 19 ACC Input
10 Sensor GND Input 20 Unswitched power supply Input
*: Never connect to NC or malfunctions or failures will occur.
10-700 14 PC20MR-3
Monitor system SEN04782-00
Operation
Gauge and monitor display unit
Light
Type of
No. Display item Display range Display method Display color source
display
element
When below red When normal: OFF
1a Pilot Red LCD
Fuel level range When below red range: Flashing
1b Gauge Empty - Full Indication with pointer White LED
Display of
2 Service meter 0 99999.9 h Operation during run of engine
clock time
3a Gauge 55 135C Indication with pointer White
Coolant When coolant
temperature When normal: OFF
3b Pilot temperature is Red
When above 110C: Flashing
abnormal
During
4 Caution Preheating During operation: Flashing (18 sec) Green
preheating
Electrical When system is LED
5 Caution When abnormal: Lighting or flashing
system warning abnormal
Engine oil Below specified
6 Caution When abnormal: Flashing Red
pressure pressure
Battery charge When charge is
7 Caution When abnormal: Flashing
level defective
When travel
Travel speed
8 Pilot speed is When speed is increased: Lighting Orange
increase
increased
PC20MR-3 10-700 15
SEN04782-00 Sensors
Sensors 1
q The signal from each sensor is input to the panel directly.
q The sensors are classified into contact type and resistance type.
q Either side of a sensor of contact type is always connected to the chassis ground.
Category of display Name of sensor Type of sensor When normal When abnormal
Caution Engine oil pressure Contact OFF (Open) ON (Closed)
Coolant temperature Resistance
Gauge
Fuel level Resistance
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
q The engine oil pressure sensor is installed to the engine cylinder block and its diaphragm senses oil
pressure. If the oil pressure lowers below the set level, the switch is turned ON.
Coolant temperature sensor
1. Connector 3. Thermistor
2. Plug
Function
q The coolant temperature sensor is installed to the engine cylinder block. It senses changes of tempera-
ture as changes of resistance of the thermistor in it, and then generates signals according to the mea-
sured temperature.
10-700 16 PC20MR-3
Sensors SEN04782-00
Fuel level sensor
1. Float
2. Arm
3. Variable resistor
4. Connector
Function
q The fuel level sensor is installed to the top of the fuel tank and its float moves up and down according to
the fuel level in the tank. The movement of the float operates the variable resistor through the arm, and
then signals are generated according to the change of the resistance.
PC20MR-3 10-700 17
SEN04782-00

2009 KOMATSU
All Rights Reserved
10-700 18
SEN04867-01
PC20MR-3
SEN04867-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

20 Standard value table

100 Standard service value table
Standard value table for engine related parts ............................................................................................. 2

Standard value table for chassis related parts............................................................................................ 3
PC20MR-3 20-100 1
SEN04867-01 Standard value table for engine related parts
Standard value table for engine related parts

Applicable model PC20MR-3
Engine 3D76E-6
Cate- Standard value for
Item Measurement condition Unit Service limit value
gory new machine
High idle 2,680 50
Engine speed Low idle rpm 1,450 50
Rated speed 2,500
At sudden acceleration Max. 4.0 5.5

Bosch
Exhaust gas color
index
At high idle Max. 1.0 2.5
Intake valve 0.20

Valve clearance Normal temperature mm
Exhaust
0.20
valve
Engine
Compres- MPa 3.43 2.75

Compression pres- Oil temperature: 40 sion pressure {kg/cm}2} {35} {28}
sure 60C Engine
(rpm) (250) (250)
speed
Coolant temperature: operating range kPa
Blow-by pressure
at high idle (mmH2O) {} {}
0.29 0.44
Coolant temperature: At high idle
MPa {3.0 4.5}
Oil pressure Within operating range
Oil: SAE30W {kg/cm2} Min. 0.15 Min. 0.1
At low idle
{Min. 1.5} {Min. 1.0}
Oil temperature Whole speed range (inside oil pan) C Max. 120 Max. 120

Fuel injection timing B.T.D.C. 16
(degree)
Deflection when pressed with finger 9 13 7 10
Fan belt tension mm
force of approx. 98 N{10 kg} (When testing) (When adjusting)
20-100 2 PC20MR-3
Standard value table for chassis related parts SEN04867-01
Standard value table for chassis related parts

Machine model PC20MR-3
Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
q Engine coolant temperature: Within
Speed when 1 pump
operating range
Engine speed
Min. 2,230 Min. 2,230

is relieved
q Hydraulic oil temperature: 45 55C
q Relief of 1 pump: Relieve bucket cir- rpm
cuit.
Speed when 2 pumps
q Relief of 2 pumps: Relieve backet and Min. 2,030 Min. 2,030
are relieved
blade circuits
Boom control valve
Arm control valve
Bucket control valve

Stroke of control valve spool
Swing control valve

l=30 l=30
a For details, see Fig. Control valve at
Breaker control valve mm a=6 a=6
the end of this section.
b=6 b=6
Boom swing
Control valve
Blade control valve
Left travel control

valve
Right travel control
valve
Boom control lever NoRAISE, LOWER 80 10 80 10
Arm control lever NoIN, OUT 80 10 80 10
Bucket control lever NoCURL, DUMP 80 10 80 10

Stroke of control lever and pedal
q Engine stopped NoSwing to LEFT,

Swing control lever 80 10 80 10
q Measure at cen- RIGHT
Boom swing control ter of lever grip. N o Swing boom to
q Measure at ped- 25 5 25 5
pedal LEFT, RIGHT
al tip. mm
Blade control lever q Read max. value NoRAISE, LOWER 50 5 50 5
to stroke end
(excluding neu- N o FORWARD,
Travel control lever tral play). 100 10 100 10
REVERSE
SLOWioFULL
Fuel control lever 160 20 160 20
THROTTLE
Work equipment,
Max. 5 Max. 5
swing
Play of control lever
Travel Max. 5 Max. 5
PC20MR-3 20-100 3
SEN04867-01 Standard value table for chassis related parts

15.68 4.9 15.68 9.8
Boom control lever
{1.6 0.5} {1.6 1.0}
Operating effort of control levers and pedals
15.68 4.9 15.68 9.8

Arm control lever
{1.6 0.5} {1.6 1.0}
15.68 4.9 15.68 9.8
Bucket control lever
{1.6 0.5} {1.6 1.0}
q Hydraulic oil temperature: 45 55C 15.68 4.9 15.68 9.8
Swing control lever q Run engine at full throttle.
N {1.6 0.5} {1.6 1.0}
q Install push-pull scale to center of lever
Boom swing control {kg} 78.4 19.6 78.4 29.4
grip or pedal tip to measure.
pedal q Read max. value to stroke end. {8.0 2.0} {8.0 3.0}
29.4 9.8 29.4 19.6
Blade control lever
{3.0 1.0} {3.0 2.0}
19.6 4.9 19.6 9.8
Travel control lever
{2.0 0.5} {2.0 1.0}
29.4 14.7 29.4 29.4
Fuel control lever
{3.0 1.5} {3.0 3.0}

q Set all levers in neutral. 3.9(+0.98/0) 3.9 (+0.98/0)
Unload pressure
q Run engine at full throttle. {39.6(+10/0)} {39.6 (+10/0)}
q Measure pump outlet pressure.
24.5 24.5
Boom relief pressure (+0.98/-0.49) (+0.98/-0.49)
{250 (+10/-5)} {250 (+10/-5)}
24.5 24.5
Arm relief pressure (+0.98/-0.49) (+0.98/-0.49)
{250 (+10/-5)} {250 (+10/-5)}
24.5 24.5
Bucket relief pressure (+0.98/-0.49) (+0.98/-0.49)
{250 (+10/-5)} {250 (+10/-5)}
q Run engine at full throttle and measure MPa
relief pressure (Relieve only circuit to 16.2 0.98 16.2 0.98
Swing relief pressure {kg/cm2}
be measured). {215 10} {215 10}
q Measure pump outlet pressure. 24.5 24.5
Oil pressure
Boom swing relief

(+0.98/-0.49) (+0.98/-0.49)
pressure
{250 (+10/-5)} {250 (+10/-5)}
21.1 0.98 21.1 0.98
Blade relief pressure
{215 10} {215 10}
24.5 24.5
Travel relief pressure (+0.98/-0.49) (+0.98/-0.49)
{250 (+10/-5)} {250 (+10/-5)}
q Run engine at full throttle.
Control circuit oil pres- 3.72 (+0.39/-0.1) 3.72 (+0.39/-0.1)
q Measure circuit oil pressure when all
sure {38 (+4/-1)} {38 (+4/-1)}
control levers are in neutral.
q Measure pump outlet pressure.
q Hydraulic oil
temperature When all levers are 4.0 (+0.98/0) 4.0 (+0.98/0)
:45 55C in neutral {40.8 (+10/0)} {40.8 (+10/0)}
LS differential pres- q Run engine at MPa
sure full throttle.
When arm lever is {kg/cm2}
q Pump outlet 1.57 0.1 1.57 0.1
moved IN
pressure {16 1} {16 1}
(half stroke)
-LS pressure
20-100 4 PC20MR-3

q No load, max. reach
q Stop after swinging 1 turn and mea-
deg. Max. 40 50
Overrun of swing sure shifting distance of swing circle.
(mm) () ()
q Value in ( ) is shifting distance of out-
side of swing circle.
q For measuring posture, see Fig.
Swing 1 at end of this section.
q Hydraulic oil temperature:
90 2.0 0.3 2.7
45 55C
Time required to start q Measure time required to
swinging pass 90 and 180 points af-
ter starting swinging.
180
q For measuring posture, see
Fig Swing 1 at end of this sec.
section
Run engine at full throttle.
Swing
q
Time required for
q Measure time required to swing 5 turns 31 3 36
swinging
after swinging 1 turn.
q Max. reach
q Stop engine.
q Fill bucket with rated load or dirt and
sand. (Rated load: 1,058 N {108 kg})
q Stop machine on slope of 15 and set
Hydraulic drift of deg. 0 0
its upper structure at 45 upward.
swing (mm) (0) (0)
q Make match marks on swing circle out-
er race and track frame.
q Measure shifting distance of match
marks in 15 minutes
Leakage from swing q Run engine at full throttle.
cc/min
motor q Relieve swing circuit and measure
leakage in 1 minute.
PC20MR-3 20-100 5

45 55C Low 25.7 2 25.7 4
q Run engine at full throttle. speed (25.0 2) (25.0 4)
q After approach run of at
least 10 m on flat ground,
measure time required to
Travel speed sec.
travel 20 m.
q ( ): Machine with steel shoe High 15.7 2 15.7 4
specification speed (16.7 2) (16.7 4)
Fig. Travel 1 at end of this
section.
45 55C Low
Max. 500 550
q Run engine at full throttle. speed
q After approach run of at
least 10 m on hard and flat
Travel
Travel deviation ground, measure travel de- mm

viation (X) in the travel of 20
High
m after approach run. Max. 500 550
speed
Fig. Travel 2 at end of this
section.
q Stop engine.
q Stop machine on slope of 30 with
sprocket on upper side.
Hydraulic drift of travel mm 0 0
q Measure hydraulic drift of travel in 5
minutes.
q For measuring posture, see Fig. Trav-
el 3 at end of this section.

Leakage from travel
q Run engine at full throttle. l/min.
motor
q Lock shoe to relieve travel circuit.
20-100 6 PC20MR-3

Whole work
equipment
q Measure extension and retraction of Max. 300 450
(Hydraulic drift of
each cylinder and lowering of bucket
bucket tooth tip)
tooth tip from above position.
Boom cylinder q Stop machine on level and flat ground.
(Retraction of cyl- q Bucket: Rated load Max. 20 30
inder) (Rated load: 1,058 N {108 kg})
q Stop engine
Arm cylinder q Set lever in neutral.
(Extension of cyl- q Start measurement just after setting. Max. 20 30
inder) q Measure hydraulic drift every 5 min-
utes for 15 minutes.
Work equipment
Hydraulic drift
Bucket cylinder q For measuring posture, see Fig. Work

(Retraction of cyl- equipment 1 at end of this section. Max. 20 30
inder) mm

q Stop engine
Boom swing cylin- q Bucket: Rated load
der (Rated load: 1,058 N {108kg})
(Retraction and q Set machine in above position on Max. 20 30
extension of cylin- slope of 15 with upper structure at
der) right angle to its body and measure re-
traction and extension of cylinder for
15 minutes.
Blade q Stop engine
(Hydraulic drift of q Measure hydraulic drift of blade tip Max. 30 45
blade tip) from maximum raising height for 15
minutes.
PC20MR-3 20-100 7

45 55C 2.0 0.3 2.8
q Run engine at full throttle. RAISE (To just before (To just before
q Measure time required to cushion) cushion)
move cylinder between ex-
Boom speed tension stroke end and posi-
tion at which bucket tooth is
in contact with ground.
q For measuring posture, see LOWER 2.0 0.3 2.8
Fig. Work equipment 2 at
end of this section.
45 55C
q Run engine at full throttle. IN 2.5 0.3 3.1
q Measure time required to
Arm speed
tension and retraction stroke
ends.
q For measuring posture, see OUT 2.2 0.3 2.8
end of this section. sec.
45 55C
Work equipment speed
q Run engine at full throttle. CURL 2.2 0.3 2.8

Work equipment

Bucket speed
tension and retraction stroke
ends.
q For measuring posture, see DUMP 2.2 0.3 2.8
45 55C Swing
q Run engine at full throttle. boom to 7.0 1.5 10
q Measure time required to LEFT
Boom swing move cylinder between ex-
speed tension and retraction stroke
ends. Swing
q For measuring posture, see boom to 7.0 1.5 10
Fig. Work equipment 5 at RIGHT
45 55C
q Run engine at full throttle. RAISE 1.0 0.3 1.6
move cylinder between po-
sition at which blade is in
Blade speed sec.
contact with ground and
maximum blade raising po-
sition.
For measuring posture, see LOWER 1.0 0.3 1.6
q
20-100 8 PC20MR-3


q Run engine slow.
q Set arm to OUT stroke end, bucket to
DUMP stroke end, and boom at RAISE
Boom time lag stroke end. Then, lower bucket and Max. 2 Max. 3.9
measure time required to raise ma-
chine after bucket touches ground.
q For measuring posture, see Fig. Work
equipment 7 at end of this section.

q Run engine slow.
q Set upper side of boom horizontally,
bucket to DUMP stroke end, and arm
Arm time lag to IN stroke end. Then, move arm IN Max. 1 Max. 2
and measure time required to start it
again after it stops temporarily.
Time lag
sec.
Work equipment
q Run engine slow.

q Set upper side of boom horizontally,
arm to IN stroke end, and bucket to
Bucket time lag DUMP stroke end. Then, CURL buck- Max. 1 Max. 2
et and measure time required to start it
again after it stops temporarily.

q Run engine slow.
q Lower blade from RAISE stroke end
Blade time lag and measure time required to raise Max. 2 Max. 3.9
machine after blade touches ground.
Internal leackage
Leakage from
Max. 2 10
each cylinder
q Run engine at full throttle. cc/min.
q Relieve circuit to be measured.
Leakage from

center swivel joint
Performance of
See section of Performance of hydraulic pump.
hydraulic pump
PC20MR-3 20-100 9
Performance of hydraulic pump
Gear pump
Standard value for

Item Measurement condition Unit Service limit value
new machine

Discharge of gear
q Engine speed: 2,500 rpm l/min 15.2 12.5
pump
q Measure at set pressure of relief valve.
Piston pump
Discharge Discharge pres Stan- Criterion
pressure of sure of gear dard Stan-
Check
Item Measurement condition piston pump pump dis- dard
point
2}) 2}) charge value
(MPa {kg/cm (MPa {kg/cm (l/min.) (l/min.)
Hydraulic oil temperature: 45 55C
q
Engine speed: 2,500 rpm
q Q Q
Discharge of
a Avoid measuring near broken part of Any point P1 P2 (See (See
piston pump
graph since error become large at that graph) graph)
part.
20-100 10 PC20MR-3
Posture of machine for measuring performance

and measurement procedure
Control valve: Set spool to stroke end Travel 1: Travel speed and travel deviation
(Travel posture)
Swing 1: Overrun of the swing, time taken to

start swing, and time taken to swing Travel 2: Travel deviation (Distance of deviation)
Swing 2: Hydraulic drift of swing Travel 3: Hydraulic drift of travel
PC20MR-3 20-100 11
Work equipment 1: Hydraulic drift of work equip- Work equipment 4: Bucket speed
ment
Work equipment 5: Boom swing speed

Work equipment 2: Boom speed
Work equipment 6: Blade speed

Work equipment 3: Arm speed
20-100 12 PC20MR-3
Work equipment 7: Boom time lag Work equipment 10: Blade time lag
Work equipment 8: Arm time lag
Work equipment 9: Bucket time lag
PC20MR-3 20-100 13
SEN04867-01
2010 KOMATSU
All Rights Reserved
20-100 14
SEN04868-00
PC20MR-3
SEN04868-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


List of testing, adjusting, and troubleshooting tools .................................................................................... 3

Measuring engine speed............................................................................................................................. 6
Adjusting valve clearance ........................................................................................................................... 7
Measuring compression pressure............................................................................................................... 8
Measuring engine oil pressure.................................................................................................................... 9
Testing and adjusting fuel injection timing .................................................................................................. 10
Bleeding air from fuel circuit........................................................................................................................ 12
Testing and adjusting fan belt tension ........................................................................................................ 13
Adjusting fuel control lever linkage ............................................................................................................. 14
Measurement of clearance in swing circle bearings ................................................................................... 15
Testing and adjusting track shoe tension.................................................................................................... 16
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits .......................... 18
Measuring control circuit basic pressure..................................................................................................... 21
Testing and adjusting pump LS differential pressure.................................................................................. 22
Measuring solenoid valve output pressure ................................................................................................. 24
Measuring PPC valve output pressure ....................................................................................................... 26
Adjusting play of work equipment and swing PPC valves .......................................................................... 28
Measuring swing holding brake release pressure....................................................................................... 28
Measurement of oil leakage from cylinder .................................................................................................. 30
Releasing residual pressure from hydraulic circuit ..................................................................................... 32
PC20MR-3 30-100 1
SEN04868-00 Shop Manual
Bleeding air from cylinder............................................................................................................................ 32

Pressurizing hydraulic tank ......................................................................................................................... 33
How to open and close (tilt) floor................................................................................................................. 34
Inspection procedures for diode.................................................................................................................. 38
How to start operation of KOMTRAX terminal ............................................................................................ 39
Lamp display of KOMTRAX terminal .......................................................................................................... 43
Preparation work for troubleshooting of electrical system........................................................................... 46
30-100 2 PC20MR-3
List of testing, adjusting, and troubleshooting tools SEN04868-00
List of testing, adjusting, and troubleshooting tools

Symb-
Testing/Adjusting item Part No. Part Name Q'ty Remarks
ol
Measuring engine speed A 799-205-1100 Tachometer kit 1 Degital display: 6-99,999.9 rpm
1 799-201-9001 Handy smoke checker 1 Pollution level: 0 70% (with stan-
dard color)
Measuring exhaust gas color B Commercially
2 Smoke meter 1 (Pollution level: 1/10 C Bosch
available index)
Commercially Intake: 0.20 mm, Exhaust: 0.20
Adjusting valve clearance C Clearance gauge 1
available mm
1 795-502-1590 Compression gauge 1 0 6.9 MPa { 0 70kg/cm2}
Measuring compression pres-
D 2 795-111-1120 Adapter 1 For 3D76E-6 (YC-2)
sure
3 795-101-1571 Joint 1 For 3D76E-6
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil pres- Pressure gauge: 60 MPa {600
E
sure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
Pressure gauge: 1 MPa {10
2 799-401-2320 Hydraulic tester 1
kg/cm2}
Measuring swing circle bear- Commercially
F Dial gauge 1
ing clearance available
799-101-5002 Hydraulic tester 1
Measuring and adjusting oil 1 * Common with E1
pressures in work equip- 790-261-1204 Digital hydraulic tester 1
G
ment, travel, boom swing, 799-101-5220 Nipple 2
swing, and blade circuits 2 Size:10 1.25 mm
07002 - 11023 O-ring 2
Measuring control circuit oil 1 * Common with E1
H 790-261-1204 Digital hydraulic tester 1
pressure
2 799-401-3100 Adapter 1 Size: 02
1 * Common with E1
790-261-1204 Digital hydraulic tester 1
Measuring pump LS differen- Differential pressure
tial pressure
J 2 799-401-2701
gauge
1 49 MPa {500 kg/cm2}
799-101-5220 Nipple 2
3 * Common with G2
07002-11023 O-ring 2
Measuring solenoid valve out- 1 * Common with E1
K 790-261-1204 Digital hydraulic tester 1
put pressure
2 799-401-3100 Adapter 1 * Common with H2
Measuring PPC valve output 1 * Common with E1
L 790-261-1204 Digital hydraulic tester 1
pressure
2 799-401-3100 Adapter 1 *Common with H2
Measuring swing holding 1 * Common with E1
M 790-261-1204 Digital hydraulic tester 1
brake release pressure
2 799-401-3200 Adapter 1 Size: 03
Measuring leakage from work Commercially
N Measuring cylinder 1
equipment cylinder available
PC20MR-3 30-100 3
SEN04868-00 List of testing, adjusting, and troubleshooting tools
Symb-
ol
Measuring coolant tempera-
799-101-1502 Digital thermometer 1 * Common with B
ture and oil temperature
Measuring operating effort 79A-264-0021 1 0 294 N {0 30 kg}
Push-pull scale
and pressing force 79A-264-0091 1 0 490 N {0 50 kg}
Measuring stroke and hydrau- Commercially
Scale 1
lic drift available
Measuring work equipment Commercially
Stopwatch 1
speed available
Measuring voltage and resis- Commercially
Tester 1
tance available
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
799-601-9020 T-adapter 1 For coolant temperature sensor
Troubleshooting for engine 799-601-7000

controller/sensors/actuators or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 T-adapter 1 Fuel pump
799-601-7030 T-adapter 1 Fuel level sensor
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
799-601-9020 q Adapter for DT 1 For DT2P
For DT3P
799 -601-9030 q Adapter for DT 1 (Not including 799-601-4101 and
799-601-4201)
Troubleshooting for chas-
799-601-9040 q Adapter for DT 1 For DT4P
sis/sensors/wiring harnesses
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 q Adapter for X 1 For X2P
30-100 4 PC20MR-3
List of testing, adjusting, and troubleshooting tools SEN04868-00
Symb-
ol
799-601-7090 q Adapter for M 1 For M2P
799-601-7110 q Adapter for M 1 For M3P
Troubleshooting for chas- For SW6P (Not including
799-601-7050 q Adapter for SWP 1
sis/sensors/wiring harnesses 799-601-8000)
For SW8P (Not including
799-601-7060 q Adapter for SWP 1
799-601-8000)
799-601-7310 T-adapter for SWP 1 For SW12P
a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the ma-
chine monitor, controllers, sensors, actuators, and wiring harnesses, see Troubleshooting, T-branch box
and T-branch adapter table.
PC20MR-3 30-100 5
SEN04868-00 Measuring engine speed
Measuring engine speed
a Measuring instruments for engine speed

Symbol Part No. Part Name
A 799-205-1100 Tachometer kit
a Measure the engine speed under the following

conditions.
q Coolant temperature: Within operating range
1. Preparation work
1) Open the engine rear cover and stick
reflector tape [1] of tachometer kit A to the
end face of fan pulley (1).
2. Measuring low idling speed
1) Start the engine and set the fuel control lever
in the low idling position.
2) Set all the control levers and pedals in neutral
and measure the engine speed.
3. Measuring high idling speed

in the high idling position.
2) Set all the control levers and pedals in neutral
and measure the engine speed.
4. Measuring engine speed when 1 pump is

relieved
2) Using stand [2], set probe [3] straight at 1) Start the engine and set the fuel control lever
reflector tape [1]. in the high idling position.
2) Set the lock lever in the FREE position and
move the bucket cylinder to the CURL stroke
end.
3) Relieve the bucket circuit in the CURL posi-
tion under this condition and measure the
engine speed.
5. Measuring engine speed when 2 pumps are

relieved
in the high idling position.
2) Set the lock lever in the FREE position and
move the bucket cylinder to the CURL stroke
end and move the blade cylinder to the
3) Connect probe [3] to tachometer [4]. RAISE stroke end.
3) Relieve the bucket circuit in the CURL posi-
tion and the blade circuit in the RAISE posi-
tion under this condition and measure the
engine speed.
6. Work after finishing measurement

After finishing measurement, remove the
measuring instruments and return the removed
parts.
30-100 6 PC20MR-3
Adjusting valve clearance SEN04868-00
Adjusting valve clearance

5. While the No. 1 cylinder is at the compression
a Adjusting tools for valve clearance top dead center, adjust the valve clearance
Symbol Part No. Part Name according to the following procedure.
Commercially 1) Insert feeler gauge C in clearance (c)
C Clearance gauge
available between rocker arm (4) and valve stem (5)
and adjust the valve clearance with adjust-
ment screw (6).
1. Tilt the floor open. For details, see How to open
a With the feeler gauge inserted, turn the
and close (tilt) floor.
adjustment screw to a degree that you
can move the filler gauge lightly.
2. Remove air cleaner assembly (1) and bracket
2) Fix adjustment screw (6) and tighten locknut
together, and then remove cylinder head cover
(7).
(2).
a After tightening the locknut, check the
valve clearance again.
a After adjusting the air intake valve and ex-
haust valve, go to the next procedure.
3. Remove inspection cap (3) of the flywheel

housing.
4. Rotate the crankshaft forward to set stamp line

6. Rotate the crankshaft forward by 240 and
of "1" (a) on the flywheel to stamp line (b) on the
adjust the valve clearance of each cylinder in the
flywheel housing and bring the No. 1 cylinder to
firing order.
the compression top dead center.
q Firing order: 1-3-2
a The No. 1 cylinder is on the flywheel side.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the 7. After finishing adjustment, return the removed
No. 1 cylinder can be moved by the valve parts.
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
the compression top dead center. In this
case, rotate the crankshaft one more turn.
PC20MR-3 30-100 7
SEN04868-00 Measuring compression pressure
Measuring compression pressure
a Measuring instruments for compression pres-

sure
1 795-502-1590 Compression gauge
D 2 795-111-1120 Adapter (YC-2)
3 795-101-1571 Joint
a When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold or muffler or get caught in a rotating
part.
a Measure the compression pressure under the
following condition.
q Engine oil temperature: 40 60 C. 5. Disconnect connector M9 (2) of the engine stop
solenoid.
1. Adjust the valve clearance. For details, see
Adjusting valve clearance.
2. Prepare for measuring the engine speed. For

details, see Measuring engine speed.
3. Remove nozzle holder (1) of the cylinder to

measure the compression pressure.
6. Crank the engine with the starting motor and

measure the compression pressure.
a Read the compression gauge when its point-
er is stabilized.
a When measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.
4. Install adapter D2 and joint D3 to the nozzle 7. After finishing measurement, remove the
holder mounting part and connect compression measuring instruments and return the removed
gauge D1. parts.
a Install the gasket and protector to the end of 3 Nozzle holder :
the adapter. 49.0 53.0 Nm {5.0 5.4 kgm}

3 Adapter: 49.0 53.0 Nm {5.0 5.4 kgm}
a Since the compression gauge cannot be
pulled out of the revolving frame, keep the
floor tilted open.
30-100 8 PC20MR-3
Measuring engine oil pressure SEN04868-00
Measuring engine oil pressure

3. Start the engine and measure the oil pressure at
a Measuring instruments for engine oil pressure low idling and high idling.
799-101-5002 Hydraulic multimeter
1 Hydraulic multimeter (Digi-
E 790 -261-1204
tal)
2 799-401-2320 Hydraulic multimeter
a Measure the engine oil pressure under the fol-

lowing condition.
q Coolant temperature: Within operating range
1. Open the engine rear cover and remove engine

oil pressure switch (1).
4. After finishing measurement, remove the

parts.
2. Install adapter [1] of hydraulic tester E1 and

connect them to hydraulic tester E2.
PC20MR-3 30-100 9
SEN04868-00 Testing and adjusting fuel injection timing
Testing and adjusting fuel injec-

tion timing
a After removing and installing the fuel injection

pump, test and adjust the fuel injection timing ac-
cording to the following procedure.
a Before testing and adjusting the fuel injection
timing, bleed air from the fuel circuit.
Testing
1. Check that stamp line (a) on the fuel injection
pump is matched to stamp line (b) on the front
cover.
5. Return the crankshaft about 20 from the state
of step 4 above.
6. Rotate the crankshaft forward slowly again.

When the fuel swells at the end of delivery
holdee (2), stop the crankshaft.
7. Remove inspection cap (3) of the flywheel

housing and check that injection timing stamp
line (c) on the flywheel is matched to stamp line
(d) on the flywheel housing.
2. Remove fuel injection pipe (1).
8. Repat 4 7 by 2 3 times and check the fuel

injection timing by 2 3 times.
a The fuel injection timing can be checked with
any cylinder.
3. Turn the starting switch ON and set the fuel a The fuel injection timing of all the cyliners can
control lever in the high idling position. be checked by rotating the crankshaft by 240
a Keep the fuel control lever in this position. from the No.1 cylinder in the firing order.
q Firing order: 1-3-2
4. Rotate the crankshaft forward slowly. When the a The No. 1 cylinder is on the flywheel side.
fuel swells at the end of delivery holder (2) of the
fuel injection pump, stop the crankshaft.
a After the fuel swells, wipe it off to check
again.
30-100 10 PC20MR-3
Testing and adjusting fuel injection timing SEN04868-00
9. After finishing testing, return the removed parts.

3 Fuel injection pipe sleeve nut:
29.4 34.4 Nm {3.0 3 .5 kgm}
a If the fuel injection timing is abnormal, adjust
it before connecting the fuel injection pipe.
Adjustment
a If the fuel injection timing stamp line on the fly-
wheel is not matched to the stamp line on the fly-
wheel housing, the fuel injection timing is
abnormal. In this case, adjust according to the
following procedure.
1. Loosen mounting nut (4) of the fuel injection

pump.
2. Adjust stamp line (a) on the fuel injection pump

and center stamp line (b) on the front cover by
the difference of the fuel injection timing.
a To advance the fuel injection timing, tilt the
fuel injection pump toward the cylinder block.
a To delay the fuel injection timing, tilt the fuel
injection pump toward the counterweight.
a If stamp line (b) on the front cover is moved
by 1 division, the fuel injection timing chang-
es by 2.
3. After finishing adjusting, check that the fuel

injection timing is normal according to the above
testing procedure.
PC20MR-3 30-100 11
SEN04868-00 Bleeding air from fuel circuit
Bleeding air from fuel circuit
a After any fuel circuit part is removed and in-

stalled or a fuel piping is disconnected and con-
nected or the fuel runs out, bleed air from the fuel
piping according to the following procedure.
1. Fill the fuel tank with fuel.
2. Check that the fuel filter valve is in the OPEN

position.
3. Hold the starting switch in the ON position for 10

15 seconds, and then return it to the OFF posi-
tion.
a The air in the fuel circuit is bled automatically by

the above operation.
30-100 12 PC20MR-3
Testing and adjusting fan belt tension SEN04868-00
Testing and adjusting fan belt

tension
Testing
1. Open the engine rear cover.
2. Press the intermediate point of the belt between

the crank pulley and fan pulley with a finger and
measure the deflection of the belt.
q Force to press belt: Approx. 98 N {10 kg}
q Deflection: 9 13 mm
a If the deflection is about 10 mm, the belt ten-
sion is normal.
5. After finishing adjustment, return the removed
parts.
Adjusting
a If the deflection of the belt is abnormal, adjust it
according to the following procedure.

and close (tilt) floor.
2. Loosen alternator mounting bolt (1) and adjust-

ment bolt (2).
3. Move alternator (3) with a bar to adjust the belt

tension, and then tighten adjustment bolt (2)
temporarily.
a Put a wood piece, etc. between the bar and
alternator to protect the alternator.
q Force to press belt for adjustment: Approx.
98 N {10 kg}
q Deflection in adjustment: Approx. 7 10 mm
4. Tighten adjustment bolt (2) and mounting bolt

(1).
a Check breakage of the pulleys, wear of the
V-grooves, and contact of the belts and
V-grooves.
a If a belt is lengthened to the adjustment limit,
cut, or cracked, replace it with new one.
PC20MR-3 30-100 13
SEN04868-00 Adjusting fuel control lever linkage
Adjusting fuel control lever

linkage
1. Adjusting low idling

1) Tilt fuel control lever (1) forward until it
reaches stopper (2) on the low idling side.
2) Under this condition, adjust low idling adjust-
ment screw (3) on the fuel injection pump
side to set the low idling speed to the speci-
fied level.
2. Adjusting high idling

1) Tilt fuel control lever (1) backward until
governor lever (4) of the fuel injection pump
reaches screw (5) on the high idling side.
2) Under this condition, tighten stopper bolt (6)
until it reaches fuel control lever (1), and then
return the stopper bolt by 1/2 turn and fix it
with the locknut.
a Screw (5) on the high idling side of the
fuel injection pump is not adjustable. If
the high idling speed or power is still low
even when the governor lever reaches
the screw on the high idling side, check
the nozzle holder, etc.
30-100 14 PC20MR-3
Measurement of clearance in swing circle bearings SEN04868-00
Measurement of clearance in 4. Hold the arm nearly perpendicular to the ground,

swing circle bearings and lower the boom until the track shoes will be
lifted at the work equipment.
a The upper structure is raised at the front and
a Swing circle bearing clearance measurement lowered at the rear at that time.
tools
Mark Part No. Part Name 5. Read off the value in dial gauge Fin this condi-
Commercially Dial gauge
F tion.
available
a The value indicated in dial gaugeF expresses
clearance in the bearings.
a Follow the steps explained below, when measur-
ing clearance in the swing circle bearing in the
actual machine.
k Be careful not to put a hand or foot under the
undercarriage, while taking measurement.
1. Fix dial gauge F to the track frame and apply the

probe to the underside of outer race (1) perpen-
dicularly.
a Set dial gauge F at the track frame rear.
6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge F is
zero.
a If zero value is not indicated, repeat the steps
in Items 2 through 5.

parts.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
frame.
a At this time, the front side of the upper struc-
ture rises and the rear side lowers.
3. Under this condition, set dial gauge Fto the zero

point.
PC20MR-3 30-100 15
SEN04868-00 Testing and adjusting track shoe tension
Testing and adjusting track shoe

tension
Testing
1. Run the engine at low idling and move the
machine by the length of track on ground, then
stop slowly.
2. Place bar [1] on the track shoe between the idler

and the shoe plate.
a As bar [1], use an L-shape steel, etc. which
will be deflected less.
3. Measure maximum clearance (a) between bar a When steel shoe is installed
[1] and track shoe. You may supply grease until distance (b)
q Standard maximum clearance (a)
between the idler guide and track frame
Steel shoe specification or load liner specifi- end is 0 mm. If the tension is still low, the
cation: 5 15 mm pin and bushing are worn excessively. In
Rubber shoe specification: 1 3 mm this case, turn over or replace the pin and
bushing.
Adjusting
a If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.
1. To heighten tension
1) Supply grease throungh grease fitting (1).
2) To check that the tension is normal, run the
engine at low idling and move the machine
forward by the length of track on ground, then
stop slowly.
3) After finishing adjustment, check again that
the tension is normal according to the above
procedure.
30-100 16 PC20MR-3
Testing and adjusting track shoe tension SEN04868-00
2. To lower tension
1) Loosen valve (2) to discharge the grease.
k Since the valve may jump out because
of the internal high-pressure grease,
do not loosen it more than 1 turn.
2) Tighten valve (2).
3) To check that the tension is normal, run the
engine at low idling and move the machine
forward by the length of track on ground, then
stop slowly.
4) After adjusting, check the tension again
according to the procedure described above.
PC20MR-3 30-100 17
SEN04868-00 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits
Testing and adjusting oil pres-

sures in work equipment, travel,
swing, and blade circuits
a Testing and adjusting instruments for oil pres-

sures in work equipment, travel, swing, and
blade circuits
790-261-1204
G tal)
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
Measuring 4) Tilt down the floor and connect the hoses to

a Measure the oil pressures in the work equip- oil pressure gauges [1] of hydraulic tester G1.
ment, travel, swing, and blade circuits under the a Use oil pressure gauges of 39.2 MPa
following condition. {400 kg/cm2} for both hoses.
q Hydraulic oil temperature: 45 55 C
k Release the pressure from the hydraulic
tank. For details, see Releasing pressure
from hydraulic circuit.
1. Preparation work
1) Tilt the floor open. For details, see How to
open and close (tilt) floor.
a You can connect the measuring instru-
ments without tilting the floor open. If the
floor is tilted open, however, you can work
easily.
2) Remove pump discharge pressure pickup
plugs (1) and (2).
q Plug (1): For piston pump 5) Pressurize the hydraulic tank. For details,
q Plug (2): For gear pump see Pressurizing hydraulic tank.
2. Measuring unload pressure

1) Start the engine.
2) Run the engine at high idling and set all the
control levers and pedals in neutral and
measure the oil pressure.
a Measure with the oil pressure gauge on
the piston pump side.
a The pressure measured when the unload
valve of the control valve is unloaded is
indicated.
3. Measuring work equipment

(boom/arm/bucket/boom swing) circuit relief pres-
3) Install nipples G2 and pull the oil pressure sure
measurement hoses out of the revolving 1) Start the engine and move the cylinder to be
frame. measured to the stroke end.
2) Run the engine at high idling and relieve the
cylinder and measure the oil pressure.
30-100 18 PC20MR-3
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits SEN04868-00
a The pressure measured when the main 2) Run the engine at high idling and relieve the
relief valve on the piston pump side is re- cylinder and measure the oil pressure.
lieved is indicated. a Measure with the oil pressure gauge on
the gear pump side.
4. Measuring travel circuit relief pressure a The pressure measured when the main
1) Start the engine and lock the travel mecha- relief valve on the gear pump side is re-
nism on the side to be measured. lieved is indicated.
k Set pin [1] between the sprocket and
track frame to lock the travel mecha- 7. Work after finishing measurement
nism securely. After finishing measurement, remove the
parts.
Adjusting
1. Adjusting unload pressure
a The unload pressure (unload valve of control
valve) cannot be adjusted.
2. Adjusting main relief pressure on piston pump

side
a If the relief pressure of the work equipment
circuit and travel circuit is abnormal, adjust
main relief valve (3) on the piston pump side
of the control valve according to the following
procedure.
a When adjusting the main relief valve on the
travel circuit and measure the oil pressure.
piston pump side, tilt the floor open. For de-
tails, see How to tilt (open and close) floor.
a The pressure measured when the main
relief valve on the piston pump side is re-
lieved is indicated.
5. Measuring swing circuit relief pressure

1) Start the engine and lock the swing mecha-
nism with the work equipment securely.
k Stick the bucket into the ground or
press it against the blade.
swing circuit and measure the oil pressure.
the gear pump side.
a The pressure measured when the swing
motor safety valve is relieved is indicated. 1) Fixing adjustment screw (4), loosen locknut
a The swing motor safety valves are in- (5).
stalled to the right and left sides. Accord- 2) Turn adjustment screw (4) to adjust the pres-
ingly, measure the relief pressures on sure.
both sides respectively. a If the adjustment screw is
a The swing motor relief pressure is lower q turned to the right, the pressure rises.
than the main relief pressure on the gear q turned to the left, the pressure lowers.
pump side. a Quantity of adjustment per turn of adjust-

ment screw: Approx. 12.6 MPa {128
6. Measuring blade circuit relief pressure kg/cm2}
1) Start the engine and move the blade cylinder 3) Fixing adjustment screw (4), tighten locknut
to the stroke end. (5).
3 Locknut:59 79 Nm {6 8 kgm}
PC20MR-3 30-100 19
SEN04868-00 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits
a Quantity of adjustment per turn of adjust-

ment nut:
Approx. 19.6 MPa {200 kg/cm2}
3) Fixing adjustment nut (7), tighten locknut (8).
3 Locknut:39 49 Nm {4 5 kgm}
4) After finishing adjustment, check again that

the oil pressure is normal according to the
above described measurement procedure.
3. Adjusting swing circuit relief pressure

a The swing circuit relief pressure (swing motor 4) After finishing adjustment, check again that
safety valve) cannot be adjusted. the oil pressure is normal according to the
above described measurement procedure.
4. Adjusting main relief pressure on gear pump side
a If the relief pressure of the work equipment
circuit and travel circuit is abnormal, adjust
main relief valve (6) on the gear pump side of
the control valve according to the following
procedure.
a When adjusting the main relief valve on the
gear pump side, remove the undercover of
the control valve.
1) Fixing adjustment nut (7), loosen locknut (8).

2) Turn adjustment nut (7) to adjust the pres-
sure.
k Do not remove the adjustment nut. If it
is removed, the internal parts may fall.
a If the adjustment nut is
q turned to the right, the pressure rises.
q turned to the left, the pressure lowers.
30-100 20 PC20MR-3
Measuring control circuit basic pressure SEN04868-00
Measuring control circuit basic 4. Pressurize the hydraulic tank. For details, see
pressure Pressurizing hydraulic tank.
5. Run the engine at high idling and set all the

a Measuring instruments for control circuit basic control levers and pedals in neutral and measure
pressure the oil pressure.
799-101-5002 Hydraulic tester
1
H 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (02)
a Measure the control circuit basic pressure under

the following condition.
tank. For details, see Releasing pressure
from hydraulic circuit.
1. Remove the undercover of the control valve and

disconnect outlet hose (1) of the self-reducing
pressure valve. 6. After finishing measurement, remove the
parts.
a Do not adjust the relief valve of the control circuit

basic pressure.
2. Install adapter H2 and connect the disconnected

hose again.
3. Install nipple [1] of hydraulic tester H1 and

connect them to oil pressure gauge [2].
a Use oil pressure gauge of 5.9 MPa {60
kg/cm2}.
PC20MR-3 30-100 21
SEN04868-00 Testing and adjusting pump LS differential pressure
Testing and adjusting pump LS

differential pressure
a Testing and adjusting instruments for pump LS

differential pressure
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Differential pressure
J 2 799-401-2701
gauge
799-101-5220 Nipple (10 1.25 mm)
3
07002-11023 O-ring
Measuring 4. Tilt down the floor and connect the hose to oil
a Measure the pump discharge pressure and LS pressure gauge [1] of hydraulic tester J1 or to
pressure (actuator load pressure) simultaneous- differential pressure gauge J2.
ly and calculate the difference between them. a When using differential pressure gauge:
a Measure the LS differential pressure under the Connect the pump discharge pressure to the
following condition. high pressure side (back side) and connect
the LS pressure to the low pressure side
(lower side).
tank. For details, see Releasing pressure Since the differential pressure gauge needs
from hydraulic circuit. a 12-V power source, connect it to a battery.
a When using oil pressure gauge:
Use the oil pressure gauge of 39.2 MPa {400
and close (tilt) floor. kg/cm2} graduated in 0.98 MPa {10 kg/cm2}.
a You can connect the measuring instruments Since the differential pressure is about 4.0
without tilting the floor open. If the floor is tilt- MPa {40 kg/cm2} at maximum, measure it by
ed open, however, you can work easily. installing the same gauge to the pickup plugs
alternately.
2. Remove pump discharge pressure pickup plugs
(1) and (2).
q Plug (1): Pump discharge pressure pickup
plug
q Plug (2): LS pressure pickup plug
5. Pressurize the hydraulic tank. For details, see

Pressurizing hydraulic tank.
6. Run the engine and operate the work equipment

to set the boom top horizontally.
3. Install nipple J3 and pull the oil pressure
measurement hose out of the revolving frame.
30-100 22 PC20MR-3
Testing and adjusting pump LS differential pressure SEN04868-00
7. While running the engine at high idling, measure 3. Turn plug (5) to adjust the differential pressure.
the pump discharge pressure and LS pressure a If the plug is
(actuator load pressure) simultaneously under q turned to the right, the differential pres-
the following condition. sure rises.
q Work equipment, travel, swing, and blade cir- q turned to the left, the differential pressure
cuits: lowers.
Set all the levers in neutral and move the arm a Quantity of adjustment (LS differential pres-
IN. sure) per turn of plug:
a Move the arm lever halfway to move the arm 127 kPa {13 kg/cm2}
IN and measure the oil pressure during this a Tighten hose sleeve nut (4) temporarily and
operation. turn the plug, while checking the LS differen-
a Calculation of LS differential pressure (when tial pressure.
oil pressure gauge is used):
LS differential pressure = Pump discharge 4. Fixing plug (5), tighten locknut (6).
3 Locknut: 27.4 34.3 Nm {2.8 3.5 kgm}
pressure LS pressure
a If the LS differential pressure is as follows, it
is normal.
5. Tighten hose sleeve nut (4).
Work equipment,
LS differential pres-
travel, swing, and
sure
blade levers
Unload pressure
Set all levers in neu-
(See standard value
tral
table)
Standard LS differen-
Set arm lever in IN tial pressure
position (halfway) (See standard value
table)

parts.
Adjusting
a If the LS differential pressure is abnormal, adjust
LS valve (3) according to the following proce-
dure.
a When adjusting the LS valve, remove the trian-
gular cover from the left side of the machine.
1. Loosen hose sleeve nut (4).
2. Fixing plug (5), loosen locknut (6).
PC20MR-3 30-100 23
SEN04868-00 Measuring solenoid valve output pressure
Measuring solenoid valve output

pressure
a Measuring instruments for solenoid valve output

pressure
K 790-261-1204
tal)
2 799-401-3100 Adapter (02)
a Before measuring the solenoid valve output
pressure, check that the basic pressure in the
control circuit is normal.
a Measure the solenoid valve output pressure un-
der the following condition. 5. Tilt down the floor and connect the hose to oil
pressure gauge [2] of hydraulic tester K1.
k Release the residual pressure from the hy-
a Use the oil pressure gauge of 5.9 MPa
draulic tank. For details, see Releasing re- {60 kg/cm2}.
sidual pressure from hydraulic circuit.
1. Tilt the floor open. For details, see How to tilt

(open and close) floor.
2. Disconnect outlet hoses (1) and (2) of the sole-

noid valves to be measured.
q Hose (1): PPC lock solenoid valve
q Hose (2): 2nd travel speed selection solenoid
valve

7. Run the engine at high idling, turn the solenoid

valve ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operations table
of each solenoid valve.
a If the output pressure of each solenoid valve
is as shown in the operation table of the sole-
3. Install adapter K2 and connect the disconnected noid valve, it is normal.
hose again.
4. Install nipple [1] of hydraulic tester K1 and pull measuring instruments and return the removed
the oil pressure measurement hose out of the parts.
revolving frame.
a The figure shows the measuring instruments
connected to the outlet hose of the 2nd travel
speed selection solenoid valve.
30-100 24 PC20MR-3
Measuring solenoid valve output pressure SEN04868-00
Operation table of solenoid valves

Output pressure of
No Solenoid valve Operating condition State of solenoid
solenoid valve
Lock lever: LOCK OFF 0 MPa {0 kg/cm2}
1 PPC lock 2.843.43 MPa
Lock lever: FREE ON
{2935 kg/cm2}
Travel speed shifting switch: Low speed mode
(2nd travel speed monitor: OFF)
OFF 0 MPa {0 kg/cm2}
2nd travel speed
2 2.843.43 MPa
selection Travel speed shifting switch: High speed mode
ON
(2nd travel speed monitor: ON) {2935 kg/cm2}
PC20MR-3 30-100 25
SEN04868-00 Measuring PPC valve output pressure
Measuring PPC valve output pres-

sure
a Measuring instruments for PPC valve output

pressure
L 790-261-1204
tal)
2 799-401-3100 Adapter (02)
a Before measuring the PPC valve output pres-
sure, check that the basic pressure in the control
circuit is normal.
a Measure the PPC valve output pressure under
the following condition. 5. Tilt down the floor and connect the hose to oil
pressure gauge [2] of hydraulic tester L1.
a Use oil pressure gauge of 5.9 MPa {60
draulic tank. For details, see Releasing re- kg/cm2}.

2. Disconnect PPC hose (1) of the solenoid valve to

be measured.
a The figure shows the hose of the left travel
forward circuit.

7. Run the engine at high idling, set the control

lever or pedal of the circuit to be measured in the
neutral position and stroke end, and measure
the oil pressure.
a If the output pressure of PPC valve is as fol-
lows, it is normal.
3. Install adapter L2 and connect the disconnected PPC valve output pres-
Control lever/pedal
hose again. sure
0 MPa
4. Install nipple [1] of hydraulic tester L1 and pull Neutral
(0 kg/cm2)
the oil pressure measurement hose out of the Almost same as basic
revolving frame. pressure in control circuit
Stroke end
a The figure shows the measuring instruments (See Standard values
connected to the hose of the left travel for- table)
ward circuit.
parts.
30-100 26 PC20MR-3
Measuring PPC valve output pressure SEN04868-00
Connection diagram of PPC valve and control valve (ISO pattern)

a The port position of each PPC valve is the position seen from the operator's seat side. Colors of hose
bands are shown ( ).
PC20MR-3 30-100 27
SEN04868-00 Adjusting play of work equipment and swing PPC valves
Adjusting play of work equipment Measuring swing holding brake

and swing PPC valves release pressure
a If the play of the left or right work equipment con- a Measuring instruments for swing holding brake
trol lever is excessive, adjust it according to the release pressure
following procedure. Symbol Part No. Part Name
1. Remove the PPC valve assembly. 1 Hydraulic multimeter (Digi-
M 790-261-1204
tal)
2 799-401-3200 Adapter (02)
2. Remove boot (1).
a Before measuring the swing holding brake re-
3. Loosen locknut (2) and screw in disc (3) until it lease pressure, check that PPC valve output
touches the heads of 4 pistons (4). pressure (swing LEFT, swing RIGHT, and arm
a At this time, do not move the pistons. IN) is normal.
a Measure the swing holding brake release pres-
sure under the following condition.
4. Fix disc (3) and tighten locknut (2) to the speci-
q Hydraulic oil temperature : 45 55 C
fied torque.
3 Locknut: 98 127 Nm {10 13 kgm}
draulic tank. For details, see Releasing re-
5. Install boot (1).
6. Install the PPC valve assembly.
2. Disconnect swing holding brake hose (1) of the

swing motor.
3. Install adapter M2 and connect the disconnected

hose again.
4. Install nipple [1] of hydraulic tester M1 and pull

the oil pressure measurement hose out of the
revolving frame.
30-100 28 PC20MR-3
Measuring swing holding brake release pressure SEN04868-00
<Reference>
q The swing holding brake release pressure is the
PPC circuit pressure for swing LEFT, swing
RIGH, and arm IN to the swing motor through the
shuttle valve in the control valve.
q Accordingly, if the swing holding brake is not re-
leased, check the PPC valve output pressure for
swing LEFT, swing RIGHT, and arm IN first.
q If the output pressure of each PPC valve is nor-
mal but the release pressure is not normal, the
shuttle valve in the control valve may be mal-
functioning.
q If the output pressure of each PPC valve is nor-
mal and the release pressure is also normal, the
swing holding brake in the swing motor may be
5. Tilt down the floor and connect the hose to oil
malfunctioning.
pressure gauge [2] of hydraulic tester M1.
a Use the oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

7. Run the engine at high idling, set all the control

levers in the neutral position and operating posi-
tion, and measure the oil pressure.
a If the swing holding brake release pressure is
as follows, it is normal.
Swing holding brake
Control lever/pedal
release pressure
Neutral or other than 0 MPa
following positions (0 kg/cm2)
Almost same as basic
Swing LEFT,
pressure in control circuit
Swing RIGHT
(See Standard values
Arm IN
table)

parts.
PC20MR-3 30-100 29
SEN04868-00 Measurement of oil leakage from cylinder
Measurement of oil leakage from k Release the residual pressure in the

cylinder arm cylinder circuit. For details, see
Releasing residual pressure from hy-
draulic circuit.
a Measuring oil leakage from cylinder 2) Disconnect hose (2) on the cylinder head
Symbol Part No. Part Name side and block the hose side with a plug.
k Take care not to disconnect the hose
Commercially
N Measuring cylinder
available
on the cylinder bottom side.
a Measure the oil leakage from each cylinder un- a Use the following part to block the hose
der the following condition. side.
q Hydraulic oil temperature: 45 55 C 07376-70315 (Plug #03)
a The figure shows the 1-attachment specification.
1. Measuring leakage from boom cylinder

1) Run the engine and move the boom cylinder
to the RAISE stroke end.
k Release the residual pressure in the
boom cylinder circuit. For details, see
draulic circuit.
2) Disconnect hose (1) on the cylinder head
side and block the hose side with a plug.
a Use the following part to block the hose
side. 3) Run the engine at high idling and relieve the
07376-70315 (Plug #03) arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".
4) Measure the oil leakage for 1 minute after 30
seconds since relieving is started.
5) After finishing measurement, remove the
measuring instruments and return the
removed parts.
3. Measuring oil leakage from bucket cylinder

1) Run the engine and move the bucket cylinder
to the CURL stroke end.
k Release the residual pressure in the
bucket cylinder circuit. For details,
see Releasing residual pressure from
hydraulic circuit.
3) Run the engine at high idling and relieve the 2) Disconnect hose (3) on the cylinder head
boom circuit by raising the boom. side and block the hose side with a plug.
k Take care not to "lower the boom". k Take care not to disconnect the hose
4) Measure the oil leakage for 1 minute after 30 on the cylinder bottom side.
seconds since relieving is started. a Use the following part to block the hose
5) After finishing measurement, remove the side.
measuring instruments and return the 07376-70315 (Plug #03)
removed parts.
2. Measuring oil leakage from arm cylinder

1) Run the engine and move the arm cylinder to
the IN stroke end.
30-100 30 PC20MR-3
Measurement of oil leakage from cylinder SEN04868-00

boom swing circuit by swinging the boom to
the left.
k Take care not to "swing the boom to
the right".
removed parts.
5. Measuring oil leakage from blade cylinder

1) Run the engine and push up the track shoe
on the blade side with the work equipment
3) Run the engine at high idling and relieve the and set a block under the track shoe.
bucket circuit by curling the bucket. a Raise the track shoe to a degree that the
k Take care not to "dump the bucket". blade will not touch the ground when it is
4) Measure the oil leakage for 1 minute after 30 lowered to the stroke end.
seconds since relieving is started. 2) Lower the blade cylinder to the stroke end
5) After finishing measurement, remove the and remove the cylinder cover.
measuring instruments and return the k Release the residual pressure in the
removed parts. blade cylinder circuit. For details, see
4. Measuring oil leakage from boom swing cylinder draulic circuit.
1) Run the engine and move the boom swing 3) Disconnect hose (5) on the cylinder head
cylinder to the left stroke end. side and block the hose side with a plug.
k Release the residual pressure in the k Take care not to disconnect the hose
boom swing cylinder circuit. For de- on the cylinder bottom side.
tails, see Releasing residual pressure a Use the following part to block the hose
from hydraulic circuit. side.
2) Disconnect hose (4) on the cylinder head 07376-70210(Plug#02)
side and block the hose side with a plug.
a Use the following part to block the hose
side.
07376-70210(Plug #02)

blade circuit by lowering the blade.
k Take care not to "raise the blade".
removed parts.
PC20MR-3 30-100 31
SEN04868-00 Releasing residual pressure from hydraulic circuit
Releasing residual pressure from Bleeding air from cylinder

hydraulic circuit
a If a cylinder was removed and installed or its pip-
1. Releasing residual pressure from hydraulic tank ing was disconnected and reconnected, bleed
k The hydraulic tank is enclosed and pres- air according to the following procedure.
surized. When removing a hose or a plug a If a cylinder was replaced, bleed air from it be-
connected to the hydraulic tank, release fore connecting the work equipment. In particu-
the residual pressure from the hydraulic lar, the boom cylinder does not move to the
tank according to the following proce- lowering stroke end, if it is installed to the work
dure. equipment.
1) Lower the work equipment to the ground in a
stable posture and stop the engine. 1. Run the engine at low idle for about 5 minutes.
2) Open the engine rear cover and cooling
cover. 2. Running the engine at low idling, raise and lower
3) Slowly loosen oil filler cap (1) of the hydraulic the boom 4 5 times.
tank to release the air from the tank. a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3. Running the engine at high idling, perform step

2).
4. Running the engine at low idling, move the

piston rod to the stroke end and relieve the oil.
5. Bleed air from the arm cylinder, bucket cylinder,

boom swing cylinder, and blade cylinder
according to steps 2 4.
2. Releasing residual pressure from hydraulic

cylinder circuit
k When disconnecting the piping between a
hydraulic cylinder and the control valve,
release the residual pressure from the
piping according to the following proce-
dure.
1) Run the engine at low idling and lower the
work equipment to the ground, taking care
not to relieve the cylinder at the stroke end,
then stop the engine.
k If the engine is stopped while the hy-
draulic cylinder is relieved at the
stroke end, do not perform the follow-
ing work for 5 10 minutes.
2) Open the engine rear cover and cooling
cover.
3) Slowly loosen the oil filler cap of the hydraulic
tank to release the air from the tank.
4) Loosen the sleeve nut of the cylinder piping
gradually to release the residual pressure
from the piping until oil does not come out
any more, then disconnect the piping.
a When performing the above work, apply
cloths to the sleeve nut to prevent the re-
sidual pressure from blowing out the oil.
30-100 32 PC20MR-3
Pressurizing hydraulic tank SEN04868-00
Pressurizing hydraulic tank
a If the oil filler cap is removed from the hydraulic

tank, pressurize the hydraulic tank according to
the following procedure.
1. Run the engine at low idling, set the work equip-

ment in the pressurizing position, and stop the
engine.
a Extract the boom, arm, and bucket cylinders
fully.
2. Open the engine rear cover and cooling cover.
3. Open oil filler cap (1) of the hydraulic tank, and

then close it again.
4. Start the engine and lower the work equipment

to the ground.
a The hydraulic tank is pressurized by the above

procedure.
PC20MR-3 30-100 33
SEN04868-00 How to open and close (tilt) floor
How to open and close (tilt) floor 7. Loosen floor tilt lock bolts (5).
a The bolts are designed so that they will not
be removed completely when they are simply
a When testing or servicing the underside of the
loosened to prevent them from falling.
floor or inside of the revolving frame, open and
a Canopy specification
close (tilt) the floor according to the following
procedure.
Opening (Tilting open)

1. Move the arm in and lower the boom until the
work equipment and blade touch the ground.
2. Stop the engine and set the work equipment lock

lever in the lock position.
3. Put blocks to the front and rear of the track shoes

to secure the machine.
4. Remove triangular cover (1).

a Cab specification
5. Remove cover (2).
8. Close the engine rear cover.
6. Open engine rear cover (4) and lock it.
30-100 34 PC20MR-3
How to open and close (tilt) floor SEN04868-00
9. Open inspection window (6). While pulling floor 10. After the floor rises, push up handle (8) until lock
lock release lever (7) in the direction of the arrow pin (9) is fitted to lock groove (11) of lock plate
with the left hand, push up handle (8) with the (10).
right hand in the direction of the arrow (about 45 a When lock pin (9) moves to lock groove (11),
). the 1st locking is completed.
q Machine with canopy: The floor and canopy
rise together. 11. Insert 2nd lock pin (12) in lock hole (13) securely.
q Machine with cab:
The floor and cab rise together. 12. Ensure that the lock hook at the top of lock pin
a If the floor does not rise, release lever (7) is (12) is hitched on pin (14) at the insertion section
not in the release position. In this case, pull and does not come off.
back handle (8) with the right hand and per-
form the above procedure again.
k Do not put any part of your body under
the floor while opening or closing the
floor.
a Since the gas cylinder assists you in opening
the floor, the operating effort is increased
when the ambient temperature is low. Take
care.
PC20MR-3 30-100 35
SEN04868-00 How to open and close (tilt) floor
Closing (Tilting close)

a Before closing the floor, check that the wiring,
piping, and seats on the underside of the floor
and inside of the revolving frame are free from
damage and abnormality.
1. Remove lock pin (9) and insert it in storage hole

(c).
a If you cannot remove the lock pin, perform
the following work.
q Canopy specification: While holding the
handle and pushing up the floor, pull out
the lock pin.
q Cab specification: While holding the han-
dle and pushing down the floor, pull out
the lock pin.
3. Open and lock engine rear cover (4).
2. While pulling floor lock release lever (7) in the 4. Tighten floor tilt lock bolts (5).
direction of the arrow (backward) with the left 3 Lock bolt: 156 196 Nm {16 20 kgm}
hand, pull down handle (8) slowly with the right a Canopy specification
hand in the direction of the arrow (about 45).
a While checking that the wiring and piping are
not caught or damaged, pull down the floor
slowly.
k Do not put any part of your body under
the floor while opening or closing the
floor.
30-100 36 PC20MR-3
How to open and close (tilt) floor SEN04868-00
5. Close the engine rear cover.
6. Install cover (2).
7. Install rectangular cover (1).
a The floor closing (tiling close) work is fin-

ished.
PC20MR-3 30-100 37
SEN04868-00 Inspection procedures for diode
Inspection procedures for diode
a Check an assembled-type diode (8 pins) and

single diode (2 pins) in the following manner.
a The continuity direction of the assembled-type
diode is as follows.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the
following connections.
1] Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
a The conductive direction of each diode is cathode (N) of diode.
marked on its surface as shown below. 2] Put the red probe (+) of the test lead to the
cathode (N) and the black probe () to the
anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
will differ depending on a circuit tester
type or a selected measurement range)
q If the needle swings in either case of i)
and ii): Defective (short-circuited internal-
ly)
q If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)
1. When using digital type circuit tester
1) Switch the testing mode to diode range and
confirm the indicated value.
a Voltage of the battery inside is displayed
with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
cathode (N) of diode, and confirm the
displayed value.
3) Determine if a specific diode is good or no
good with the indicated value.
q No change in the indicated value: No con-
tinuity (defective).
q Change in the indicated value: Continuity
established (normal) (Note)
a A silicon diode shows a value between
460 and 600.
30-100 38 PC20MR-3
How to start operation of KOMTRAX terminal SEN04868-00
How to start operation of

KOMTRAX terminal
In the case where the KOMTRAX terminal has al-

ready been installed at the plant before ship-
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already been
installed at the plant before shipment (as stan-
dard equipment).
1. Notification of model, model number and serial

number
Notify the model, model number and serial 4) Turn the starting switch ON and keep that
number of the machine to the KOMTRAX opera- condition for 5 seconds.
q Check that the 7-segment indicator lamp
tions administrator.
indicates a bar.
2. Registration of machine
The KOMTRAX operations administrator regis-
ters the machine using a KOMTRAX client
personal computer.
a For the procedure, see Manual for
KOMTRAX operations administrator.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted on the machine after shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal is retrofitted after
shipment of the machine (retrofitted machine).
a For details, see Disassembly and sssembly.
5) Disconnect test connectors F33 and F34 and
1. Sign-up test on machine side keep that condition for 5 seconds.
a Complete procedures 4) 6) in 60 seconds. 6) Reconnect test connectors F33 and F34 and
1) Park the machine in a place sufficiently apart keep that condition for 5 seconds.
from buildings etc. where its top is seen from a If the KOMTRAX terminal detects discon-
every direction so that it can receive the radio nection or reconnection of the connec-
waves from the satellite. tors, the dot of the 7-segment indicator
a The inspection cannot be completed nor- lamp blinks 2 3 times.
mally indoors. Be sure to perform the in- a If procedures 4) 6) are not completed in
spection outdoors. 60 seconds, repeat from 2).
2) Turn the starting switch OFF and wait for at
least 5 seconds and then go to the next step.
3) Check visually that the test connectors under
KOMTRAX terminal (1) are connected.
q Test connectors: F33, F34 (male, female)
PC20MR-3 30-100 39
SEN04868-00 How to start operation of KOMTRAX terminal
7) Check that the 7-segment indicator lamp of a Go to the next step if you can check that
the KOMTRAX terminal is displaying the display is normal.
normally. a If the display is abnormal, repeat from
a If the indication is normal, the 7-segment procedure 2) again. ( is displayed
indicator lamp (a) is displayed for 30 sec- continuously.)
onds after 6) is completed. (d, 0 and 8) Turn the starting switch to the START posi-
are displayed repeatedly.) tion, keep it more than 5 seconds, and check
q Display of the 2nd letter 0 may be that the engine does not start.
different from the first. a If the engine starts, repeat from proce-
q Display of the 3rd letter changes dure 2).
30 seconds after the operation of 6). a If the engine starts again, the engine start
lock function does not work normally.
Stop the inspection and check of the re-
lays and wiring harnesses for trouble.
9) Return the starting switch to the ON position
and keep it there for 5 seconds.
a Do not return the starting switch to the
OFF position.
10)Turn the starting switch to the START posi-
tion again and ensure that the engine starts.
11)Check that the 7-segment indicator lamp of
the KOMTRAX terminal is indicating normally
without stopping the engine.
a Go to the next step if you ensured that the
display is [normal]. (It takes from 90 sec-
onds to 15 minutes before the display
turns normal.)
a If [GPS position data detection trouble] is
indicated, check if there is any external
abnormality on the GPS antenna or ca-
ble. If there is any abnormality, repair it
and repeat from procedure 1) again.
a If [Reception trouble] is indicated, check if
there is any external abnormality on the
appearance of the communication anten-
na or cable. If there is any abnormality,
repair it then repeat from procedure 1)
again.
a If [GPS position data detection trouble
and reception trouble] is indicated, check
if there is any external abnormality on the
GPS antenna or cable and communica-
tion antenna or cable. If there is any ab-
normality, repair it and repeat from
procedure 1) again.
a If [Network trouble] is indicated, check the
display of [LED-4] referring to Lamp dis-
play of KOMTRAX terminal. (If CAN is
not recognized, check the CAN harness
of the KOMTRAX terminal, and then if
there is any abnormality, repair it and re-
peat from procedure 1) again.)
30-100 40 PC20MR-3
How to start operation of KOMTRAX terminal SEN04868-00
[A]: Normal finish (It takes at least 90 12)Turn the starting switch OFF.
seconds for the system to display this) 13)Check that the 7-segment indicator lamp is
[B]: GPS position data detection trouble indicating normally in 10 seconds.
Check the GPS antenna and cable for a If you checked that the display is [Nor-
external abnormality. mal], that is the end of the sign-up test.
(It takes 90 seconds 5 minutes) a If the display shows [Abnormal], repeat
[C]: Incomplete receiving from procedure 1) again because the
Check the communication antenna and sign-up test has not been completed suc-
cable for external abnormality. cessfully.
(It takes 30 seconds 1 minute)
[D]: Network trouble or wiring harness trouble
The network type selection input does
not agree with the obtained network
data.
Check the machine wiring for an error.
a If the display is not any of the above, call

Customer Support Division.
a It takes 90 seconds 5 minutes for the
system to display Normal finish after
the operation of 6).
PC20MR-3 30-100 41
SEN04868-00 How to start operation of KOMTRAX terminal
2. Application for the start of use

a Application for the start of use must be made
only after the sign-up test is finished.
1) Notify to the KOMTRAX operations adminis-
trator of the following information concerning
the machine whose sign-up test on the
machine side is completed.
1] Information on the machine whose
sign-up test on the machine side is
completed (Model, model number and
serial number)
2] Part number and serial number of the
KOMTRAX terminal
3] Reading of the service meter when the
KOMTRAX terminal was installed (0.1h
unit)
2) The KOMTRAX operations administrator

registers the machine using KOMTRAX
client personal computer.
a For the procedure, see Manual for
KOMTRAX operations administrator.
a Now the terminal is ready for use.
30-100 42 PC20MR-3
Lamp display of KOMTRAX terminal SEN04868-00
Lamp display of KOMTRAX terminal
CPU LED 7-segment and dot for CPU

1. LED-1 (R signal and ACC signal) 6. 7-segment (Sign-up test status and operation sta-
2. LED-2 (Starting output status) tus)
3. LED-3 (S-NET status and C signal status) 7. Dot (GPS positioning status and test connector
4. LED-4 (Fuel sensor and CAN connection status) disconnection/connection status))
5. LED-5 (Downloading and writing status)
PC20MR-3 30-100 43
SEN04868-00 Lamp display of KOMTRAX terminal
In the KOMTRAX system, various information and processing details are displayed on the LED of the upper
surface of the KOMTRAX terminal. Therefore, if a defect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side must be completed in advance in order
to use KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication antenna
and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable must not be broken and must be connected to the KOMTRAX terminal
normally.
q The GPS antenna must not be off or damaged.
q The GPS antenna cable must not be broken and must be connected to the KOMTRAX terminal normally.
30-100 44 PC20MR-3
Lamp display of KOMTRAX terminal SEN04868-00
1. Contents of CPU LED, 7-segment and dot displays

a The LED displays must be checked with the starting switch in the ON or START position or with the engine
started.
LED Display
No. Name/function Contents of display
(Color) (*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
Fast blink-
Starting switch ACC sig- Starting switch ACC signal: OFF, Alternator R signal: ON
LED-1 ing
1 nal and alternator R sig-
(Green) Slow
nal Starting switch ACC signal: ON, Alternator R signal: OFF
blinking
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
LED-2 ON Engine control signal: ON
2 Starting output status
(Red) OFF Engine control signal: OFF
Fast blink-
Starting switch C signal: ON
S-NET connection sta- ing
LED-3
3 tus and starting switch C ON Starting switch C signal: OFF, S-NET connection: Made
(Yellow)
signal status
OFF Starting switch C signal: OFF, S-NET connection: Not made
ON CAN: Connected, (Fuel sensor: Disconnected)
Fast blink-
CAN: Connected, (Fuel sensor: Connected)
LED-4 Fuel sensor and CAN ing
4
(Green) connection status Slow
CAN: Disconnected, (Fuel sensor: Connected)
blinking
OFF CAN: Disconnected, (Fuel sensor: Disconnected)
Downloading and writ- ON Downloading and writing mode: ON
5 LED-5
ing status OFF Downloading and writing mode: OFF (Normal mode)
Before execution of sign-up test
Sign-up status [] When sign-up test is not completed, (bar) is always displayed.
During sign-up test

* For display during sign-up test, see How to start operation of
Sign-up progress status *
KOMTRAX terminal.
After completion of sign-up test
If server initialization communication is not completed, [C] is dis-
7 seg- [C]
6 Initialization communi- played.
ments ON
cation incompletion sta- ON indicates that machine is within communication range.
Fast blink-
tus Fast blinking indicates that machine is out of communication
ing
range.
Operation status
Figure indicates number of mails waiting for to be sent (9 is dis-
[0 - 9]
played when number is 9 or larger).
Number of unsent mails ON
ON indicates that terminal is capturing satellite.
or within/out of commu-
[0 - 9] Figure indicates number of mails waiting for to be sent (9 is dis-
nication range status
Fast blink- played when number is 9 or larger).
ing Fast blinking indicates that terminal has not captured satellite.
GPS connector position- ON GPS positioning has been executed. See *2.
ing/
Dot OFF GPS positioning has not been executed. See *2.
7 Test connector discon-
(Red)
nection and connection Fast blink- If sign-up test connector is disconnected or connected, dot blinks 2
status ing 3 times.
*1 Types and periods of blinking
Fast blinking: Blinking at cycles of about 1 second (ON for 0.5 seconds o OFF for 0.5 seconds)
Slow blinking: Blinking at cycles of about 4 seconds (ON for 2 seconds o OFF for 2 seconds)
*2 It may take more than 1 minute from turning on the starting switch to the completion of positioning even in
an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio
waves.
PC20MR-3 30-100 45
SEN04868-00 Preparation work for troubleshooting of electrical system
Preparation work for trouble-

shooting of electrical system
a When carrying out troubleshooting of an electric

circuit related to the KOMTRAX terminal, expose
the related connectors according to the following
procedure.
a The KOMTRAX terminal is installed at the right
front of the operator seat.
1. Remove the top cover of the KOMTRAX

terminal.
2. Remove KOMTRAX terminal (1).
3. Insert or connect a troubleshooting T-adapter to

connector F32 of KOMTRAX terminal (1).
a Cable (2) is for the communication antenna
(system 1).
a Cable (3) is for the GPS antenna.
30-100 46 PC20MR-3
Preparation work for troubleshooting of electrical system SEN04868-00
PC20MR-3 30-100 47
SEN04868-00
2009 KOMATSU
All Rights Reserved
30-100 48
SEN04869-00
PC20MR-3
SEN04869-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

40 Troubleshooting
100 General Information on troubleshoot-
ing
Points to remember when troubleshooting ................................................................................................. 2

Sequence of events in troubleshooting....................................................................................................... 3
Check before troubleshooting ..................................................................................................................... 4
Classification and troubleshooting steps..................................................................................................... 5
Probable problems and troubleshooting No................................................................................................ 6
Connection table for connector pin numbers .............................................................................................. 9
T- branch box and T- branch adapter table ................................................................................................ 45
PC20MR-3 40-100 1
100 General Information on troubleshooting
SEN04869-00 Points to remember when troubleshooting
Points to remember when troubleshooting
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 3) Make checks of other items.

hurry to disassemble the components. 4) Check other maintenance items which can
If components are disassembled immedi- be visually checked and are considered
ately after any failure occurs: necessary.
q Parts that have no connection with the failure
or other unnecessary parts will be disassem- 4. Confirming failure
bled. Confirm the extent of the failure by yourself, and
q It will become impossible to find the cause of judge whether to treat it as a real failure or as a
the failure. problem of handing, operation, etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact the
oil or grease, and at the same time, will also lose troubleshooting symptoms, do not carry out
the confidence of the user or operator. any investigation or measurement that may
For this reason, when carrying out trouble- make the problem worse.
shooting, it is necessary to carry out thorough
prior investigation and to carry out trouble- 5. Troubleshooting
shooting in accordance with the fixed procedure. Use the results of the investigation and inspec-
tion in Items 2 to 4 to narrow down the causes of
2. Points to ask user or operator failure, then use the troubleshooting table or
1) Have any other problems occurred apart flowchart (matrix) to find out the failure part
from the problem that has been reported? exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting is as
machine before the failure occurred? follows.
3) Did the failure occur suddenly, or were there 1] Start from the simple points.
problems with the machine condition before 2] Start from the most likely points.
this? 3] Investigate other related parts or informa-
4) Under what conditions did the failure occur? tion.
5) Had any repairs been carried out before the
failure? When were these repairs carried 6. Measures to remove root cause of failure
out? Even if the immediate failure is removed, the
6) Has the same kind of failure occurred same failure may occur again, unless the root
before? cause of the failure is repaired. To prevent this,
always investigate why the cause of the failure
3. Check before troubleshooting occurred. Then, remove the root cause.
1) Are abnormal symptoms detected in the
machine?
2) Make checks before starting day's work.
40-100 2 PC20MR-3
Sequence of events in troubleshooting SEN04869-00
Sequence of events in troubleshooting
PC20MR-3 40-100 3
SEN04869-00 Check before troubleshooting
Check before troubleshooting
Item Judgement value Action
1. Check fuel level, type of fuel Add fuel
2. Check for impurities in fuel Clean, drain
3.Check for clogging of fuel filter cartridge Replace
4. Check engine oil level in oil pan, type of oil Add oil
Lubricating oil/coolant
5. Check for clogging of engine oil filter Replace
6. Check coolant level Add coolant
7. Check for clogging of air cleaner Clean or replace
8. Check hydraulic oil level, type of oil Add oil
9. Check for clogging of hydraulic oil strainer Clean, drain
10. Check for clogging of hydraulic oil filter Replace
11. Check swing machinery oil level, type of oil Add oil
12. Check final drive oil level, type of oil Add oil
Electrical equipment
1. Check for looseness, corrosion of battery terminal, wiring Tighten or replace
2. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace
Hydraulic/mechani-
1. Check for abnormal noise, smell Repair

cal equipment
2. Check for oil leakage Repair
3. Carry out air bleeding Bleed air
1. Check battery voltage (engine stopped) 1015 V Charge or replace
2. Check battery electrolyte level Add or replace

Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring Replace
4. Check for missing wiring clamps, hanging wiring Repair

5. Check for water leaking on wiring (be particularly careful attention to Disconnect con-

water leaking on connectors or terminals) nector and dry
6. Check for blown, corroded fuses Replace
After running for
7. Check alternator voltage (engine running at 1/2 throttle or above) several minutes Replace
13.5 14.5 V
8. Check operating sound of battery relay (when switch is turned
Replace
ON/OFF)
40-100 4 PC20MR-3
Classification and troubleshooting steps SEN04869-00
Classification and troubleshooting steps
Classification of troubleshooting
Mode Contents
E-mode Troubleshooting for electric system [Except monitor panel]
H-mode Troubleshooting for hydraulic and mechanical system
M-mode Troubleshooting for machine moniter
S-mode Troubleshooting for engine unit
Procedure for troubleshooting

If a possible fault is detected in the machine, find a corresponding fault in the table of "Possible faults and
troubleshooting Nos.", then go to the indicated troubleshooting section.
PC20MR-3 40-100 5
SEN04869-00 Probable problems and troubleshooting No.
Probable problems and troubleshooting No.
Troubleshooting
No. Possible fault
E-mode H-mode M-mode S-mode
Possible faults related to engine
1 Engine does Engine does not start E-1 q

not start nor-
2 mally Engine starts but stops later q
3 Engine output is insufficient H-2 q
4 Exhaust gas color is bad q
5 Knocking sound is high q
6 Engine makes abnormal sound q
7 Combustion sound is uneven q
8 Engine During idling q
9 hunts During work q
10 Engine vibrates largely q
11 Engine speed does not lower quickly q
12 Fuel is consumed much q
13 Lubricating oil is consumed much q
14 Lubricating Lubricating oil is diluted with fuel q
15 oil Lubricating oil is mixed in coolant q
16 Lubricating oil pressure is low q
17 Much blow-by gas is produced q
18 Engine overheats q
Coolant
19 Coolant temperature is high q
20 Intake air pressure is low q
Intake air
21 Intake air pressure is high q
22 Exhaust temperature is high q
23 Engine does not stop E-2
Possible faults related to work equipment, travel, swing, and blade

When lock lever is in FREE position, whole work equip-
24 E-3
ment, travel, swing, and blade systems do not work
When lock lever is in LOCK position, whole work equip-
25 E-4
ment, travel, swing, and blade systems work
Speed or power of whole work equipment, travel, swing,
26 H-1
and blade is low
27 Engine speed lowers extremely or engine stalls H-2
Work equipment, travel, swing, and blade systems do not
28 H-3
work
29 Abnormal sound comes out from around hydraulic pump H-4
30 Fine control performance or response is low H-5
40-100 6 PC20MR-3
Probable problems and troubleshooting No. SEN04869-00
Troubleshooting
No. Possible fault
Possible faults related to work equipment
31 Speed or power of boom is low H-6
32 Speed or power of arm is low H-7
33 Speed or power of bucket is low H-8
34 Speed or power of boom swing is low H-9
35 Work equipment does not move singly H-10
36 Hydraulic drift of work equipment is large H-11
37 Time lag of work equipment is large H-12
Possible fault related to compound operation

In compound operation of work equipment, speed of part
38 H-13
loaded more is low
Possible faults related to travel
39 Machine deviates during travel H-14
40 Speed or power of travel is low H-15
41 Machine is not steered well or steering power is low H-16
42 Travel speed does not change H-17
43 Travel motor does not work (One-side only) H-18

When machine starts traveling, travel alarm does not
44 E-5
sound
When machine stops traveling, travel alarm does not stop
45 E-5
sounding
Possible faults related to swing
46 Speed or power of swing is low H-19
47 Machine does not swing H-20
48 Swing acceleration is low H-21
49 Machine overruns when it stops swinging H-22
50 Large shock is made when machine stops swinging H-23
51 Large sound is made when machine stops swinging H-24
52 Hydraulic drift of swing is large H-25
Possible fault related to blade
53 Speed or power of blade is low H-26
54 Blade does not move H-27
55 Hydraulic drift of blade is large H-28
Possible fault related to machine monitor

When starting switch is turned ON, no monitor/gauge oper-
56 M-1
ates
When starting switch is turned ON, some monitors/gauges
57 M-2
do not operate
58 Caution buzzer does not sound or does not stop sounding M-3
PC20MR-3 40-100 7
SEN04869-00 Probable problems and troubleshooting No.
Troubleshooting
No. Possible fault
While engine is running, engine oil pressure monitor
59 M-4
flashes
60 While engine is running, charge level monitor flashes M-5
61 Preheating system does not operate normally M-6
62 Coolant temperature gauge does not indicate normally M-7
63 Fuel level gauge does not indicate normally M-8
64 Service meter does not operate while engine is running M-9
65 Travel speed shifting system does not operate normally M-10

Machine monitor night lamp and working lamp do not right
66 M-11
up
Other possible faults
67 Windshield wiper does not operate (Cab specification) E-7
68 Windshield washer does not operate (Cab specification) E-8
69 Heater does not operate E-9
40-100 8 PC20MR-3
Connection table for connector pin numbers SEN04869-00
Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
PC20MR-3 40-100 9
SEN04869-00 Connection table for connector pin numbers
40-100 10 PC20MR-3
PC20MR-3 40-100 11
40-100 12 PC20MR-3
PC20MR-3 40-100 13
40-100 14 PC20MR-3
PC20MR-3 40-100 15
40-100 16 PC20MR-3
PC20MR-3 40-100 17
40-100 18 PC20MR-3
PC20MR-3 40-100 19
40-100 20 PC20MR-3
PC20MR-3 40-100 21
40-100 22 PC20MR-3
PC20MR-3 40-100 23
40-100 24 PC20MR-3
PC20MR-3 40-100 25
40-100 26 PC20MR-3
PC20MR-3 40-100 27
40-100 28 PC20MR-3
PC20MR-3 40-100 29
40-100 30 PC20MR-3
PC20MR-3 40-100 31
40-100 32 PC20MR-3
PC20MR-3 40-100 33
40-100 34 PC20MR-3
PC20MR-3 40-100 35
40-100 36 PC20MR-3
PC20MR-3 40-100 37
40-100 38 PC20MR-3
PC20MR-3 40-100 39
40-100 40 PC20MR-3
PC20MR-3 40-100 41
40-100 42 PC20MR-3
PC20MR-3 40-100 43
40-100 44 PC20MR-3
T- branch box and T- branch adapter table SEN04869-00
T- branch box and T- branch adapter table

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 q Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
ECONO12
799-601-2790 Adapter for ECONO 12
P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
ECONO12
799-601-2840 Extension cable (ECONO type) 12
P
q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for M 8 S8P q q q q
PC20MR-3 40-100 45
SEN04869-00 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
799-601-7150 Adapter for S (White) 10 S10P q q q q

799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 - q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799 -601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799 -601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapterfor relay 5 REL-5P q
799-601-7370 Adapterfor relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 - q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 K q q
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
40-100 46 PC20MR-3
T- branch box and T- branch adapter table SEN04869-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol
795-799-5520* Socket for engine (HPI-T2) 2 S q

Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 - q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 - q
799-601-4280* Box for controller (PUMP) 121 - q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 25 HST26A q
2,
799-601-9890 Multi-adapter for DT2 4 and DTM2 3, - q
4
* Shows not T-adapter but socket.
PC20MR-3 40-100 47
SEN04869-00
2009 KOMATSU
All Rights Reserved
40-100 48
SEN04870-00
PC20MR-3
SEN04870-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

40 Troubleshooting
200 Troubleshooting of electrical system
(E-mode)
Before starting E-mode troubleshooting ..................................................................................................... 2

Information contained in troubleshooting table ........................................................................................... 4
E-1 Engine does not start ........................................................................................................................... 5
E- 2 Engine does not stop........................................................................................................................... 11
E- 3 When lock lever is in FREE position, whole work equipment, travel, swing,
and blade systems do not work .................................................................................................................. 13
E- 4 When lock lever is in LOCK position, whole work equipment, travel, swing, and blade systems work 16
E- 5 When machine starts traveling, travel alarm does not sound.............................................................. 18
E- 6 When machine stops traveling, travel alarm does not stop sounding ................................................. 21
E- 7 Windshield wiper does not operate [Cab specification]....................................................................... 23
E- 8 Windshield washer does not operate [Cab specification].................................................................... 25
E- 9 Heater does not operate...................................................................................................................... 27
PC20MR-3 40-200 1
200 Troubleshooting of electrical system (E-mode)
SEN04870-00 Before starting E-mode troubleshooting
Before starting E-mode troubleshooting
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power di-
rectly (A switch power supply is a device which supplies power while the starting switch is at the ON po-
sition and a constant power supply is a device which supplies power while the starting switch is at the OFF
position).
a When carrying out troubleshooting related to the electric system, you should check the fuse box to see if
the power is supplied normally.
Fuse box (FB1)

Type of power sup-
Fuse No. Fuse capacity Destination of power
ply
Switch power sup-
1
ply 30A (cab)
(Between termi- Work lamp
(Starting switch ter- 10A (canocpy)
nal 1 11)
minal BR)
Horn
2 Fuel pump
(Between termi- 10A
nal 2 12) Safety relay (ACC signal)
Alternator (ACC signal)
Machine monitor (Switch power supply)
3
(Between termi- 10A Alarm buzzer
nal 3 13)
2nd travel speed selection solenoid valve
Switch power sup-
4
ply KOMTRAX terminal, Connector (For service)
(Between termi- 10A
(Starting switch ter- PPC lock switch (LEFT), Relay (For starting motor)
nal 4 14)
minal ACC)
Heater [Canopy specification]
10A (canopy)
5 Travel alarm [Canopy specification]
(Between termi-
nal 5 15) Heater [Cab specification]
20A (Cab)
Travel alarm [Cab specification]
Wiper motor [Cab specification]
6
(Between termi- 20A (Cab) Radio [Cab specification]
nal 6 16)
Room lamp [Cab specification], Cigarette lighter
7 Engine stop solenoid relay
Constant power (Between termi- 10A
supply nal 7 17) Engine stop solenoid, Timer
(Fusible link : M4) 8 (Canopy): Relay (For PPC lock solenoid), Connector (For ser-
(Between termi- 10A vice), Machine monitor, KOMTRAX terminal
nal 8 18) (Cab): Canopy + Radio
9 (Unused)
10 (Unused)
40-200 2 PC20MR-3
Before starting E-mode troubleshooting SEN04870-00
Locations of fusible link (M4) and fuse box (FB1) and fuse Nos.
PC20MR-3 40-200 3
SEN04870-00 Information contained in troubleshooting table
Information contained in troubleshooting table
a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their
contents fully before proceeding to actual troubleshooting work.
Failure informa-
Phenomena occurring on machine
tion
Related infor-
Information on the failure occurred as well as the troubleshooting
mation
Cause Standard value in normalcy and references for troubleshooting
<Content Included>
q Standard value in normalcy by which to pass "good" or "no
1
good" judgement over the presumed cause
q Reference for passing the above "good" or "no good"
judgement
<Phenomenon of Wiring Harness Failure>

q Disconnection
There is a faulty contact at the connector or disconnection
of wiring harness occurred.
q Defective grounding
2
A wiring harness that is not connected with a grounding
circuit has a contact with the grounding circuit.
q Short-circuiting
A wiring harness that is not connected with a 12 V electric
Presumed Cause that presumably
circuit has a contact with the electric circuit.
cause and stan- triggered failure in ques-
dard value in tion(The assigned No. is
<Precaution for Troubleshooting>
normalcy for filing purpose only. It
1) Connector No. display method and handling of T-adapter
does not stand for any pri-
Insert or connect T-adapters in the following manner before
ority)
starting troubleshooting unless otherwise instructed.
q If there is no indication of "male" or "female" in a specif-
ic connector No., disconnect the connector and insert
the T-adapter into both male and female sides.
q If there is an indication of "male" or "female" in a specif-
ic connector No., disconnect the connector and connect
3 the T-adepter with only one side of either "male" or "fe-
male".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative () lead OFF
a circuit tester in the following manner unless otherwise in-
structed.
q Connect the positive (+) lead with the pin No. indicated
at the front or the wiring harness.
q Connect the negative () lead with the pin No. indicated
Relative circuit diagram
This is part of the electrical circuit diagram

which shows the portion where the failure
occurred.
q Connector No.: Indicates (Type - numbers
of a pin) (color)
q Arrow (io): Indicates the rough location on
the machine
40-200 4 PC20MR-3
E-1 Engine does not start SEN04870-00
E-1 Engine does not start

Failure informa-
(1) When the starting switch is set in START, the starting motor does not revolve.
tion
q Since the engine starting circuit has the neutral safety function, the engine does not start unless the
Relative infor- lever is in the LOCK position.
mation q The PPC lock lever and switch are installed to only the left side of the canopy model and to both
sides of the cab model

Low charge level of battery Battery voltage Electrolyte specific gravity
1 or low electrolyte specific
gravity Min. 12 V Min. 1.26
If the fusible link is broken, the circuit probably has a grounding fault.
2 Defective fusible link
(See Cause 12.)
Defective fuse No. 2 or No. If the fuse is broken, the circuit probably has a grounding fault. (See
3
3 Cause 12.)
a Prepare with starting switch OFF, then hold starting switch in
OFF/ON/START and carry out troubleshooting.
Starting switch Position of switch Resistance
Defective starting switch Between T-F1 (B) OFF Min. 1 M

4
(Internal disconnection) and T-F3 (ACC) ON Max. 1
Between T-F1 (B) OFF Min. 1 M

and T-F4 (C) START Max. 1
a Prepare with starting switch OFF, then carry out troubleshooting
Presumed without turning starting switch.
cause and stan- Defective left PPC lock
dard value in F5 (male) Left lock lever Resistance
5 switch
normalcy (Internal disconnection) FREE Min. 1 M
Between (1) and (2)
LOCK Max. 1
without turning starting switch.
Defective right PPC lock
switc F14 (male) Right lock lever Resistance
6
(Internal disconnection)
FREE Min. 1 M
[Only canopy specification] Between (1) and (2)
LOCK Max. 1
R1 (male) Resistance
Defective relay for engine Between (1) and (2) 86 106
7 start circuit (Internal discon-
nection) Between (3) and (4) Max. 1
Between (3) and (5) Min. 1 M

When relay (R1) for the engine start circuit is replaced with another
one, if the condition becomes normal, relay (R1) is defective.
PC20MR-3 40-200 5
SEN04870-00 E-1 Engine does not start

START and carry out troubleshooting.
RM4, RM5 Voltage
Between RM4 (3)
ACC Input 10 15 V
and (5)
Between RM4 (1)
Start input 10 15 V
Defective safety relay and (5)
8 Between RM4 (4)
(Internal defect) Charge input Max. 1 V
and (5)
Between RM5 (1)
Power input 10 15 V
and chassis ground
Between RM5 (2)
Start output 10 15 V
and chassis ground
If the ACC input, start input, charge input, and power input are nor-
mal but the start output is not normal, the safety relay is defective.
START and carry out troubleshooting.
T-M5, M16 Voltage
Defective starting motor Between T-M5 (B)
9 Power input 10 15 V
(Internal defect) and (E)
Between M16 (S)
Start input 10 15 V
and (E)
If the power input and start input are normal but the starting motor
does not revolve, the starting motor is defective.
Presumed a Prepare with starting switch OFF, then hold starting switch ON
cause and stan- and carry out troubleshooting.
Defective alternator
dard value in 10 M7 Voltage
(Internal short circuit)
normalcy Between M7 (3) and chassis
Max. 1 V
ground
Wiring harness between battery () and Resis-
Max. 1
chassis ground tance
Wiring harness between T-M1 (+) and T-M5 Resis-
Max. 1
(B) tance
Wiring harness between T-M1 (+) and M4 Resis-
Max. 1
(female) (1) tance
Wiring harness between M4 (female) (2) and Resis-
Max. 1
T-F1 (B) or RM5 (female) (1) tance
Wiring harness between T-F4 (C) and R1 Resis-
Max. 1
Disconnection in wiring har- (female) (4) tance
ness Wiring harness between R1 (female) (3) and Resis-
11 Max. 1
(Disconnection or defective RM4 (female) (1) tance
contact of connector) Wiring harness between RM4 (female) (5) Resis-
Max. 1
and chassis ground (T-M7) tance
Wiring harness between RM5 (female) (2) Resis-
Max. 1
and M16 (female) (1) tance
Wiring harness between T-F3 (ACC) and Resis-
Max. 1
FB1 (4) tance
Wiring harness between FB1 (14) and F5 Resis-
Max. 1
(female) (2) tance
Wiring harness between F5 (female) (1) and Resis-
Max. 1
F14 (female) (2) [Canopy specification] tance
Wiring harness between F14 (female) (1) Resis-
Max. 1
and R1 (female) (1) [Canopy specification] tance
40-200 6 PC20MR-3

Max. 1
R1 (female) (1) [Cab specification] tance
Disconnection in wiring har- Wiring harness between R1 (female) (2) and Resis-
Max. 1
ness chassis ground (T-M7) tance
11
(Disconnection or defective Wiring harness between FB1 (12) and RM4 Resis-
Max. 1
contact of connector) (female) (3) tance
Wiring harness between RM4 (female) (5) Resis-
Max. 1
Between T-M1(+) M5 (B) wiring harness Resis-
Min. 1 M
and chassis ground tance
Between T-M(+) M4 (female) (1) wiring Resis-
Min. 1 M
harness and chassis ground tance
Between M4 (female) (2) T-F1 (B) or RM5
Resis-
(female) (1) wiring harness and chassis Min. 1 M
tance
ground
Between T-F4 (C) R1 (female) (4) or other
Resis-
related circuit wiring harness and chassis Min. 1 M
tance
ground
Between R1 (female) (3) RM4 (female) (1) Resis-
Min. 1 M
Presumed wiring harness and chassis ground tance
cause and stan- BetweenRM5 (female) (2) M16 (female) Resis-
Min. 1 M
dard value in (1) wiring harness and chassis ground tance
normalcy Between T-F3 (ACC) FB1 (4) or other
Grounding fault in wiring Resis-
12 harness tance
ground
(Contact with ground circuit)
Between FB1 (14) F5 (female) (2) or other
Resis-
tance
ground
Between F5 (female) (1) F14 (female) (2)
Resis-
wiring harness and chassis ground Min. 1 M
tance
[Canopy specification]
Between F14 (female) (1) R1 (female) (1)
or other related circuit wiring harness and Resis-
Min. 1 M
Between F5 (female) (1) R1 (female) (1) or
other related circuit wiring harness and Resis-
Min. 1 M
[Cab specification]
Between FB1 (15) RM4 (female) (3) or
Resis-
other related circuit wiring harness and Min. 1 M
tance
chassis ground
Short circuit with power
without turning starting switch ON.
13 source in wiring harness
Between M7 (female) (3) RM4 (female) (4)
(Contact with 12 V circuit) Voltage Max. 1 V
wiring harness and chassis ground
PC20MR-3 40-200 7
Failure informa-
(2) When the starting switch is set in START, the starting motor revolves.
tion
Relative infor-
mation

If the fuse is broken, the circuit probably has a grounding fault. (See
1 Defective fuse No. 1
Cause 8.)
a Prepare with starting switch OFF, then hold starting switch ON
and START and carry out troubleshooting.
Defective starting switch Starting switch Position of switch Resistance
2
and T-F2 (BR) ON Max. 1
M9 (male) Resistance
Defective engine stop sole-
3 noid (Internal disconnection Between (1) and (3) 22 28
or short circuit)
Between (2) and (3) 0.63 0.77
Between (1), (2) and chassis
Min. 1 M
ground
Presumed a Prepare with starting switch OFF.
cause and stan-
Defective timer M3 Starting switch Voltage
dard value in
4 (Internal disconnection or
normalcy 1 sec: 10 15 V
short circuit)
Between (1) and (2) OFFoON 1 sec and after: Max. 1
V
without turning starting switch (Troubleshooting for coil).
RM1 (male) Resistance
Defective engine stop sole- Between (1) and (2) 33 41

noid relay
5 a Prepare with starting switch OFF (Troubleshooting for contacts).
(Internal disconnection or
short circuit) RM3 (male) Starting switch Voltage
1 sec: 10 15 V
Between (1) and
OFFoON 1 sec and after: Max. 1
chassis ground
V
Defective diode
6 D1 (male) Resistance/Continuity
Between (1) and (2) Min. 1 M (No continuity)
40-200 8 PC20MR-3

Wiring harness between T-F2 (BR) and FB1
Resistance Min. 1 M
(7)
Wiring harness between FB1 (17) and M3
(female) (4) or RM2 (female) (1) or M9 Resistance Min. 1 M
(female) (1)
Wiring harness between M3 (female) (1) and
Disconnection in wiring har- Resistance Min. 1 M
RM1 (female) (1)
ness
7
(Disconnection or defective Wiring harness between M3 (female) (2) and
Resistance Min. 1 M
contact of connector) RM1 (female) (2)
Resistance Min. 1 M
chassis ground (T-M7)
Wiring harness between RM3 (female) (1)
Resistance Min. 1 M
and M9 (female) (2)
Resistance Min. 1 M
Between T-F2 (BR) FB1 (7) wiring harness
Resistance Min. 1 M
and chassis ground
Between FB1 (17) M3 (female) (4) or RM2
Presumed (female) (1) or M9 (female) (1) or D1
Grounding fault in wiring Resistance Min. 1 M
cause and stan- (female) (1) wiring harness and chassis
8 harness ground
dard value in
normalcy Between M3 (female) (1) RM1 (female) (1)
Resistance Min. 1 M
Between M3 (female) (2) RM1 (female) (2)
Resistance Min. 1 M
Between RM3 (female) (1) M9 (female) (2)
Resistance Min. 1 M
PC20MR-3 40-200 9
Related circuit diagram
40-200 10 PC20MR-3
E- 2 Engine does not stop SEN04870-00
E- 2 Engine does not stop

Failure informa-
q Engine does not stop
tion
Relative infor-

mation

a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting
1
and T-F2 (BR) ON Max. 1
Presumed
cause and stan- Between (1) and (3) 22 28
Defective engine stop sole-
dard value in 2
normalcy
noid (Internal defect) Between (2) and (3) 0.63 0.77
Between (1), (2) and chassis
Min. 1 M
ground
After connector M9 is disconnected, if the engine does not start, the
engine stop solenoid may be burnt or seized.
and carry out troubleshooting.
Between T-F2 (BR) FB1 (7) wiring harness
Short circuit with power Voltage Max. 1 V
and chassis ground
Between FB1 (17) M3 (female) (4) or RM2
(Contact with 12 V circuit)
(female) (1) or M9 (female) (1) or D1
Voltage Max. 1 V
(female) (1) wiring harness and chassis
ground
PC20MR-3 40-200 11
SEN04870-00 E- 2 Engine does not stop
Circuit diagram related to engine preheating, start, charge, and stop
40-200 12 PC20MR-3
E- 3 When lock lever is in FREE position, whole work equipment, travel, swing, and blade systems SEN04870-00
E- 3 When lock lever is in FREE position, whole work equipment, travel,

swing, and blade systems do not work
Failure informa- q When the lock lever is in FREE position, the whole work equipment, travel, swing, and blade sys-
tion tems do not work.
Relative infor- q The PPC lock lever and switch are installed to only the left side of the canopy model and to both
mation sides of the cab model.

Defective fuse No. 2 If the fuse is broken, the circuit probably has a grounding fault. (See
1
or No. 3 Cause 8.)
a Prepare with starting switch OFF, then hold starting switch OFF and ON
Defective starting and carry out troubleshooting.
switch Starting switch Position of switch Resistance
2
(Internal disconnec-
Between T-F1 (B) and OFF Min. 1 M
tion)
T-F3 (ACC) ON Max. 1
a Prepare with starting switch OFF, then carry out troubleshooting without
Defective left PPC turning starting switch.
lock switch F5 (male) Left lock lever Resistance
3
(Internal disconnec-
FREE Min. 1 M
tion) Between (1) and (2)
LOCK Max. 1
Defective right PPC a Prepare with starting switch OFF, then carry out troubleshooting without
lock switch turning starting switch.
(Internal disconnec- F14 (male) Right lock lever Resistance
4
tion)
FREE Min. 1 M
[Only canopy specifi- Between (1) and (2)
cation] LOCK Max. 1
turning starting switch.
Presumed R2 (male) Resistance
cause and stan- Defective relay for
PPC lock solenoid Between (1) and (2) 86 106
dard value in 5
normalcy (Internal disconnec- Between (3) and (4) Max. 1
tion)
Between (3) and (5) Min. 1 M
When relay (R2) for the PPC lock solenoid is replaced with another one, if
the condition becomes normal, relay (R2) is defective.
Defective PPC lock turning starting switch.
solenoid valve (Inter- M12 (male) Resistance
6
nal disconnection or
Between (1) and (2) 10.5 12
short circuit)
Between (1) and chassis ground Min. 1 M
Wiring harness between T-F3 (ACC) and FB1 (4) Resistance Max. 1
Wiring harness between FB1 (14) and F5 (female)
Resistance Max. 1
(2)
Disconnection in wir- Wiring harness between F5 (female) (1) and F14
ing harness Resistance Max. 1
(female) (2) [Canopy specification]
7 (Disconnection or Wiring harness between F14 (female) (1) and R2
defective contact of Resistance Max. 1
(female) (1) [Canopy specification]
connector) Wiring harness between F5 (female) (1) and R2
Resistance Max. 1
(female) (1) [Cab specification]
Wiring harness between R2 (female) (2) and
Resistance Max. 1
Wiring harness between FB1 (18) and R2
Resistance Max. 1
(female) (3)
PC20MR-3 40-200 13
SEN04870-00 E- 3 When lock lever is in FREE position, whole work equipment, travel, swing, and blade systems

Disconnection in wir- Wiring harness between R2 (female) (5) and M12
Resistance Max. 1
ing harness (female) (1)
7 (Disconnection or
defective contact of Resistance Max. 1
connector)
Between T-F3 (ACC) FB1 (4) or other related
Resistance Min. 1 M
circuit wiring harness and chassis ground
Resistance Min. 1 M
Presumed related circuit wiring harness and chassis ground
cause and stan- Between F5 (female) (1) F14 (female) (2) wiring
dard value in harness and chassis ground Resistance Min. 1 M
normalcy [Canopy specification]
Grounding fault in wir-
ing harness
8 other related circuit wiring harness and chassis
(Contact with ground Resistance Min. 1 M
ground
circuit)
other related circuit wiring harness and chassis
Resistance Min. 1 M
ground
[Cab specification]
Between FB1 (18) R2 (female) (3) or other
Resistance Min. 1 M
related circuit wiring harness and chassis ground
Between R2 (female) (5) M12 (female) (1) wir-
Resistance Min. 1 M
ing harness and chassis ground
40-200 14 PC20MR-3
E- 3 When lock lever is in FREE position, whole work equipment, travel, swing, and blade systems SEN04870-00
Circuit diagram related to PPC lock solenoid valve
PC20MR-3 40-200 15
SEN04870-00 E- 4 When lock lever is in LOCK position, whole work equipment, travel, swing, and blade systems
E- 4 When lock lever is in LOCK position, whole work equipment, travel,

swing, and blade systems work
Failure informa- q When the lock lever is in LOCK position, the whole work equipment, travel, swing, and blade sys-
tion tems work.
Relative infor- q The PPC lock lever and switch are installed to only the left side of the canopy model and to both
mation sides of the cab model.

Defective left PPC lock F5 (male) Left lock lever Resistance
1 switch
(Internal disconnection) FREE Min. 1 M
Between (1) and (2)
LOCK Max. 1
Defective right PPC lock
switch F14 (male) Right lock lever Resistance
2
FREE Min. 1 M
[Only canopy specification] Between (1) and (2)
LOCK Max. 1
Defective relay for PPC lock Between (1) and (2) 86 106
3 solenoid (Internal disconnec-
tion) Between (3) and (4) Max. 1
Presumed
cause and stan- Between (3) and (5) Min. 1 M
dard value in When relay (R2) for the PPC lock solenoid is replaced with another
normalcy one, if the condition becomes normal, relay (R2) is defective.
Defective PPC lock solenoid
Between (1) and (2) 10.5 12
4 valve (Internal disconnection
or short circuit) Between (1) and chassis ground Min. 1 M
After connector M12 is disconnected, if the condition does not
become normal, the PPC lock solenoid valve may be burnt or
seized.
or other related circuit wiring harness and
Voltage Max. 1 V
chassis ground
other related circuit wiring harness and
Voltage Max. 1 V
chassis ground
[Cab specification]
Between R2 (female) (5) M12 (female) (1)
Voltage Max. 1 V
40-200 16 PC20MR-3
E- 4 When lock lever is in LOCK position, whole work equipment, travel, swing, and blade systems SEN04870-00
Circuit diagram related to PPC lock solenoid valve
PC20MR-3 40-200 17
SEN04870-00 E- 5 When machine starts traveling, travel alarm does not sound
E- 5 When machine starts traveling, travel alarm does not sound

Failure informa-
q When the machine starts traveling, the travel alarm does not sound.
tion
Relative infor-

mation

If the fuse is broken, the circuit probably has a grounding fault.
(See Cause 9.)
a Prepare with starting switch OFF, then hold starting switch
OFF and ON and carry out troubleshooting.
2
and T-F3 (ACC) ON Max. 1
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
T1 (female) Travel lever Voltage/Resistance
Operated
Defective travel alarm Between (1) and
3 (Right, left, forward, 10 15 V
(Internal defect) chassis ground
or reverse)
Between (2) and
Neutral Max. 1
chassis ground
If the voltage and resistance are normal but the alarm does not
sound, the travel alarm is defective.
Presumed cause Defective left forward PPC oil T2 (male) Left travel lever Resistance
and standard 4 pressure switch
value in nor- (Internal disconnection) Neutral Min. 1 M
malcy Between (1) and (2) Operated for forward
Max. 1
trave
Defective left reverse PPC oil T5 (male) Left travel lever Resistance
5 pressure switch
(Internal disconnection) Neutral Min. 1 M
Between (1) and (2) Operated for reverse
Max. 1
travel
Defective right forward PPC oil T3 (male) Right travel lever Resistance
6 pressure switch
Between (1) and (2) Operated for forward
Max. 1
travel
Defective right reverse PPC oil T4 (male) Right travel lever Resistance
7 pressure switch
Max. 1
travel
40-200 18 PC20MR-3
E- 5 When machine starts traveling, travel alarm does not sound SEN04870-00

a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch.
Max. 1
FB1 (5) tance
Disconnection in wiring har- Wiring harness between FB1 (15) and T2
Resis-
ness (female) (1) or T3 (female) (1) or T4 Max. 1
8 tance
(Disconnection or defective (female) (1) or T5 (female) (1)
contact of connector) Wiring harness between T2 (female) (2) or
Resis-
T3 (female) (2) or T4 (female) (2) or T5 Max. 1
tance
Presumed cause (female) (2) and T1 (female) (1)
and standard Wiring harness between T1 (female) (2) Resis-
Max. 1
value in nor- and chassis ground (T-M7) tance
malcy a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch.
Between T-F3 (ACC) FB1 (5) or other
related circuit wiring harness and chassis Voltage Min. 1 M
ground
Grounding fault in wiring har-
Between FB1 (15) T2 (female) (1), T3
9 ness
(female) (1), T4 (female) (1), or T5 (female) Voltage Min. 1 M
(1) wiring harness and chassis ground
Between T2 (female) (2), T3 (female) (2),
T4 (female) (2), or T5 (female) (2) T1
Voltage Min. 1 M
(female) (1) wiring harness and chassis
ground
PC20MR-3 40-200 19
SEN04870-00 E- 5 When machine starts traveling, travel alarm does not sound
Circuit diagram related to travel alarm
40-200 20 PC20MR-3
E- 6 When machine stops traveling, travel alarm does not stop sounding SEN04870-00
E- 6 When machine stops traveling, travel alarm does not stop sounding
Failure infor-
q When the machine stops traveling, the travel alarm does not stop sounding.
mation
Relative infor-

mation

Defective left forward PPC oil T2 (male) Left travel lever Resistance
1 pressure switch
Max. 1
travel
Defective left reverse PPC oil T5 (male) Left travel lever Resistance
2 pressure switch
Max. 1
travel
Presumed a Prepare with starting switch OFF, then start engine and carry
cause and out troubleshooting.
standard value
Defective right forward PPC oil T3 (male) Right travel lever Resistance
in normalcy
3 pressure switch
Max. 1
travel
Defective right reverse PPC oil T4 (male) Right travel lever Resistance
4 pressure switch
Operated for forward
travel Operated for reverse
Max. 1
travel
a Prepare with starting switch OFF, then carry out troubleshoot-
Short circuit with power source ing without turning starting switch.
5 in wiring harness (Contact with Wiring harness between T2 (female) (2) or
12 V circuit) T3 (female) (2) or T4 (female) (2) or T5 Voltage Max. 1 V
(female) (2) and T1 (female) (1)
PC20MR-3 40-200 21
SEN04870-00 E- 6 When machine stops traveling, travel alarm does not stop sounding
Circuit diagram related to travel alarm
40-200 22 PC20MR-3
E- 7 Windshield wiper does not operate [Cab specification] SEN04870-00
E- 7 Windshield wiper does not operate [Cab specification]

Failure infor-
q Windshild wiper does not operate
mation
Relative infor-

mation

(See Cause 5.)
and ON and carry out troubleshooting.
2
F7 (female) Starting switch Voltage/Resistance
Defective wiper motor and Between (4) and
3 OFF 10 15 V
switch (Internal defect) chassis ground
Presumed Between (1) and
cause and ON Max. 1
chassis ground
standard value If the voltage and resistance are normal but the wiper does not
in normalcy operate, the wiper motor and switch are defective.
Disconnection in wiring har- Wiring harness between T-F3 (ACC) and Resis-
Max. 1
ness FB1 (6) tance
4
(Disconnection or defective Wiring harness between FB1 (16) and F7 Resis-
Max. 1
Max. 1
chassis ground (T-M7) tance
Grounding fault in wiring har- Resis-
5 ness tance
ground
Resis-
tance
ground
PC20MR-3 40-200 23
SEN04870-00 E- 7 Windshield wiper does not operate [Cab specification]
Circuit diagram related to widshield wiper and window washer
40-200 24 PC20MR-3
E- 8 Windshield washer does not operate [Cab specification] SEN04870-00
E- 8 Windshield washer does not operate [Cab specification]

Failure infor-
q Windshield washer does not operate [Cab specification]
mation
Relative infor- q Before carrying out troubleshooting, check that the wiper operates normally. (If the wiper does not
mation operate, carry out troubleshooting for"E-7 Wiper does not operate" first.)

M6 (female) Wiper switch Voltage/Resistance
Defective washer motor Between (2) and
1 Water 10 15 V
(Internal disconnection) chassis ground
Between (1) and
Stop/Speed Max. 1
chassis ground
If the voltage and resistance are normal but the washer does not
operate, the washer motor is defective.
Presumed without turning starting switch.
cause and stan- Defective wiper motor and F7 (male) Wiper switch Resistance
dard value in 2 switch
normalcy (Internal disconnection) Stop/Speed Min. 1 M
Between (3) and (4)
Water Max. 1
Disconnection in wiring har- without turning starting switch.
ness Wiring harness between F7 (female) (3) Resis-
3 Max. 1
(Disconnection or defective and M6 (female) (2) tance
contact of connector) Wiring harness between M6 (female) (1) Resis-
Max. 1
4 ness
Between F7 (female) (3) M6 (female) (2) Resis-
(Contact with ground circuit) Min. 1 M
wiring harness and chassis ground tance
PC20MR-3 40-200 25
SEN04870-00 E- 8 Windshield washer does not operate [Cab specification]
Circuit diagram related to widshield wiper and window washer
40-200 26 PC20MR-3
E- 9 Heater does not operate SEN04870-00
E- 9 Heater does not operate

Failure informa-
(1) Air does not blow out or air flow does not change [Canopy specification]
tion
Relative infor- q The same heater is used for both canopy specification and cab specification, but it is wired differ-
mation ently for these 2 specifications.

(See Cause 6.)
2
(Internal disconnection) Min. 1 M
Between T-F1 (B) OFF
F27 (female) Heater switch Voltage/Resistance
Between (1) and
0 10 15 V
Defective heater chassis ground
3 Between (2) and
(Internal defect) 1 Max. 1
chassis ground
Between (3) and
2 Max. 1
chassis ground
If the voltage and resistance are normal but the heater does not
operate, the heater is defective.
F26 (male) Heater switch Resistance
Presumed Defective heater switch Between (3) and (4) Min. 1 M
cause and stan- 4 (Internal defect) 0
Between (2) and (4)
dard value in
normalcy Between (3) and (4) 1 Max. 1
Between (2) and (4) 2 Max. 1

Max. 1
FB1 (5) tance
Disconnection in wiring har- Wiring harness between FB1 (15) and F27 Resis-
Max. 1
ness (female) (1) tance
5
(Disconnection or defective Wiring harness between F27 (female) (2) Resis-
Max. 1
contact of connector) and F26 (female) (3) tance
Max. 1
and F26 (female) (2) tance
Max. 1
Resis-
related circuit wiring harness and chassis Max. 1
tance
ground
Between FB1 (15) F27 (female) (1) or
6 ness Resis-
other related circuit wiring harness and Max. 1
(Contact with ground circuit) tance
chassis ground
Between F27 (female) (2) F26 (female) (3) Resis-
Max. 1
Max. 1
PC20MR-3 40-200 27
SEN04870-00 E- 9 Heater does not operate
Failure informa-
(2) Air does not blow out or air flow does not change [Cab specification]
tion
Relative infor- q The same heater is used for both canopy specification and cab specification, but it is wired differ-
mation ently for these 2 specifications.

(See Cause 6.)
2
F11 (female) Heater switch Voltage/Resistance
Between (1) and
0 1015V
Defective heater chassis ground
3 Between (2) and
(Internal defect) 1 Max. 1
chassis ground
Between (3) and
2 Max. 1
chassis ground
If the voltage and resistance are normal but the heater does not
operate, the heater is defective.
F12 (male) Heater switch Resistance
Presumed Defective heater switch Between (3) and (4)
cause and stan- 4 (Internal defect) 0 Min. 1 M
Between (2) and (4)
dard value in
normalcy Between (3) and (4) 1 Max. 1
Between (2) and (4) 2 Max. 1

Max. 1
FB1 (5) tance
Disconnection in wiring har- Wiring harness between FB1 (15) and F11 Resis-
Max. 1
ness (female) (1) tance
5
(Disconnection or defective Wiring harness between F11 (female) (2) Resis-
Max. 1
contact of connector) and F12 (female) (3) tance
Max. 1
and F12 (female) (2) tance
Max. 1
Resis-
tance
ground
6 ness Resis-
other related circuit wiring harness and Min. 1 M
(Contact with ground circuit) tance
chassis ground
Min. 1 M
Min. 1 M
40-200 28 PC20MR-3
Failure infor-
(3) Air blows out but it is not hot [Canopy specification, cab specification]
mation
Relative infor-
mation
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and Check the coolant temperature gauge. If the coolant temperature is
1 Coolant temperature is low
standard value low, warm up the engine sufficiently.
in normalcy 2 Defective heater piping The stop valve of the heater piping may be closed. Check it directly.
PC20MR-3 40-200 29
SEN04870-00 E- 9 Heater does not operate
Circuit diagram related to heater
40-200 30 PC20MR-3
PC20MR-3 40-200 31
SEN04870-00
2009 KOMATSU
All Rights Reserved
40-200 32
SEN04871-00
PC20MR-3
SEN04871-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

40 Troubleshooting
300 Troubleshooting of hydraulic and
mechanical system (H-mode)

H- 1 Speed or power of whole work equipment, travel, swing, and blade is low ........................................ 4
H- 2 Engine speed lowers extremely or engine stalls ................................................................................. 7
H- 3 Whole work equipment, travel system, swing system, and blade do not work ................................... 8
H- 4 Abnormal sound comes out from around hydraulic pump................................................................... 11
H- 5 Fine control performance or response is low ...................................................................................... 11
H- 6 Speed or power of boom is low........................................................................................................... 12
H- 7 Speed or power of arm is low.............................................................................................................. 13
H- 8 Speed or power of bucket is low ......................................................................................................... 14
H- 9 Speed or power of boom swing is low................................................................................................. 15
H-10 Work equipment does not move in its single operation...................................................................... 16
H-11 Work equipment hydraulic drift is large .............................................................................................. 16
H-12 Time lag of work equipment is large .................................................................................................. 17
H-13 In compound operation of work equipment, speed of part loaded more is low .................................. 17
H-14 Machine deviates during travel .......................................................................................................... 18
H-15 Travel speed or travel power is low.................................................................................................... 20
H-16 Machine is not steered well or steering power is low ......................................................................... 20
H-17 Travel speed does not change........................................................................................................... 21
PC20MR-3 40-300 1
300 Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Travel motor does not work (one side only) ....................................................................................... 21
H-19 Speed or power of swing is low.......................................................................................................... 22
H-20 Machine does not swing..................................................................................................................... 24
H-21 Swing acceleration performance is low .............................................................................................. 26
H-22 Machine overruns when it stops swinging.......................................................................................... 27
H-23 Large shock is made when machine stops swinging ......................................................................... 28
H-24 When upper structure stops swinging, it makes large sound ............................................................. 28
H-25 Hydraulic drift of swing is large........................................................................................................... 29
H-26 Speed or power of blade is low .......................................................................................................... 30
H-27 Blade does not move.......................................................................................................................... 31
H-28 Hydraulic drift of blade is large ........................................................................................................... 31
40-300 2 PC20MR-3
Information contained in troubleshooting table SEN04871-00
a Troubleshooting Table and relative circuit diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure informa-
tion
Relative infor-
Information on occurred failures and troubleshooting
mation
Causes Standard value in normalcy and references for troubleshooting

1
Presumed Cause for presumed failure
cause and stan- 2 (The attached No. for filing <Contents>
dard value in q The standard values in normalcy by which to judge "good"
3 and reference purpose
normalcy or "no good" about presumed causes.
only. It does not stand for
4 q References for making judgement of "good" or "no good"
any priority)
5
PC20MR-3 40-300 3
SEN04871-00 H- 1 Speed or power of whole work equipment, travel, swing, and blade is low
H- 1 Speed or power of whole work equipment, travel, swing, and blade

is low
[Check before troubleshooting]

Before carrying out troubleshooting, check each actuator for trouble. Then, carry out proper troubleshooting,
depending on the combination of troubled actuators.
Q: Normal : Low in speed or power

Whole work equipment Contents of
Boom Travel Swing Blade trouble to
Boom Arm Bucket
swing be checked
(1)
Q Q (2)
Q Q Q Q Q (3)
Q Q (4)
Q Q Q Q Q (5)
<Reference>
Contents of trouble (1): Trouble mainly caused by PPC circuit
Contents of trouble (2): Trouble mainly caused by piston pump circuit
Contents of trouble (3): Trouble mainly caused by gear pump circuit
Contents of trouble (4): Trouble mainly caused by centralized safety valve circuit
Contents of trouble (5): Trouble mainly caused by center swivel joint circuit
Failure informa-
(1) Speed or power of whole work equipment, travel, swing, and blade is low
tion
Relative infor- q Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.
mation q Check the oil pressure while the hydraulic oil temperature is 45 55 C.

The suction filter of the hydraulic tank may be clogged. Check it
1 Clogging of suction filter
directly.
a Prepare with engine stopped, then run engine at high idling and
carry out troubleshooting.
Malfunction of self-reducing Control lever Control circuit basic pressure
2
pressure valve 2.84 3.43 MPa
Presumed All levers in neutral
cause and stan- {29 35 kg/cm2}
dard value in a Prepare with engine stopped, then run engine at high idling and
normalcy carry out troubleshooting.
PPC lock solenoid
Lock lever All control levers
Malfunction of PPC lock valve output pressure
3 0 MPa
solenoid valve LOCK Neutral
{0 kg/cm2}
2.84 3.43 MPa
FREE Neutral
{29 35 kg/cm2}
40-300 4 PC20MR-3
H- 1 Speed or power of whole work equipment, travel, swing, and blade is low SEN04871-00
Failure informa-
(2) Speed or power of whole work equipment and travel is low
tion

1 Malfunction of PC valve The PC valve may be malfunctioning. Check it directly.
Control lever LS differential pressure
4.0 4.98 MPa
All levers in neutral
Malfunction or defective {40.8 50.8 kg/cm2}
2
adjustment of LS valve Arm IN 1.47 1.67 MPa
(Half stroke) {15 17 kg/cm2}
If normal oil pressure is not obtained by adjustment, the LS valve
may be malfunctioning or may have internal defect. Check the LS
valve directly.
Lowering of performance or
The performance of the piston pump may be lowered or piston
Presumed 3 internal defect of piston
pump may have internal defect. Check the piston pump directly.
cause and stan- pump
dard value in a Prepare with engine stopped, then run engine at high idling and
normalcy carry out troubleshooting.
Control lever Main relief pressure
Malfunction or defective 24.01 25.48 MPa
4 adjustment of main relief Relieved by arm IN
{245 260 kg/cm2}
valve (on piston pump side)
If normal oil pressure is not obtained by adjustment, main relief
valve may be malfunctioning or may have internal defect. Check
main relief valve directly.
5 Malfunction of unload valve Control lever Unload pressure
3.90 4.88 MPa
{39.6 49.6 kg/cm2}
Malfunction of self-reducing The sequence valve of the self-reducing pressure valve may be
6
pressure valve malfunctioning. Check it directly.
Failure informa-
(3) Speed or power of swing and blade is low
tion

Lowering of performance or The performance of the gear pump may be lowered or gear pump
1
internal defect of gear pump may have internal defect. Check the gear pump directly.
Presumed
cause and stan- Control lever Main relief pressure
dard value in Malfunction or defective 20.12 22.08 MPa
normalcy 2 adjustment of main relief Relieved by blade RAISE
{205 225 kg/cm2}
valve (on gear pump side)
PC20MR-3 40-300 5
SEN04871-00 H- 1 Speed or power of whole work equipment, travel, swing, and blade is low
Failure informa-
(4) Speed or power of whole work equipment and blade is low
tion

Relieved by boom RAISE
Relieved by boom LOWER
Relieved by arm IN 24.01 25.48 MPa
Relieved by arm DUMP
Presumed Relieved by bucket CURL {245 260 kg/cm2}
cause and stan- Improper set pressure or Relieved by bucket DUMP
dard value in 1 malfunction of centralized Relieved by boom RIGHT SWING
normalcy safety valve 20.12 22.08 MPa
Relieved by blade LOWER
{205 225 kg/cm2}
If the oil pressure is low during each of the above operations, the
set pressure and operation of the centralized safety valve may be
defective. Check the centralized safety valve directly.
<Reference> The centralized safety valve does not act on the bot-
tom circuit of the boom swing cylinder and the head circuit of the
blade cylinder.
Failure informa-
(5) Speed or power of travel and blade is low
tion

Presumed Relieved by left travel FORWARD
cause and stan- Relieved by left travel REVERSE 24.01 25.48 MPa
Defective seal of center
dard value in 1 Relieved by right travel FORWARD {245 260 kg/cm2}
swivel joint Relieved by right travel REVERSE
normalcy
Relieved by blade RAISE 20.12 22.08 MPa
Relieved by blade LOWER {205 225 kg/cm2}
If the oil pressure is low during any of the above operations, seal of
the center swivel joint may be defective. Check the seal directly.
40-300 6 PC20MR-3
H- 2 Engine speed lowers extremely or engine stalls SEN04871-00
H- 2 Engine speed lowers extremely or engine stalls

Failure informa-
q Engine speed lowers extremely or engine stalls
tion
Work equipment control lever LS differential pressure
4.0 4.98 MPa
2
valve directly.
The LS circuit orifices (on pump side and control valve side) may be
3 Clogging of LS circuit orifice
clogged. Check them directly.
Presumed
cause and stan-
Work equipment control lever Main relief pressure
normalcy 4 adjustment of main relief Relieved by arm IN
{245 260 kg/cm2}
valve (on piston pump side)
the main relief valve directly.
Malfunction or defective 20.12 22.08 MPa
5 adjustment of main relief Relieved by blade RAISE
{205 225 kg/cm2}
the main relief valve directly.
If none of causes 1 5 is the cause of the trouble, the engine out-
6 Lowering of engine output put may be low. Carry out troubleshooting for engine unit
(S-mode).
PC20MR-3 40-300 7
SEN04871-00 H- 3 Whole work equipment, travel system, swing system, and blade do not work
H- 3 Whole work equipment, travel system, swing system, and blade do

not work
[Check before troubleshooting]

Before carrying out troubleshooting, check each actuator for trouble. Then, carry out proper troubleshooting,
depending on the combination of troubled actuators.
Q: Normal : Does not work

Whole work equipment Contents of
trouble to
Travel Swing Blade
Boom Arm Bucket Boom swing be
checked
(1)
Q Q (2)
Q Q Q Q Q (3)
Q Q (4)
Q Q Q Q Q (5)
<Reference>
Contents of trouble (1): Trouble mainly caused by pump drive system and PPC circuit
Contents of trouble (2): Trouble mainly caused by piston pump circuit
Contents of trouble (3): Trouble mainly caused by gear pump circuit
Contents of trouble (4): Trouble mainly caused by centralized safety valve circuit
Contents of trouble (5): Trouble mainly caused by center swivel joint circuit
Failure informa-
(1) Whole work equipment, travel system, swing system, and blade do not work
tion

Defective damper or pump The damper or pump drive shaft may be defective. Check them
1
drive shaft directly.
The suction filter of the hydraulic tank may be clogged. Check it
2 Clogging of suction filter
directly.
Malfunction of self-reducing Control lever Control circuit basic pressure
Presumed 3
pressure valve 2.84 3.43 MPa
cause and stan- All levers in neutral
dard value in {29 35 kg/cm2}
normalcy a Prepare with engine stopped, then run engine at high idling and
PPC lock solenoid
Lock lever All control levers
Malfunction of PPC lock valve output pressure
4 0 MPa
solenoid valve LOCK Neutral
{0 kg/cm2}
2.84 3.43 MPa
FREE Neutral
{29 35 kg/cm2}
40-300 8 PC20MR-3
H- 3 Whole work equipment, travel system, swing system, and blade do not work SEN04871-00
Failure informa-
(2) Whole work equipment and travel system do not work
tion

The piston pump may be malfunctioning or may have internal
defect. Check it directly.
Malfunction or internal defect
1 q Remove the pump discharge pressure pickup plug and rotate
of piston pump
the engine (with the hand).
o If oil flows out, the pump is normal.
Presumed Malfunction or defective 24.01 25.48 MPa
cause and stan- 2 adjustment of main relief Relieved by arm IN
{245 260 kg/cm2}
dard value in valve (on piston pump side)
normalcy
3 Malfunction of unload valve Control lever Unload pressure
3.90 4.88 MPa
{39.6 49.6 kg/cm2}
Malfunction of self-reducing The sequence valve of the self-reducing pressure valve may be
4
pressure valve malfunctioning. Check it directly.
Failure informa-
(3) Swing and blade systems do not work
tion

1 Defective dry coupling The dry coupling may be defective. Check it directly.
2 Internal defect of gear pump The gear pump may have internal defect. Check it directly.
Presumed carry out troubleshooting.
cause and stan- Control lever Main relief pressure
normalcy 3 adjustment of main relief Relieved by blade RAISE
{205 225 kg/cm2}
PC20MR-3 40-300 9
SEN04871-00 H- 3 Whole work equipment, travel system, swing system, and blade do not work
Failure informa-
(4) Whole work equipment and blade systems do not work
tion

Relieved by boom RAISE
Relieved by boom LOWER
Relieved by arm IN 24.01 25.48 MPa
Relieved by arm DUMP
Presumed Relieved by bucket CURL {245 260 kg/cm2}
cause and stan- Improper set pressure or Relieved by bucket DUMP
dard value in 1 malfunction of centralized Relieved by boom RIGHT SWING
normalcy safety valve 20.12 22.08 MPa
Relieved by blade RAISE
{205 225 kg/cm2}
If the oil pressure is low during each of the above operations, the
set pressure and operation of the centralized safety valve may be
defective. Check the centralized safety valve directly.
<Reference> The centralized safety valve does not act on the bot-
tom circuit of the boom swing cylinder and the head circuit of the
blade cylinder.
Failure informa-
(5) Travel system and blade system do not work
tion

Presumed Relieved by left travel FORWARD
cause and stan- Relieved by left travel REVERSE 24.01 25.48 MPa
dard value in 1 Relieved by right travel FORWARD {245 260 kg/cm2}
swivel joint Relieved by right travel REVERSE
normalcy
Relieved by blade RAISE 20.12 22.08 MPa
Relieved by blade LOWER {205 225 kg/cm2}
If the oil pressure is low during any of the above operations, seal of
the center swivel joint may be defective. Check the seal directly.
40-300 10 PC20MR-3
H- 4 Abnormal sound comes out from around hydraulic pump SEN04871-00
H- 4 Abnormal sound comes out from around hydraulic pump

Failure informa-
q Abnormal sound comes out from around hydraulic pump
tion
Relative infor-
q Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.
mation
1 Low hydraulic oil level The hydraulic oil level may be low. Check it directly.
2 Hydraulic oil of low quality The hydraulic oil may contain air. Check it directly.
Clogging of hydraulic tank The hydraulic tank cap may be clogged and negative pressure may
3
Presumed cap be applied to the tank. Check the cap directly.
cause and stan- Insufficient pressurization of The hydraulic tank may not be pressurized normally and negative
4
dard value in hydraulic tank pressure may be applied to the tank. Pressurize the tank.
normalcy Clogging of hydraulic tank The hydraulic tank strainer may be clogged and negative pressure
5
strainer may be supplied to the suction circuit. Check the strainer directly.
6 Defective piston pump The piston pump may have internal defect. Check it directly.
If none of causes 1 6 is the cause of the trouble, operate the
7 Cause cannot be found out
machine for a while and see if the condition changes.
H- 5 Fine control performance or response is low

Failure informa-
q Fine control performance or response is low
tion
Control levers LS differential pressure
4.0 4.98 MPa
2
Presumed
cause and stan-
dard value in
normalcy
valve directly.
The LS circuit orifices (on pump side and control valve side) may be
3 Clogging of LS circuit orifice
clogged. Check them directly.
4 Malfunction of unload valve Control levers Unload pressure
3.90 4.88 MPa
{39.6 49.6 kg/cm2}
PC20MR-3 40-300 11
SEN04871-00 H- 6 Speed or power of boom is low
H- 6 Speed or power of boom is low

Failure infor-
q Speed or power of boom is low
mation
q Before carrying out troubleshooting, check that other work equipment, travel system, swing system,
and blade system are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or
Relative
power of whole work equipment, travel, swing, and blade speed is low".)
information
q Check the oil pressure and leakage from the cylinder while the hydraulic oil temperature is 45 55 C.
a Prepare with engine stopped, then run engine at high idling and car-
ry out troubleshooting.
Right work equipment control lever PPC valve output pressure
Malfunction of right PPC 0 MPa
1 Set in neutral
valve (boom circuit)
{0 kg/cm2}
Operate to raise boom 2.84 3.43 MPa
Operate to lower boom {29 35 kg/cm2}
Malfunction of boom control The boom control valve spool may have a malfunction. Check it
2
Presumed valve (spool) directly.
cause and Malfunction of boom control
The pressure compensation valve of the boom control valve may be
standard 3 valve (pressure compensa-
malfunction. Check it directly.
value in nor- tion valve)
malcy Malfunction or defective
The suction valve of the boom control valve may have a malfunction or
4 seal of boom control valve
defective seal. Check it directly.
(suction valve)
The centralized safety valve may be malfunctioning or its seal may be
Malfunction or defective
defective. Check the centralized safety valve directly. (A trouble in the
5 seal of centralized
centralized safety valve has effects on the arm, bucket, boom swing,
safety-suction valves
and blade, too.)
a Prepare with engine stopped, then run engine at high idling and car-
Defective seal of boom cyl- ry out troubleshooting.
6
inder Boom cylinder Leakage from cylinder
Relieve by raising boom 10 cc/min
40-300 12 PC20MR-3
H- 7 Speed or power of arm is low SEN04871-00
H- 7 Speed or power of arm is low

Failure
q Speed or power of arm is low
information
Relative
information
Left work equipment control lever PPC valve output pressure
Malfunction of left PPC valve 0 MPa
1 Set in neutral
(arm circuit)
{0 kg/cm2}
Operated to move arm IN 2.84 3.43 MPa
Operated to move arm OUT {29 35 kg/cm2}
Malfunction of arm control The arm control valve spool may have a malfunction. Check it
2
cause and Malfunction of arm control
The pressure compensation valve of the arm control valve may be
standard 3 valve (pressure compensation
value in nor- valve)
malcy Malfunction or defective seal
Since the suction valves of the arm control valve may have a mal-
4 of arm control valve (suction
function, check them directly.
valve)
Malfunction or defective seal
defective. Check the centralized safety valve directly. (A trouble in
5 of arm control valve (suction
the centralized safety valve has effects on the arm, bucket, boom
valve)
swing, and blade, too.)
6 Defective seal of arm cylinder
Arm cylinder Leakage from cylinder
Relieved in move-IN operation 10 cc/min
PC20MR-3 40-300 13
SEN04871-00 H- 8 Speed or power of bucket is low
H- 8 Speed or power of bucket is low

Failure infor-
q Speed or power of bucket is low
mation
Relative
information
Right work equipment control lever PPC valve output pressure
Malfunction of right PPC valve 0 MPa
1 Set in neutral
(bucket circuit)
{0 kg/cm2}
Operated to move CURL bucket 2.84 3.43 MPa
Operated to move bucket DUMP {29 35 kg/cm2}
Malfunction of bucket control The bucket control valve spool may have a malfunction. Check it
2
cause and Malfunction of bucket control
The pressure compensation valve of the bucket control valve may be
standard 3 valve (pressure compensation
value in nor- valve)
malcy Malfunction or defective seal
Since the suction valves of the bucket control valve may have a mal-
4 of bucket control valve (suc-
function, check them directly.
tion valve)
5 of centralized safety-suction
valves
Defective seal of bucket cylin- carry out troubleshooting.
6
der Bucket cylinder Leakage from cylinder
Relieved in move-CURL operation 10 cc/min
40-300 14 PC20MR-3
H- 9 Speed or power of boom swing is low SEN04871-00
H- 9 Speed or power of boom swing is low

Failure
q Speed or power of boom swing is low
information
q Before carrying out troubleshooting, check that other work equipment, travel system, swing system, and
blade system are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or power
Relative
of whole work equipment, travel, swing, and blade speed is low".)
information
Boom swing control pedal PPC valve output pressure
Malfunction of boom swing 0 MPa
1 Set in neutral
PPC valve
{0 kg/cm2}
2.84 3.43 MPa
Swing boom to right or left
{29 35 kg/cm2}
Malfunction of boom swing The boom swing control valve spool may have a malfunction. Check it
2
Presumed control valve (spool) directly.
cause and Malfunction of boom swing
The pressure compensation valve of the boom swing control valve
standard 3 control valve (pressure com-
may have a malfunction. Check it directly.
value in pensation valve)
normalcy Malfunction or defective seal
The suction valve of the boom swing control valve may have a mal-
4 of boom swing control valve
function. Check it directly.
(suction valve)
5 of centralized safety-suction
valves
Defective seal of boom swing carry out troubleshooting.
6
cylinder Boom swing cylinder Leakage from cylinder
Relieve at left swing 10 cc/min
PC20MR-3 40-300 15
SEN04871-00 H-10 Work equipment does not move in its single operation
H-10 Work equipment does not move in its single operation

(1) Boom does not move singly.
Failure informa- (2) Arm does not move singly.
tion (3) Bucket does not move singly.
(4) Boom swing system does not move singly.
Relative infor- q Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
mation q When starting troubleshooting, warm up the hydraulic oil to 45 55 C.

Work equipment control lever
Presumed PPC valve output pressure
and pedal
cause and stan- 1 Malfunction of PPC valve 0 MPa
dard value in Set lever in neutral
{0 kg/cm2}
normalcy
2.84 3.43 MPa
Operate lever
{29 35 kg/cm2}
Malfunction of control valve
2 The control valve spool may have a malfunction. Check it directly.
(spool)
H-11 Work equipment hydraulic drift is large

(1) Hydraulic drift of boom is large
Failure informa- (2) Hydraulic drift of arm is large
tion (3) Hydraulic drift of bucket is large
(4) Hydraulic drift of boom swing is large
mation q Check the leakage from the cylinder while the hydraulic oil temperature is 45 55 C.

Work equipment cylinder Leakage from cylinder
Defective seal of hydraulic
1 Relieved by boom RAISE
Presumed cylinder
Relieved by arm IN
cause and stan- 10 cc/min
Relieved by bucket CURL
dard value in
Relieved by boom SWING LEFT
normalcy
2 The control valve spool may be malfunctioning. Check it directly.
(spool)
The suction valve of the control valve may be malfunctioning.
3 (suction valve)
Check it directly.
[excluding boom swing]
40-300 16 PC20MR-3
H-12 Time lag of work equipment is large SEN04871-00
H-12 Time lag of work equipment is large

(1) Time lag of boom is large
Failure informa-
(2) Time lag of arm in large
tion
(3) Time lag of bucket in large
Relative infor-
q Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
mation
cause and stan-
Malfunction of control valve The suction valve of the control valve may have a malfunction.
dard value in 1
(suction valve) Check it directly.
normalcy
H-13 In compound operation of work equipment, speed of part loaded

more is low
Failure informa-
q In compound operation of work equipment, speed of part loaded more is low
tion
Relative infor-
mation
The pressure compensation valve of the control valve on less load
side may have a malfunction. Check it directly.
Presumed More load Less load
Combination of operations
cause and stan- Malfunction of pressure com- side side
dard value in 1 pensation valve on less load RAISE boom + Move arm IN Boom Arm
normalcy side RAISE boom + Move arm OUT Arm Boom
RAISE boom + CURL bucket Boom Bucket
Move arm OUT + CURL bucket Arm Bucket
LOWER boom + Move arm OUT Arm Boom
PC20MR-3 40-300 17
SEN04871-00 H-14 Machine deviates during travel
H-14 Machine deviates during travel

Failure informa-
(1) Machine deviates during ordinary travel
tion

The undercarriage may be defective. Check the following items.
q Check that the track shoe tension is adjusted evenly on both
1 Defective undercarriage sides.
q Check that the idlers, rollers, etc. are free from revolution trou-
ble, deformation, and damage.
Travel lever PPC valve output pressure
0 MPa
Malfunction of travel PPC Neutral
2 {0 kg/cm2}
valve 2.84 3.43 MPa
Operated to right, left, forward,
or reverse {29 35 kg/cm2}
Output difference of above Max. 0.4 MPa
Presumed between right and left {Max. 4 kg/cm2}
cause and stan- 3 Malfunction of travel control The travel control valve spool may be malfunctioning. Check it
dard value in valve (spool) directly.
normalcy Malfunction of travel control The pressure compensation valve (with right and left junction mech-
4 valve (pressure compensa- anism) of the travel control valve may be malfunctioning. Check it
tion valve) directly.
The seal of the center swivel joint may be defective. Check it
directly.
5 q Replace right and left hoses between the center swivel joint and
swivel joint
travel motor with each other. If the turning direction becomes op-
posite, the center swivel joint is defective.
The travel motor unit may be malfunctioning or its performance is
Malfunction or low perfor- low. Check it directly.
6 mance of travel motor (motor q Replace right and left hoses between the center swivel joint and
unit) travel motor with each other. If the turning direction does not
change, the motor is defective.
The final drive of the travel motor may be malfunctioning. Check it
Malfunction of travel motor
7 directly. (It can be judged by abnormal sound, abnormal heating,
(final drive)
quantity of metal dust in drained oil, etc.)
40-300 18 PC20MR-3
H-14 Machine deviates during travel SEN04871-00
Failure informa-
(2) Machine deviates when it starts (It does not deviate during ordinary travel)
tion

0 MPa
Malfunction of travel PPC Set in neutral
Presumed 1 {0 kg/cm2}
valve 2.84 3.43 MPa
cause and stan- Operate to drive left-right, for-
dard value in ward-reverse {29 35 kg/cm2}
normalcy Output difference between Max. 0.4 MPa
above both sides {Max. 4 kg/cm2}
Malfunction of travel motor The travel motor counterbalance valve may have a malfunction.
2
(counterbalance valve) Check it directly.
Malfunction of travel motor The travel motor holding brake may have a malfunction. Check it
3
(holding brake) directly.
PC20MR-3 40-300 19
SEN04871-00 H-15 Travel speed or travel power is low
H-15 Travel speed or travel power is low

Failure informa-
q Travel speed or travel power is low
tion
q Before carrying out troubleshooting, check that work equipment, swing system, and blade system
are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or power of whole
Relative infor-
work equipment, travel, swing, and blade speed is low".)
mation
q Check the oil pressure while the hydraulic oil temperature is 45 55 C.
The undercarriage may be defective. Check the following items.
q Check that the track shoe tension is adjusted evenly on both
1 Defective undercarriage sides.
q Check that the idlers, rollers, etc. are free from revolution trou-
ble, deformation, and damage.
Presumed carry out troubleshooting.
cause and stan- Travel lever PPC valve output pressure
Malfunction of travel PPC
dard value in 2 0 MPa
valve Neutral
normalcy {0 kg/cm2}
Operated to right, left, forward, 2.84 3.43 MPa
Malfunction of travel control The travel control valve spool may be malfunctioning. Check it
3
valve (spool) directly.
Malfunction of travel control
The pressure compensation valve of the travel control valve may be
4 valve (pressure compensa-
malfunctioning. Check it directly.
tion valve)
H-16 Machine is not steered well or steering power is low

Failure informa-
q Machine is not steered well or steering power is low
tion
Malfunction of travel PPC 0 MPa
1 Neutral
valve
{0 kg/cm2}
Presumed
Operated to right, left, forward, 2.84 3.43 MPa
cause and stan-
dard value in
normalcy Malfunction of travel control The travel control valve spool may be malfunctioning. Check it
2
Malfunction of travel control
The pressure compensation valve of the travel control valve may be
3 valve (pressure compensa-
tion valve)
Defective seal of center The seal of the center swivel joint may be defective. Check it
4
swivel joint directly.
40-300 20 PC20MR-3
H-17 Travel speed does not change SEN04871-00
H-17 Travel speed does not change

Failure informa-
q Travel speed does not change
tion
q The travel motor has the automatic speed change mechanism. If the travel load increases while
the machine is traveling in the high speed mode, the travel speed is set low automatically. (If the
Relative infor-
travel load decreases, the travel speed is set high again.)
mation
2nd travel speed
Travel speed shift- 2nd travel speed
Presumed Malfunction of 2nd travel selection solenoid
ing switch selection monitor
cause and stan- 1 speed selection solenoid valve output pressure
dard value in valve 0 MPa
Low speed mode OFF
normalcy {0 kg/cm2}
2.84 3.43 MPa
High speed mode ON
{29 35 kg/cm2}
Malfunction of travel motor The speed change section (selector valve and servo valve) of the
2
(speed change section) travel motor may be malfunctioning. Check it directly.
H-18 Travel motor does not work (one side only)

Failure informa-
q Travel motor does not work (one side only)
tion
Malfunction of travel PPC 0 MPa
1 Neutral
valve
Presumed {0 kg/cm2}
cause and stan- Operated to right, left, forward, 2.84 3.43 MPa
dard value in or reverse {29 35 kg/cm2}
normalcy Malfunction of travel control The travel control valve spool may be malfunctioning. Check it
2
Malfunction of travel motor The counterbalance valve of the travel motor may be malfunction-
3
(with counterbalance valve) ing. Check it directly.
Malfunction of travel motor The motor unit of the travel motor may be malfunctioning. Check it
4
(motor unit) directly.
PC20MR-3 40-300 21
SEN04871-00 H-19 Speed or power of swing is low
H-19 Speed or power of swing is low

Failure informa-
(1) Speed or power of swing is low in both directions
tion
q Before carrying out troubleshooting, check that work equipment, travel system, and blade system
Relative infor-
mation

Work equipment control levers Swing holding brake inlet pressure
Malfunction of shuttle valve 0 MPa
1 All levers in neutral
for swing holding brake {0 kg/cm2}
Presumed Operated to swing LEFT 2.84 3.43 MPa
cause and stan- Operated to swing RIGHT
dard value in Operated to arm IN {29 35 kg/cm2}
normalcy Malfunction of swing control The swing control valve spool may be malfunctioning. Check it
2
Malfunction or clogging of The parking brake section (selector valve, pressure reducing valve,
3 swing motor (parking brake and orifice) of the swing motor may be malfunctioning or clogged.
section) Check it directly.
Malfunction of swing motor The machinery section of the swing motor may be malfunctioning.
4
(machinery section) Check it directly.
40-300 22 PC20MR-3
H-19 Speed or power of swing is low SEN04871-00
Failure informa-
(2) Speed or power of swing is low in only 1 direction
tion

Work equipment control levers PPC valve output pressure
Malfunction of swing PPC 0 MPa
valve
{0 kg/cm2}
Operated to swing LEFT 2.84 3.43 MPa
Operated to swing RIGHT {29 35 kg/cm2}
Presumed
cause and stan- 2 All levers in neutral
dard value in for swing holding brake {0 kg/cm2}
normalcy Operated to swing LEFT 2.84 3.43 MPa
Operated to swing RIGHT
Operated to arm IN {29 35 kg/cm2}
Malfunction of swing control The swing control valve spool may be malfunctioning. Check it
3
Malfunction of swing motor Work equipment control levers Swing relief pressure
4
(safety valve) 15.22 17.18 MPa
Relieved by swing
(to right and left) {155 175 kg/cm2}
Malfunction of swing motor The suction valve of the swing motor may be malfunctioning.
5
PC20MR-3 40-300 23
SEN04871-00 H-20 Machine does not swing
H-20 Machine does not swing

Failure informa-
(1) Machine does not swing in either direction
tion
q Before carrying out troubleshooting, check that work equipment, travel system, and blade system
are normal. (If any of them is abnormal, perform troubleshooting for "H-2 Whole work equipment,
Relative infor-
travel system, swing system, and blade system do not work".)
mation

Presumed Operated to swing RIGHT
cause and stan- Operated to arm IN {29 35 kg/cm2}
dard value in Malfunction of swing control The swing control valve spool may be malfunctioning. Check it
2
normalcy valve (spool) directly.
Malfunction of swing motor The machinery section of the swing motor may be malfunctioning.
4
Malfunction of swing motor The motor unit of the travel motor may be malfunctioning. Check it
5
40-300 24 PC20MR-3
H-20 Machine does not swing SEN04871-00
Failure informa-
(2) Machine does not swing in only 1 direction
tion

valve
{0 kg/cm2}
Presumed 2 All levers in neutral
cause and stan- Operated to swing LEFT 2.84 3.43 MPa
dard value in Operated to swing RIGHT
normalcy Operated to arm IN {29 35 kg/cm2}
3
Malfunction of swing control
The load check valve in the spool of the swing control valve may be
4 valve (load check valve in
spool)
5
Relieved by swing
6
PC20MR-3 40-300 25
SEN04871-00 H-21 Swing acceleration performance is low
H-21 Swing acceleration performance is low

Failure informa-
(1) Swing acceleration performance is low in both directions
tion
Relative infor-
mation
1
Presumed Malfunction or clogging of The parking brake section (selector valve, pressure reducing valve,
cause and stan- 2 swing motor (parking brake and orifice) of the swing motor may be malfunctioning or clogged.
dard value in section) Check it directly.
normalcy Malfunction of swing motor The machinery section of the swing motor may be malfunctioning.
3
4
Failure informa-
(2) Swing acceleration performance is low in only 1 direction
tion

valve
{0 kg/cm2}
Presumed Malfunction of swing control The swing control valve spool may be malfunctioning. Check it
cause and stan- 2 valve (spool) directly.
dard value in Malfunction of swing control
The load check valve in the spool of the swing control valve may be
normalcy 3 valve (load check valve in
spool)
4
Relieved by swing
5
40-300 26 PC20MR-3
H-22 Machine overruns when it stops swinging SEN04871-00
H-22 Machine overruns when it stops swinging

Failure informa-
(1) Machine overruns when it stops swinging in both directions
tion
Relative infor-
mation
Presumed
cause and stan- 1
dard value in
normalcy 2
Failure informa-
(2) Machine overruns when it stops swinging in only 1 direction
tion

valve
{0 kg/cm2}
Presumed
cause and stan-
dard value in 2
normalcy
3
Relieved by swing
4 Malfunction of swing motor The suction valve of the swing motor may be malfunctioning.
PC20MR-3 40-300 27
SEN04871-00 H-23 Large shock is made when machine stops swinging
H-23 Large shock is made when machine stops swinging

Failure informa-
q Large shock is made when machine stops swinging
tion
mation q When starting troubleshooting, set the hydraulic oil temperature to 45 55 C.
Work equipment control lever PPC valve output pressure
1 Set all in neutral
valve
{0 kg/cm2}
Presumed Malfunction of shuttle valve The shuttle valve for the swing holding brake may be malfunction-
cause and stan- 2 for swing holding brake ing. Check it directly.
dard value in Malfunction of swing control Since the swing control valve spool may have a malfunction, check
3
normalcy valve (spool) it directly.
4
Relieved by swing
H-24 When upper structure stops swinging, it makes large sound

Failure informa-
q When upper structure stops swinging, it makes large sound
tion
Relative infor-
mation
Malfunction of back pres- The back pressure check valve may have a malfunction. Check it
1
sure check valve directly.
The swing motor safety valves may have a malfunction. Check the
Presumed Malfunction of swing motor
2 valves directly. (They may be checked by exchanging with each
cause and stan- (safety valve)
other and checking change of the phenomenon.)
dard value in
The swing motor suction valves may have a malfunction. Check
normalcy Malfunction of swing motor
3 the valves directly. (They may be checked by exchanging with
(suction valves)
each other and checking change of the phenomenon.)
Malfunction of swing motor The swing machinery portion of swing motor may have a malfunc-
4
(swing machinery) tion. Check it directly.
40-300 28 PC20MR-3
H-25 Hydraulic drift of swing is large SEN04871-00
H-25 Hydraulic drift of swing is large

Failure informa-
(1) While swing holding brake is applied
tion

Presumed 0 MPa
cause and stan- Malfunction or defective seal {0 kg/cm2}
dard value in 1 of swing motor (parking Operated to swing LEFT 2.84 3.43 MPa
normalcy brake section) Operated to swing RIGHT
Operated to arm IN {29 35 kg/cm2}
If the above oil pressure is normal, the parking brake section (selec-
tor valve, pressure reducing valve, and orifice) of the swing motor
may be malfunctioning or its seal is defective. Check it directly.
Failure informa-
(2) While swing holding brake is released
tion
Relative infor-
q Release the swing holding brake by swinging the boom and moving the arm IN.
mation
Defective seal of swing con- The seal of the swing control valve spool may be defective. Check
1
trol valve (spool) it directly.
The seal of the safety valve of the swing motor may be defective.
Presumed
Defective seal of swing Check it directly. (The sealing condition can be judged by replacing
cause and stan- 2
motor (safety valve) the right and left safety valves and checking the change of the phe-
dard value in
nomenon.)
normalcy
The seal of the suction valve of the swing motor may be defective.
Defective seal of swing Check it directly. (The sealing condition can be judged by replacing
3
motor (suction valve) the right and left suction valves and checking the change of the
phenomenon.)
PC20MR-3 40-300 29
SEN04871-00 H-26 Speed or power of blade is low
H-26 Speed or power of blade is low

Failure informa-
q Speed or power of blade is low
tion
q Before carrying out troubleshooting, check that work equipment, travel system, and swing system
Relative infor-
mation
q When starting troubleshooting, warm up the hydraulic oil to 45 55 C.
Blade control lever PPC valve output pressure
Malfunction of blade PPC 0 MPa
1 Set in neutral
valve
{0 kg/cm2}
2.84 3.43 MPa
Operate to raise or lower blade
Presumed {29 35 kg/cm2}
cause and stan- 2 Malfunction of blade control The blade control valve spool may have a malfunction. Check it
dard value in valve (spool) directly.
normalcy Malfunction of blade control
The load check valve in the blade control valve spool may have a
3 valve (load check valve in
spool)
Malfunction of blade control The suction valve of the blade control valve may have a malfunc-
4
valve (suction valve) tion. Check it directly.
Defective seal of blade cylin- carry out troubleshooting.
5
der Blade cylinder Leakage from cylinder
Relieve by lowering blade 10 cc/min
40-300 30 PC20MR-3
H-27 Blade does not move SEN04871-00
H-27 Blade does not move

Failure informa-
q Blade does not move
tion
q Before carrying out troubleshooting, check that work equipment, travel system, and swing system
are normal. (If any of them is abnormal, perform troubleshooting for "H-2 Whole work equipment,
travel system, swing system, and blade system do not work".)
Relative infor-
q Since the circuit from the gear pump through the swing control valve to the blade control valve is
mation
tandem, the blade does not operate while the swing system is operated.
q When starting troubleshooting, warm up the hydraulic oil to 45 55 C.
Blade control lever PPC valve output pressure
Malfunction of blade PPC 0 MPa
1 Set in neutral
valve
{0 kg/cm2}
Presumed 2.84 3.43 MPa
cause and stan- Operate to raise or lower blade
{29 35 kg/cm2}
dard value in Malfunction of blade control The blade control valve spool may have a malfunction. Check it
normalcy 2
3
Relieve by lowering blade 10 cc/min
Deformation of blade cylin-
4 The blade cylinder or blade is deformed. Check them directly.
der or blade
H-28 Hydraulic drift of blade is large

Failure informa-
q Hydraulic drift of blade is large
tion
Defective seal of blade con- The seal of blade control valve spool may be defective. Check it
1
trol valve (spool) directly.
Presumed
Defective seal of blade con- The blade control valve suction valve may have a malfunction.
cause and stan- 2
trol valve (suction valve) Check it directly.
dard value in
normalcy
3
Relieve by lowering 10 cc/min
PC20MR-3 40-300 31
SEN04871-00
2009 KOMATSU
All Rights Reserved
40-300 32
SEN04872-00
PC20MR-3
SEN04872-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

40 Troubleshooting
400 Troubleshooting of engine (S-mode)
Troubleshooting charts ............................................................................................................................... 2
PC20MR-3 40-400 1
SEN04872-00 Troubleshooting charts
Troubleshooting charts
Symptom of trouble
Engine out- Exhaust
Engine makes abnormal sound

Engine does not
Combustion sound is uneven

put is insuffi- gas color
start normally
cient is bad
Knocking sound is high

Engine starts Exhaust gas During
Engine does not start

but stops later color work
Exhaust
smoke
Normal
White
White
Much
Black
Black
None
Little
Improper intake/exhaust valve clearance Q Q Q Q
Leakage through valve seat Q Q Q Q
Seizure of intake/exhaust valve Q Q Q Q Q Q
Blow-off through head gasket Q
Seizure of breakage of piston ring Q Q Q Q Q
Wear of piston ring, piston, or cylinder Q Q Q Q
Seizure of crank pin bearing metal or bearing unit Q Q Q
Improper position of abutment joint Q Q
Reverse fitting of piston ring Q Q
Wear of crank pin and journal bearing metal Q Q
Looseness of connecting rod bolt Q
Entry of foreign matter in combustion chamber Q Q
Engine system
Increase of backlash of gears Q

Cause
Wear of intake/exhaust valve guide Q

Defective governor Q
Defective timing of intake/exhaust valve Q Q Q Q Q Q
40-400 2 PC20MR-3
Troubleshooting charts SEN04872-00
a This troubleshooting chart is transferred from the Shop Manual for 3D76E-6Engine.
Symptom of trouble
Engine
Lubricating oil Coolant Intake air
Engine speed does not lower quickly

hunts
Lubricating oil is consumed much
Lubricating oil is mixed in coolant

Lubricating oil is diluted with fuel
Much blow-by gas is produced

Lubricating oil pressure is low
Exhaust temperature is high

Coolant temperature is low
Intake air pressure is high

Intake air pressure is low
Fuel is consumed much
Engine vibrates largely
Remedy
Engine overheats
During idling
During work
Q Q Adjusting valve clearance

Q Q Q Q Fit valve seat
Q Q Q Q Q Repair or replace
Q Q Replace gasket
Q Q Q Q Q Q Q Replace piston ring
Q Q Q Finish by honing or use oversize parts
Q Q Q Q Repair or replace
Q Q Correct position of abutment joint
Q Q Correct assembly
Q Q Q Q Measure and replace
Q Q Tighten to specified torque
Q Q Disassemble and repair
Adjust meshing of gears
Q Q Measure and replace
Q Q Q Q Adjust
Adjusting valve clearance
PC20MR-3 40-400 3
Symptom of trouble
Engine out- Exhaust

Engine does not

start normally
cient is bad


Exhaust
smoke
Normal
White
White
Black
Black
Much
None
Little
Cooling capacity of radiator is large Q
Cooling capacity of radiator is small Q
Cooling system
Low coolant level Q

Cracked water jacket
Loosened fan belt Q
Default thermostat Q Q
Improper properties of lubricating oil Q Q Q

Lubricating oil system
Leakage through lubricating oil piping

Insufficient discharge from trochoid pump
Clogging of lubricating oil filter
Defective pressure regulator valve
Insufficient lubricating oil Q
Cause
Advance of fuel injection timing Q Q Q

Lagging of fuel injection timing Q Q Q Q
Improper properties of fuel Q Q Q Q Q Q
Entry of water in fuel Q Q Q Q Q
Clogging of fuel filter Q Q Q
Entry of air in fuel system Q Q Q
Fuel system
Clogging or cracking of fuel pipe Q Q Q

Insufficient supply of oil to fuel injection pump Q Q Q
Uneven injection by fuel injection pump Q Q Q Q Q
Excessive fuel injection rate Q
Defective fuel spray from fuel injection nozzle Q Q Q Q Q
Priming pump is defective Q
Clogging of strainer at feed pump inlet Q
40-400 4 PC20MR-3
Troubleshooting charts SEN04872-00
Symptom of trouble
Engine
Lubricating oil Coolant Intake air

hunts




Remedy
Engine overheats
During idling
During work
Q Q Defective thermostat (kept closed)

Defective thermostat (kept open)
Q Q
Slip of fan belt
Q Q Check coolant system for leakage
Q Q Q Repair or replace
Q Q Adjust belt tension
Q Q Inspect or replace
Q Q Q Use proper lubricating oil

Q Q Repair
Q Inspect and repair
Q Q Clean or replace
Q Clean, adjust or replace
Q Supply proper lubricating oil
Q Inspect and adjust

Q Q Inspect and adjust
Use proper fuel
Q Q Drain water from fuel system
Clean or replace
Bleed air
Clean or replace
Check fuel tank valve, fuel filter, fuel pipe,
and fuel feed pump
Q Q Q Q Inspect and adjust
Q Q Q Q Q Q Inspect and adjust
Q Q Q Q Inspect and adjust
Dirt in primping pump (Disassemble and
clean)
Clean strainer
PC20MR-3 40-400 5
Symptom of trouble
Engine out- Exhaust

Engine does not

start normally
cient is bad


Exhaust
smoke
Normal
White
White
Black
Black
Much
None
Little
Clogging of air cleaner Q Q Q Q
Air intake/Exhaust gas system
High ambient temperature or use of engine at high

Q Q
altitude
Clogging of exhaust pipe Q Q Q
Defective starting motor Q

Defective alternator Q
Electrical system
Disconnection of wire Q
Cause
Low battery voltage Q
40-400 6 PC20MR-3
During idling
hunts
Engine
During work
PC20MR-3

Troubleshooting charts
Q

Lubricating oil

Q
Engine overheats

Q
Q

Symptom of trouble
Coolant Intake air

Q Clean
Clean
Repair
Repair or replace
Repair or replace
Inspect and charge

Remedy
Examine matching of output and load
40-400
7
SEN04872-00
SEN04872-00
2009 KOMATSU
All Rights Reserved
40-400 8
SEN04873-00
PC20MR-3
SEN04873-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

40 Troubleshooting
500Troubleshooting of Machine monitor
System(M-mode)
Before starting M-mode troubleshooting..................................................................................................... 2

M- 1 When starting switch is turned ON, no monitor/gauge operates ........................................................ 5
M- 2 When starting switch is turned ON, some monitors/gauges do not operate ....................................... 7
M- 3 Caution buzzer does not sound or does not stop sounding................................................................ 8
M- 4 While engine is running, engine oil pressure monitor flashes............................................................. 10
M- 5 While engine is running, charge level monitor flashes........................................................................ 11
M- 6 Preheating system does not operate .................................................................................................. 13
M- 7 Coolant temperature gauge does not indicate normally ..................................................................... 15
M- 8 Fuel level gauge does not indicate normally....................................................................................... 18
M- 9 Service meter does not operate while engine is running .................................................................... 20
M-10Travel speed shifting system does not operate normally.................................................................... 21
M-11 Machine monitor night lamp and working lamp do not right up ......................................................... 24
PC20MR-3 40-500 1
500 Troubleshooting of Machine monitor System(M-mode)
SEN04873-00 Before starting M-mode troubleshooting
Before starting M-mode troubleshooting
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power di-
rectly (A switch power supply is a device which supplies power while the starting switch is at the ON po-
sition and a constant power supply is a device which supplies power while the starting switch is at the OFF
position).
a When carrying out troubleshooting related to the electric system, you should check the fuse box to see if
the power is supplied normally.
Fuse box (FB1)

Type of power sup-
Fuse No. Fuse capacity Destination of power
ply
Switch power sup-
1
ply 30A (Cab)
(Between termi- Work lamp
(Starting switch ter- 10A (Canopy)
nal 1 11)
minal BR)
Horn
2 PPC lock solenoid valve
(Between termi- 10A Fuel pump
nal 2 12) Safety relay (ACC signal)
Alternator (ACC signal)
3 Machine monitor (Switch power supply)
(Between termi- 10A Alarm buzzer
Switch power sup- nal 3 13) 2nd travel speed selection solenoid valve
ply 4
KOMTRAX terminal, Connector (For service)
(Starting switch ter- (Between termi- 10A
PPC lock switch (LEFT), Relay (For starting motor)
minal ACC) nal 4 14)
Heater [Canopy specification]
5 10A (Canopy)
Travel alarm [Canopy specification]
(Between termi-
Heater [Cab specification]
nal 5 15) 20A (Cab)
Travel alarm [Cab specification]
6 Wiper motor [Cab specification]
(Between termi- 20A (Cab) Radio [Cab specification]
nal 6 16) Room lamp [Cab specification], Cigarette lighter
7 Engine stop solenoid relay
(Between termi- 10A
Constant power Engine stop solenoid,Timer
nal 7 17)
supply
8 (Canopy): Relay (For PPC lock solenoid), Connector (For ser-
(Fusible link : M4)
(Between termi- 10A vice ), Machine monitor, KOMTRAX terminal)
nal 8 18) (Cab): Canopy + Radio
9 (Unused)
10 (Unused)
40-500 2 PC20MR-3
Before starting M-mode troubleshooting SEN04873-00
Locations of fusible link (M4) and fuse box (FB1) and fuse No.
PC20MR-3 40-500 3
SEN04873-00 Information contained in troubleshooting table
a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their
contents fully before proceeding to actual troubleshooting work.
Failure informa-
tion
Related infor-
Information on the failure occurred as well as the troubleshooting
mation
<Content Included>
q Standard value in normalcy by which to pass "good" or "no
good" judgement over the presumed cause
1
q Reference for passing the above "good" or "no good"
judgement
<Phenomenon of Wiring Harness Failure>

q Disconnection
There is a faulty contact at the connector or disconnection
of wiring harness occurred.
q Defective grounding
2 A wiring harness that is not connected with a grounding
circuit has a contact with the grounding circuit.
q Short-circuiting
A wiring harness that is not connected with a 12 V electric
Cause that presumably circuit has a contact with the electric circuit.
Presumed
triggered failure in ques-
cause and stan-
tion(The assigned No. is <Precaution for Troubleshooting>
dard value in
for filing purpose only. It 1) Connector No. display method and handling of T-adapter
normalcy
does not stand for any pri- Insert or connect T-adapters in the following manner before
ority) starting troubleshooting unless otherwise instructed.
q If there is no indication of "male" or "female" in a specif-
ic connector No., disconnect the connector and insert
the T-adapter into both male and female sides.
q If there is an indication of "male" or "female" in a specif-
ic connector No., disconnect the connector and connect
3 the T-adepter with only one side of either "male" or "fe-
male".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative () lead OFF
a circuit tester in the following manner unless otherwise in-
structed.
q Connect the positive (+) lead with the pin No. indicated
q Connect the negative () lead with the pin No. indicated
Related circuit diagram
This is part of the electrical circuit diagram

which shows the portion where the failure
occurred.
q Connector No.: Indicates (Type - numbers of
a pin) (color)
q Arrow (io): Indicates the rough location on
the machine
40-500 4 PC20MR-3
M- 1 When starting switch is turned ON, no monitor/gauge operates SEN04873-00
M- 1 When starting switch is turned ON, no monitor/gauge operates

Failure informa-
q When starting switch is turned ON, no monitor/gauge operates
tion
q If the starting switch is turned ON, the caution buzzer sounds for 1 second and all the monitor lamps
Related infor- (6 pieces) light up for about 3 seconds.
mation q If the starting switch is turned ON, the gauges (2 pieces) start display (There is a little time lag but
it does not indicate a fault).
Cause Standard value in normal state/Remarks on troubleshooting
Low charge level of battery Battery voltage Electrolyte specific gravity
1 or low electrolyte specific
Min. 12 V Min. 1.26
gravity
If the fusible link is broken, the circuit probably has a grounding fault.
2 Defective fusible link
(See Cause 6.)
3
7 Cause 6.)
Defective starting switch
4 Starting switch Position of switch Resistance
Wiring harness between battery () and
Resistance Max. 1
chassis ground
Wiring harness between T-M1 (+) and M4
Resistance Max. 1
(female) (1)
Disconnection in wiring har- Wiring harness between M4 (female) (2) and
Resistance Max. 1
ness T-F1 (B) or FB1 (8)
5
(Disconnection or defective Wiring harness between FB1 (18) and F15
Resistance Max. 1
Possible causes contact in connector) (female) (20)
and standard Wiring harness between T-F3 (ACC) and
Resistance Max. 1
value in normal FB1 (3)
state Wiring harness between FB1 (13) and F15
Resistance Max. 1
(female) (19)
Wiring harness between F15 (female) (1)
Resistance Max. 1
and chassis ground (T-M7)
Between T-M1 (+) M4 (female) (1) wiring
Resistance Min. 1 M
harness and chassis ground
Between M4 (female) (2) T-F1 (B) or FB1
(8) or other related circuit wiring harness and Resistance Min. 1 M
Ground fault in wiring har- chassis ground
ness Between FB1 (18) F15 (female) (1) or
6
(Contact with ground cir- other related circuit wiring harness and Resistance Min. 1 M
cuit) chassis ground
related circuit wiring harness and chassis Resistance Min. 1 M
ground
other related circuit wiring harness and Resistance Min. 1 M
chassis ground
If none of causes 1 6 is the cause of the trouble, the monitor panel
7 Defective machine monitor may be defective (Troubleshooting cannot be carried out since the
defect is in the monitor panel).
PC20MR-3 40-500 5
SEN04873-00 M- 1 When starting switch is turned ON, no monitor/gauge operates
Circuit diagram related to monitor panel power supply
40-500 6 PC20MR-3
M- 2 When starting switch is turned ON, some monitors/gauges do not operate SEN04873-00
M- 2 When starting switch is turned ON, some monitors/gauges do not

operate
Failure informa-
q When starting switch is turned ON, some monitors/gauges do not operate.
tion
q If the starting switch is turned ON, the caution buzzer sounds for 1 second and all the monitor lamps
Related infor- (6 pieces) light up for about 3 seconds.
mation q If the starting switch is turned ON, the gauges (2 pieces) start display (There is a little time lag but
it does not indicate a fault).
Presumed Causes Standard value in normalcy and references for troubleshooting
cause and stan-
The machine minitor may be defective (Troubleshooting cannot be
dard value in 1 Defective machine monitor
carried out since the defect is in the machine monitor).
normalcy
PC20MR-3 40-500 7
SEN04873-00 M- 3 Caution buzzer does not sound or does not stop sounding
M- 3 Caution buzzer does not sound or does not stop sounding

Failure informa-
(1) Alarm buzzer does not sound
tion
q If the starting switch is turned ON, the caution buzzer sounds for 1 second.
Related infor-
q If the engine oil pressure monitor, charge level monitor, or coolant temperature gauge pilot lamp
mation
flashes or the preheater monitor goes off, the caution buzzer sounds.
a Prepare with starting switch OFF
F28 Starting switch Voltage
Defective alarm buzzer 1 sec: 10 15 V
1 Between (1) (2) OFF o ON
(Internal disconnection) 1 sec and after: Max. 1 V
If the voltage is normal but the buzzer does not sound just after the
starting switch is turned ON, the caution buzzer is defective.
Presumed
cause and stan-
Disconnection in wiring without turning starting switch.
dard value in
harness Wiring harness between FB1 (13) and F28
normalcy 2 Resistance Max. 1
(Disconnection or defec- (female) (2)
tive contact in connector) Wiring harness between F28 (female) (1)
Resistance Max. 1
and F15 (female) (11)
3 Defective machine monitor
Between (11) and 1 sec: Max. 1 V
OFF o ON
chassis ground 1 sec and after: 10 15 V
Failure informa-
(2) Alarm buzzer does not stop sounding
tion
Related infor-
mation
Defective caution buzzer without turning starting switch.
1
(Internal disconnection) F28 (male) Resistance
Between (1) and chassis ground Min.1 M
Presumed Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
cause and stan- ness without turning starting switch.
2
dard value in (Contact with ground cir- Between F28 (female) (1) F15 (female)
Resistance Min.1 M
normalcy cuit) (11) wiring harness and chassis ground
3 Defective machine monitor 1 sec: Max. 1 V
Between (11) and
OFF o ON 1 sec and after: 10 15
chassis ground
V
40-500 8 PC20MR-3
M- 3 Caution buzzer does not sound or does not stop sounding SEN04873-00
Circuit diagram related to alarm buzzer
PC20MR-3 40-500 9
SEN04873-00 M- 4 While engine is running, engine oil pressure monitor flashes
M- 4 While engine is running, engine oil pressure monitor flashes

Failure informa-
q While the engine is running, the engine oil pressure monitor flashes.
tion
q If low engine oil pressure is detected while the engine is running, the engine oil pressure monitor
Related infor- flashes and the caution buzzer sounds.
mation q While the starting switch is in the ON position, the engine oil pressure monitor keeps lighting (Nor-
mal).
1 Low engine oil pressure Check the engine oil pressure. If it is low, repair it.
Defective engine oil pres- and start engine and carry out troubleshooting.
2 sure switch T-M3 (Switch side) Engine Resistance
(Internal short circuit) Between terminal Stopped Max. 1
and chassis ground Running Min.1 M
Presumed
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
cause and stan-
ness without turning starting switch.
dard value in 3
(Contact with ground cir- Between F15 (female) (7) T-M3 wiring har-
normalcy Resistance Min.1 M
cuit) ness and chassis ground
and start engine and carry out troubleshooting.
F15 Engine Voltage
4 Defective machine monitor
Stopped
Between (7) and Max. 1 V
(starting switch ON)
chassis ground
Running 10 15 V
Circuit diagram related engine oil pressure switch
40-500 10 PC20MR-3
M- 5 While engine is running, charge level monitor flashes SEN04873-00
M- 5 While engine is running, charge level monitor flashes

Failure informa-
q While engine is running, charge level monitor flashes.
tion
q If low charge voltage is detected while the engine is running, the charge level monitor flashes and
Related infor-
the caution buzzer sounds.
mation
q While the starting switch is in the ON position, the charge level monitor keeps lighting (Normal).
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting
Defective alternator
1 M7 (male) Engine speed Voltage
(Defective charge)
Between (1) and Medium (Half) or
13.5 14.5 V
ground higher
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
Presumed 2
(Disconnection or defective Wiring harness between F15 (female) (17)
cause and stan- Resistance Max. 1
contact in connector) and M7 (female) (1)
dard value in
normalcy Ground fault in wiring har-
3 ness
Between F15 (female) (17) M7 (female)
(Contact with ground circuit) Resistance Min. 1 M
(1)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
4 Defective machine monitor F15 Engine speed Voltage
Between (17) and Medium (Half) or
13.5 14.5 V
chassis ground higher
PC20MR-3 40-500 11
SEN04873-00 M- 5 While engine is running, charge level monitor flashes
40-500 12 PC20MR-3
M- 6 Preheating system does not operate SEN04873-00
M- 6 Preheating system does not operate

Failure informa-
(1) When the starting switch is set in the HEAT position, the preheater monitor does not indicate.
tion
q If the starting switch is set in the HEAT position, the preheater monitor starts flashing and goes off
Relative infor- about 18 seconds later.
mation q Before carrying out troubleshooting, check that the starting motor revolves normally. (If the starting
motor does not revolve, carry out troubleshooting for "E-1 Engine does not start" first.)
If the preheater does not operate either (If the intake air heater
1 Defective starting switch
does not become hot), carry out troubleshooting for Trouble (2).
Presumed ness without turning starting switch.
2
cause and stan- (Disconnection or defective Wiring harness between F15 (female) (8) Resis-
Max. 1
dard value in contact of connector) and branching point of circuit tance
normalcy a Prepare with starting switch OFF, then hold starting switch in
OFF and HEAT and carry out troubleshooting.
3 Defective machine monitor F15 Starting switch Voltage
Between (8) and OFF Max. 1 V
chassis ground HEAT 10 15 V
Failure informa-
(2) When the starting switch is set in the HEAT position, the intake air heater does not become hot.
tion
q If the starting switch is set in the HEAT position, the preheater monitor starts flashing and goes off
Relative infor- about 18 seconds later.
mation q Before carrying out troubleshooting, check that the starting motor revolves normally. (If the starting
motor does not revolve, carry out troubleshooting for "E-1 Engine does not start" first.)
OFF and HEAT and carry out troubleshooting.
and T-F5 (R1) HEAT Max. 1
Presumed
HEAT and carry out troubleshooting.
cause and stan-
M15 (female) Starting switch Voltage
dard value in Defective air heater
2 Between (1) and
normalcy (Internal disconnection) HEAT 10 15 V
chassis ground
If the voltage is normal but the intake air heater mounting part does
not become hot, the intake air heater is defective.
3
(Disconnection or defective Wiring harness between T-F5 (R1) and M15 Resis-
Max. 1
PC20MR-3 40-500 13
SEN04873-00 M- 6 Preheating system does not operate
40-500 14 PC20MR-3
M- 7 Coolant temperature gauge does not indicate normally SEN04873-00
M- 7 Coolant temperature gauge does not indicate normally

Failure informa- (1) The coolant temperature rises normally, but the coolant temperature gauge does not rise from
tion C-level.
Related infor-
mation
M8 (male) Coolant temperature Resistance
25C 38.18 47.77 k
Defective coolant tempera- 30C 31.59 39.07 k
1 ture sensor 80C 6.199 6.953 k
(Internal disconnection) 85C 5.386 5.976 k
Between (1) and (2)
90C 4.469 5.166 k
95C 4.107 4.448 k
100C 3.604 3.903 k
Presumed
105C 3.157 3.426 k
cause and stan- a Prepare with starting switch OFF, then carry out troubleshooting
dard value in Disconnection in wiring har- without turning starting switch.
normalcy ness Wiring harness between F15 (female) (16) Resis-
2 Max. 1
(Disconnection or defective and M8 (female) (1) tance
contact in connector) Wiring harness between F15 (female) (10) Resis-
Max. 1
and M8 (female) (2) tance
Between F15 (female) (16) M8 (female) (1)
If none of causes 1 3 is the cause of the trouble, the machine
4 Defective machine monitor monitor may be defective (Troubleshooting cannot be carried out
since the defect is in the machine monitor).
PC20MR-3 40-500 15
SEN04873-00 M- 7 Coolant temperature gauge does not indicate normally
Failure informa-
(2) The coolant temperature is stabilized normally, but the coolant temperature gauge rises to H-level.
tion
Related infor-

mation
25C 38.18 47.77 k
30C 31.59 39.07 k
1 ture gauge 85C 5.386 5.976 k
Between (1) and (2)
Presumed
95C 4.107 4.448 k
cause and stan-
100C 3.604 3.903 k
dard value in 105C 3.157 3.426 k
normalcy Between (1) and
All range Min. 1 M
chassis ground
Ground fault in wiring har-
2 ness
Between F15 (female) (16) M8 (female)
(Contact with ground circuit) Resistance Min. 1 M
(1) wiring harness and chassis ground
If neither of causes 1 2 is the cause of the trouble, the machine
3 Defective machine monitor monitor may be defective (Troubleshooting cannot be carried out
since the defect is in the machine monitor).
Failure informa- (3) The temperature indicated by the coolant temperature gauge is largely different from the actual
tion coolant temperature.
Related infor-
mation
25C 38.18 47.77 k
30C 31.59 39.07 k
Presumed
1 ture sensor 85C 5.386 5.976 k
cause and stan- Between (1) and (2)
dard value in
95C 4.107 4.448 k
normalcy 100C 3.604 3.903 k
105C 3.157 3.426 k
Between (1) and
All range Min. 1 M
chassis ground
If neither of causes 1 is the cause of the trouble, the machine moni-
2 Defective machine monitor tor may be defective (Troubleshooting cannot be carried out since
the defect is in the machine monitor).
40-500 16 PC20MR-3
M- 7 Coolant temperature gauge does not indicate normally SEN04873-00
Circuit diagram related to engine coolant temperature sensor
PC20MR-3 40-500 17
SEN04873-00 M- 8 Fuel level gauge does not indicate normally
M- 8 Fuel level gauge does not indicate normally

Failure informa-
(1) There is enough fuel in the tank, but the fuel level gauge does not rise from E-level.
tion
Related infor-

mation
Position of sensor
float
Defective fuel level sensor
1 FULL 10 (+1.0/-0.5)
3/4 (19 )
Between (1) and (2) 1/2 32 3
1/4 (49.5 )
EMPTY 80 (+12/-2)
Presumed
cause and stan- Disconnection in wiring without turning starting switch.
dard value in harness Wiring harness between F15 (female) (13) Resis-
normalcy 2 Max. 1
(Disconnection or defec- and M2 (female) (3) tance
tive contact in connector) Wiring harness between M2 (female) (2) and Resis-
Max. 1
chassis ground (T-M7) tance
Between F15 (female) (13) M2 (female) (3)
If none of causes 1 3 is the cause of the trouble, the machine mon-
4 Defective machine monitor itor may be defective (Troubleshooting cannot be carried out since
the defect is in the machine monitor).
Failure informa-
(2) The fuel level in the tank is low, but the fuel level gauge does not lower from F-level.
tion
Related infor-
mation
Position of sensor
float
FULL 10 (+1.0/-0.5)
Defective fuel level sensor
1 3/4 (19 )
Between (1) (2) 1/2 32 3
Presumed
1/4 (49.5 )
cause and stan-
EMPTY 80 (+12/-2)
dard value in Between (1) and
normalcy All range Min.1 M
chassis ground
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
2
(Contact with ground cir- Between F15 (female) (13) M2 (female) (3)
Resistance Min.1 M
cuit) wiring harness and chassis ground
If none of causes 1 2 is the cause of the trouble, the machine moni-
Defective machine moni-
3 tor may be defective (Troubleshooting cannot be carried out since the
tor
defect is in the machine monitor).
40-500 18 PC20MR-3
M- 8 Fuel level gauge does not indicate normally SEN04873-00
Failure informa-
(3) The fuel level indicated by the fuel level gauge is largely different from the actual fuel level.
tion
Related infor-

mation
Position of sensor Resistance(refer-
M2 (male)
Presumed Defective fuel level sensor float ence value)
1 FULL 10 (+1.0/-0.5)
cause and stan- (Ddefective internal)
3/4 (19 )
dard value in
Between (1) and (2) 1/2 32 3
normalcy
1/4 (49.5 )
EMPTY 80 (+12/-2)
If cause 1 is not the cause of the trouble, the machine monitor may
2 Defective machine monitor be defective (Troubleshooting cannot be carried out since the
Circuit diagram related to fuel level sensor
PC20MR-3 40-500 19
SEN04873-00 M- 9 Service meter does not operate while engine is running
M- 9 Service meter does not operate while engine is running

Failure informa-
q Service meter does not operate while engine is running
tion
Related infor-
q The service meter is operated with the charge signal from the alternator.
mation
Presumed Defective charge level moni- If the charge level monitor flashes, carry out troubleshooting for
1
cause and stan- tor "M-5 While engine is running, charge level monitor flashes".
dard value in If cause 1 is not the cause of the trouble, the machine monitor may
normalcy 2 Defective machine monitor be defective (Troubleshooting cannot be carried out since the
40-500 20 PC20MR-3
M-10Travel speed shifting system does not operate normally SEN04873-00
M-10Travel speed shifting system does not operate normally

Failure informa- (1) When the travel speed shifting switch is operated, the 2nd travel speed selection monitor panel
tion does not light up or go off.
Related infor-
q If the travel speed does not change, carry out troubleshooting for troubles (2) and (3).
mation
Presumed Causes Standard value in normalcy and references for troubleshooting
cause and stan-
The machine monitor may be defective (Troubleshooting cannot be
carried out since the defect is in the monitor panel).
normalcy
Failure informa-
(2) When the high speed mode is selected, the machine keeps traveling at low speed.
tion
q The 2nd travel speed selection monitor is turned ON in the high speed monitor.
Related infor- q The travel motor has the automatic speed change mechanism. If the travel load increases while the
mation machine is traveling in the high speed mode, the travel speed is set low automatically. (If the travel
load decreases, the travel speed is set high again.)
If the fuse is broken, the circuit probably has a grounding fault. (See
Cause 6.)
Between T-F1 (B) OFF Min.1 M
Defective relay for 2nd
Between (1) and (2) 86 106
travel speed selection sole-
3 Between (3) and (4) Max. 1
noid (Internal disconnec-
Between (3) and (5) Min.1 M
tion) When relay (R4) for the 2nd travel speed selection solenoid is
replaced with another one, if the condition becomes normal, relay
Presumed (R4) is defective.
cause and stan- a Prepare with starting switch OFF, then carry out troubleshooting
Defective 2nd travel speed
dard value in without turning starting switch.
selection solenoid valve
normalcy 4 M13 (male) Resistance
(Internal disconnection or
Between (1) and (2) 10.5 12
short circuit)
Between (1) and chassis ground Min.1 M
Wiring harness between T-F3 (ACC) and
Resistance Max. 1
FB1 (3)
Wiring harness between FB1 (13) and R4
Resistance Max. 1
Disconnection in wiring (female) (3)
harness Wiring harness between F15 (female) (16)
5 Resistance Max. 1
(Disconnection or defec- and R4 (female) (1)
tive contact in connector) Wiring harness between R4 (female) (2) and
Resistance Max. 1
Wiring harness between R4 (female) (5) and
Resistance Max. 1
M13 (female) (1)
Wiring harness between M13 (female) (2)
Resistance Max. 1
and chassis ground (T-M7)
PC20MR-3 40-500 21
SEN04873-00 M-10Travel speed shifting system does not operate normally

related circuit wiring harness and chassis Resistance Min.1 M
Ground fault in wiring har- ground
ness Between FB1 (15) R4 (female) (3) or other
6
Presumed (Contact with ground cir- related circuit wiring harness and chassis Resistance Min.1 M
cause and stan- cuit) ground
dard value in Between F15 (female) (15) R4 (female) (1)
Resistance Min.1 M
normalcy wiring harness and chassis ground
Resistance Min.1 M
7 Defective machine monitor F15 Position of switch Voltage
Between (15) and Low speed mode 10 15 V
chassis ground High speed mode Max. 1 V
Failure informa-
(3) When the low speed mode is selected, the machine keeps traveling at high speed.
tion
Related infor-
The 2nd travel speed selection monitor is turned OFF in the low speed monitor.
mation
Defective relay for 2nd travel Between (1) and (2) 86 106
1 speed selection solenoid Between (3) and (4) Max. 1
(Internal disconnection) Between (3) and (5) Min.1 M
When relay (R4) for the 2nd travel speed selection solenoid is
replaced with another one, if the condition becomes normal, relay
(R4) is defective.
Defective 2nd travel speed M13 (male) Resistance
Presumed selection solenoid valve Between (1) and (2) 10.5 12
2
cause and stan- (Internal disconnection or Between (1) and chassis ground Min.1 M
dard value in short circuit) When connector M13 is disconnected, if the condition does not
normalcy become normal, the 2nd travel speed selection solenoid may be
burnt or seized.
3 source in wiring harness Voltage Max. 1 V
Voltage Max. 1 V
Travel speed shifting
4 Defective machine monitor F15 Voltage
switch
Between (15) and Low speed mode 10 15 V
chassis ground High speed mode Max. 1 V
40-500 22 PC20MR-3
M-10Travel speed shifting system does not operate normally SEN04873-00
Circuit diagram related to travel speed acceleration solenoid
PC20MR-3 40-500 23
SEN04873-00 M-11 Machine monitor night lamp and working lamp do not right up
M-11 Machine monitor night lamp and working lamp do not right up
Failure informa-
(1) When the lamp switch is turned ON, the night lamp of the machine monitor does not light up.
tion
Relative infor- q If the working lamp and additional working lamp do not light up either, carry out troubleshooting for
mation troubles (2) and (3).
cause and stan-
The machine monitor may be defective (Troubleshooting cannot be
carried out since the defect is in the monitor panel).
normalcy
Failure informa-
(2) When the lamp switch is turned ON, the working lamp does not light up [Canopy specification]
tion
Relative infor-

mation
Defective working lamp
1 The bulb of the working lamp may be broken. Check it directly.
(Broken bulb)
Defective fuse No. 3 or No. If the fuse is broken, the circuit probably has a grounding fault.
2
8 (See Cause 6.)
Resistance Max. 1
Disconnection in wiring har- FB1 (1)
ness Wiring harness between FB1 (11) and F15
4 Resistance Max. 1
(Disconnection or defective (female) (12)
Presumed
contact in connector) Wiring harness between W1 (female) and
cause and stan- Resistance Max. 1
working lamp
dard value in
Wiring harness between W1 (male) (2) and
normalcy Resistance Max. 1
Ground fault in wiring har-
ground
5 ness
ground
Between W1 (female) working lamp wir-
Resistance Min. 1 M
ing harness and chassis ground
6 Defective machine monitor F15 Lamp switch Voltage
Between (12) and OFF 10 15 V
chassis ground ON Max. 1 V
40-500 24 PC20MR-3
M-11 Machine monitor night lamp and working lamp do not right up SEN04873-00
Failure informa-
(3) When the lamp switch is turned ON, the working lamp does not light up [Cab specification]
tion
Relative infor-

mation
Defective working lamp
1 The bulb of the working lamp may be broken. Check it directly.
(Broken bulb)
2
8 Cause 7.)
Resistance Max. 1
FB1 (1)
Disconnection in wiring har- Wiring harness between FB1 (11) and F15
Resistance Max. 1
ness (female) (12)
4
(Disconnection or defec- Wiring harness between W1 (female) and
Resistance Max. 1
Presumed tive contact of connector) working lamp
cause and stan- Wiring harness between F22 (female) and
Resistance Max. 1
dard value in additional working lamp
normalcy Wiring harness between W1 (male) (2) or
Resistance Max. 1
F22 (male) (2) and chassis ground (T-M7)
a out turning starting switch.
ground
Ground fault in wiring har- Between FB1 (11) F15 (female) (12) or
5 ness related circuit wiring harness and chassis Resistance Min. 1 M
(Contact with ground circuit) ground
Between W1 (female) working lamp wiring
Resistance Min. 1 M
harness and chassis ground
Between F22 (female) additional working
Resistance Min. 1 M
lamp wiring harness and chassis ground
6 Defective machine monitor F15 Lamp switch Voltage
Between (12) and OFF 10 15 V
chassis ground ON Max. 1 V
PC20MR-3 40-500 25
SEN04873-00 M-11 Machine monitor night lamp and working lamp do not right up
Circuit diagram related to working lamp and additional working lamp
40-500 26 PC20MR-3
M-11 Machine monitor night lamp and working lamp do not right up SEN04873-00
PC20MR-3 40-500 27
SEN04873-00
2009 KOMATSU
All Rights Reserved
40-500 28
SEN04874-00
PC20MR-3
SEN04874-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


100 General information on disassembly
and assembly
How to read this manual ............................................................................................................................. 2

Coating materials list................................................................................................................................... 4
Special tool list ............................................................................................................................................ 7
PC20MR-3 50-100 1
100 General information on disassembly and assembly
SEN04874-00 How to read this manual
How to read this manual
Removal and installation of assemblies
Special tools Installation of parts
q Special tools that are deemed necessary for re- q Except where otherwise instructed, install parts
moval or installation of parts are listed. is the reverse order of removal.
q List of the special tools contains the following q Instructions and precautions for installing part
kind of information. are shown with [*1] mark in the Installation sec-
1) Necessity tion, identifying which step the instructions are
t: Special tools which cannot be substituted, intended for.
should always be used. q Marks shown in the Installation section stand for
q: Speciall tools which are very useful if the following.
available, can be substituted with k This mark indicates safety-related pre-
commercially available tools. cautions, which must be followed when
doing the work.
2) Distinction of new and existing special tools. a This marks gives guidance or precautions
N : Tools with new part numbers, newly when doing the procedure.
developed for this model. 2 This mark stands for a specific coating
R : Tools with upgraded part numbers, agent to be used.

remodeled from already available tools for 3 This mark indicates the specified torque.
other models. 5 This mark indicates an amount of oil or
Blank: Tools already available for other water to be added.

models, used without any modification.
3) Circle mark (Q) in sketch column. Sketches of special tools
A circle mark means that a sketch of the
special tool is presented in the section of q Various special tools are illustrated for the con-
Sketches for Special Tools. venience of local manufacture.
a Part No. of special tools starting with 79*T
means that they are locally made parts
and as such not interchangeable with
those made by Komatsu in Japan e.g.
79*T------.
Removal of parts
q The Removal section contains procedures, pre-

cautions and the amount of oil or water to be
drained.
q Various symbols used in the Removal section
are explained and listed below.
k This mark indicates safety-related pre-
cautions, which must be followed when
doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instructions
or precautions for installing parts.
6 This mark shows oil or water be drained.
4 This mark shows the weight of a part or a
device.
50-100 2 PC20MR-3
How to read this manual SEN04874-00
Disassembly and assembly of assemblies
Special tools Assembly
q Special tools which are deemed necessary for q Section titled Assembly contain procedures, pre-
disassembly and assembly are listed in this sec- cautions and the know-how for the work, as well
tion. as the amount of oil or water to be added.
q List of the special tools contains the following q Various symbols used in the Assembly section
kind of information. are explained and listed below.
1) Necessity k This mark indicates safety-related pre-
t : Special tools which cannot be substitut- cautions, which must be followed when
ed, should always be used. doing the work.
q : Speciall tools which are very useful if a This marks gives guidance or precautions
available, can be substituted with com- when doing the procedure.
mercially available tools. 2 This mark stands for a specific coating
agent to be used.
2) Distinction of new and existing special tools. 3 This mark indicates the specified torque.
N : Tools with new part numbers, newly 5 This mark indicates an amount of oil or
developed for this model. water to be added.

R : Tools with upgraded part numbers,
remodeled from already available tools for Sketches of special tools
other models.
Blank: Tools already available for other 1) Vartious special tools are illustrated for the
models, used without any modification. convenience of local manufacture.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those made
by Komatsu in Japan e.g. 79*T------
.
Disassembly
q The Disassembly section contains procedures,

precautions and the amount of oil or water to be
drained.
q Various symbols used in the Disassembly sec-
tion are explained and listed below.
k This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
a This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or water to be
drained.
PC20MR-3 50-100 3
SEN04874-00 Coating materials list
Coating materials list

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate-
Komatsu code Part No. Q'ty Container Main features and applications
gory
q Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
q Used for plastic (except polyethylene, polypro-
20 g Polyethylene pylene, tetrafluoroethylene and vinyl chloride),
LT-1B 790-129-9050
(2 pcs.) container rubber, metal, and non-metal parts which require
immediate and strong strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container q Used to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Used to stick and seal metal, glass, and plastics.
sive and hard- Hardener:
500 g
Adhesive
ener)
Polyethylene
LT-4 790-129-9040 250 g q Used to seal plugs.
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Quick-setting adhesive.
ThreeBond Polyethylene q Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Used mainly to stick metals, rubbers, plastics,
and woods.
q Quick-setting adhesive.
Aron-alpha Polyethylene q Quick-setting type. (max. strength is obtained af-
790-129-9130 2g
201 container ter 30 minutes)
q Used mainly to stick rubbers, plastics, and met-
q Features: Resistance to heat and chemicals.
Polyethylene
Loctite 648-50 79A-129-9110 50 cc q Used for fitted portions used at high tempera-
container
tures.
q Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container q Used to seal tapered plugs, elbows, and nipples
of hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube q Used to seal flange surfaces and threaded por-
tions.
Gasket sealant
q Used to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube q Used to seal flywheel housing, intake manifold,
oil pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Used to seal transfer case, etc.
q Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped, wa-
ThreeBond 790-129-9310 200 g Tube ter resistance of the clearance at the welded ar-
1206D ea, etc.
q Can be coated with paint.
50-100 4 PC20MR-3
Coating materials list SEN04874-00
Cate-
gory
LG-10 q Used as lubricant/sealant when the radiator hos-
ThreeBond 790-129-9320 200 g Tube es are inserted.
Gasket sealant
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube q Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube q Gasket sealant used to repair engine.
1211
q Used to prevent scuffing and seizure of press-fit-
Molybdenum disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
q Used to lubricate linkages, bearings, etc.
lubricant
q Spray type
q Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
09995-00250 190 g Can
ing each other.
q Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
prevention compound
q Feature: Seizure and scuffing prevention com-

Seizure
pound with metallic super-fine-grain, etc.

LC-G
Can q Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI q Feature: Lithium grease with extreme pressure
G0-LI (*)
SYGA-160CNL Various Various lubrication performance.
*: For cold dis-
SYG0-400LI-A q General purpose type.
trict
(*)
SYG0-160CNL
(*)
q Used for parts under heavy load.
Caution:
Molybdenum
SYG2-400M 400 g 10 Bellows-type q Do not apply grease to rolling bearings like
disulfide
SYG2-400M-A 400 g 20 container swing circle bearings, etc. and spline.
grease
SYGA-16CNM 16 kg Can q The grease should be applied to work equip-
LM-G (G2-M)
ment pins at their assembly only, not applied
for greasing afterwards.
Grease
Hyper White SYG2-400T-A

Grease SYG2-16CNT q Seizure resistance, heat resistance and water re-
Bellows-type
G2-T, SYG0-400T-A 400 g sistance higher than molybdenum disulfide
container
G0-T (*) (*) 16 kg grease.
Can
*: For cold dis- SYG0-16CNT q Not conspicuous on machine since color is white.
trict (*)
Biogrease
SYG2-400B
G2-B,
SYGA-16CNB
G2-BT (*) Bellows-type q Since this grease is decomposed by natural bac-
SYG2-400BT 400 g
*: For use at container teria in short period, it has less effects on micro-
(*) 16 kg
high tempera- Can organisms, animals, and plants.
SYGA-16CNBT
ture and under
(*)
high load
q Feature: Silicone grease with wide using temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Used for oil seals of the transmission, etc.
PC20MR-3 50-100 5
SEN04874-00 Coating materials list
Cate-
gory
q Feature: Urea (organic system) grease with heat
Grease
G2-U-S resistance and long life. Enclosed type.

427-12-11871 2 kg Can
ENS grease q Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR
q Used as primer for cab side.
PAINT Glass con-
20 (Using limit: 4 months after date of manu-
PRIMER 580 tainer
facture)
SUPER
417-926-3910
SUNSTAR
q Used as primer for glass side.
GLASS Glass con-
20 (Using limit: 4 months after date of manu-
PRIMER 580 tainer
Adhesive for cab glass

facture)
SUPER
SUNSTAR q Used as primer for painted surface on cab
PAINT Glass con- side.
Primer
22M-54-27230 20
PRIMER435-9 tainer (Using limit: 4 months after date of manu-
5 facture)
q Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR
q Used as primer for sash (Almite).
SASH Glass con-
22M-54-27250 20 (Using limit: 4 months after date of manu-
PRIMER tainer
facture)
GP-402
SUNSTAR q "S" is used for high-temperature season
PENGUINE and "W" for low-temperature season as ad-
Polyethylene
SEAL580 417-926-3910 320 hesive for glass.
container
SUPER "S" or (Using limit: 4 months after date of manu-
Adhesive
"W" facture)
Sika Japan, q Used as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 (Using limit: 6 months after date of manu-
container
Adhesive for cab glass
256HV facture)
SUNSTAR q Used as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 (Using limit: 6 months after date of manu-
cial container)
SUPER 560 facture)
SUNSTAR
q Used to seal joints of glass parts.
PENGUINE Polyethylene
417-926-3920 320 (Using limit: 4 months after date of manu-
SEAL No. container
Caulking material
facture)
2505
SEKISUI SILI- q Used to seal front window.
Polyethylene
CONE SEAL- 20Y-54-55130 333 (Using limit: 6 months after date of manu-
container
ANT facture)
q Used to seal joint of glasses. Translucent
GE TOSHIBA
white seal.
SILICONES 22M-54-27220 333 Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
50-100 6 PC20MR-3
Special tool list SEN04874-00
Special tool list
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity:
t .............Cannot be substituted, must always be installed (used)
q .............Extremely useful if available or, can be substituted with commercially available part.
a New/Remodel:
N .............Tools with new part numbers, newly developed for this model.
R .............Tools with upgraded part numbers, remodeled from items already available for other mode.ls
Blank .............Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special (See sketches of
special tools).
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
790-101-5001 Push tool KIT q 1

790-101-5081 q Plate 1
Disassembly, assem- 1 Press fitting of bushing
790-101-5021 q Grip 1
bly of idler assembly
01010-50816 q Bolt 1
2 791-430-3230 Installer t 1 Installation of floating seal
L
790-101-5001 Push tool KIT q 1
Disassembly, assem- 790-101-5051 q Plate 1
3 Press fitting of bushing
bly of track roller 790-101-5021 q Grip 1
assembly 01010-50816 q Bolt 1
4 790-434-1660 Installer t 1 Installation of floating seal
Disassembly, assem-
Disassembly, assembly of
bly of recoil spring M 792-371-1400 Sleeve t 1
recoil spring assembly
assembly
790-101-2501 Push puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
Separation of rotor and
Disassembly, assem- 791-112-1180 q Nut 1
swivel joint
blyof center swivel joint T 790-101-2540 q Washer 1
assembly 790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2 Separation of rotor and swivel
790-101-2660 q Adapter 2 joint
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder assembly
Removal, installation of cylin-
2 790-330-1100 Wrench assembly t 1
der head
Commercially Width across
Socket t 1
Disassembly, assem- available flats: 32 mm
Removal,
blyof hydraulic cylinder U Commercially Width across
Socket t 1 installation
assembly available flats: 41 mm
of piston nut
3 Commercially Width across
Socket t 1
available flats: 46 mm
Removal, Width across
790-302-1390 Socket t 1 installation flats: 46 mm,
of piston nut long type
PC20MR-3 50-100 7
SEN04874-00 Special tool list
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
790-201-1702 Push tool KIT t 1

790-101-5021 q Grip 1
01010-50816 q Bolt 1 Press fitting
4
790-201-1741 q Push tool 1 of bushing Arm, swing
790-201-1721 q Push tool 1 Bucket
790-201-1731 q Push tool 1 Blade
790-101-5021 q Grip 1
Disassembly, assem- 01010-50816 q Bolt 1
blyof hydraulic cylinder U Press fitting
5 Boom, arm,
assembly 790-201-1550 q Plate 1 of dust seal
swing
790-201-1530 q Plate 1 Bucket
790-201-1540 q Plate 1 Blade
6 790-720-1000 Expander q 1
796-720-1740 Ring q 1 Installation Boom, arm,
07281-00809 Clamp q 1 of piston blade, swing
7
796-720-1620 Ring q 1 ring
Bucket
07281-00609 Clamp q 1
Removal, installation of
operators cab glass X 1 7934981210 Lifter (Suction cup) t 2 Fixing of window glass
(stuck glass)
50-100 8 PC20MR-3
Special tool list SEN04874-00
PC20MR-3 50-100 9
SEN04874-00
2009 KOMATSU
All Rights Reserved
50-100 10
SEN04875-00
PC20MR-3
SEN04875-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


Removal and installation of fuel injection pump assembly.......................................................................... 2

Removal and installation of radiator and hydraulic oil cooler assembly...................................................... 4
Removal and installation of engine and hydraulic pump assembly ............................................................ 8
PC20MR-3 50-200 1
SEN04875-00 Removal and installation of fuel injection pump assembly
Removal and installation of fuel 11. Make match marks I on the engaging points of
injection pump assembly pump drive gear (13) and idle gear with a
marker, etc.
Removal
1. Tilt up the floor frame and remove the radiator
and hydraulic oil cooler assembly. For details,
see Removal and installation of radiator and
hydraulic oil cooler assembly.
2. Close fuel valve A.
3. Remove bracket (1).
4. Disconnect heater hose (2).
5. Disconnect fuel return hose (3) and fuel supply

hose (4). 12. Install puller [1] to tap M8 and remove pump
drive gear (13) from the fuel injection pump.
6. Remove fuel injection tubes (5) together.
7. Remove pin (6) and disconnect fuel control

cable (7).
a Check the position of the hole for the pin.
8. Remove connector (8) from the clip and discon-

nect connector (9).
13. Remove lubrication tube (14).
14. Accurately record the relative position of the

stamp line of the fuel injection pump body to the
stamp line of the gear case by making a mark
with a scriber on the gear case. (Part C)
15. Remove 3 mounting nuts (15) and fuel injection

9. Remove cover (10). [*1] pump (16).
10. Remove nut (11) and washer (12). [*2]

a Take care not to drop the nut into the case.
a Never loosen mounting bolt B of pump drive
gear (13) and flange.
(If the flange and pump drive gear are shifted
from each other, it will be very difficult to
adjust the injection timing.)
50-200 2 PC20MR-3
Removal and installation of fuel injection pump assembly SEN04875-00
Installation
1. Replace O-ring (17) with new one.
2 O-ring: Grease (G2-LI)
q Carry out the rest of installation in the reverse

order to removal.
[*1]
2 Flange surface of cover (10):
Gasket sealant (LG-6)
a Take care of the length of the bolts.
[*2]
3 Pump drive gear mounting nut:
58.8 68.8 Nm {6 7 kgm}
a Adjust the injection angle. For details, see

Testing and adjusting, Testing and adjusting
fuel injection timing.
PC20MR-3 50-200 3
SEN04875-00 Removal and installation of radiator and hydraulic oil cooler assembly
Removal and installation of radi- 5) Remove bolts (6). [*1]

ator and hydraulic oil cooler
assembly
Removal
k Lower the boom until the work equipment
comes in contact with the ground.
1. Tilt up the floor frame. (See the operation

manual.)
1) Remove triangular cover (1).
2) Open covers (2) and (3).
6) While pulling lever B toward the rear with

your left hand, grasp and raise knob with your
right hand to tilt the floor frame forward until it
is locked. (The floor frame is locked when pin
C is fitted to lock plate D.) [*2]
a If the floor is not raised, lever B is not set
in the free position. (In this case, pull lever
B further with your left hand to unlock it.)
k When opening or closing the floor, do
not put any part of your body under the
floor.
3) Unlock and open cover (4).

4) Remove cover (5).
50-200 4 PC20MR-3
Removal and installation of radiator and hydraulic oil cooler assembly SEN04875-00
7) Take lock pin (8) (red) out of bracket E (red) 9. Disconnect radiator hoses (14) and (15). [*4]
and insert it in the following position.
k Check that lock pin (8) is locked as
shown in Part F.
10. Loosen the mounting bolts of alternator (16) to

loosen belt (17). [*5]
2. Release the pressure from the hydraulic tank.

For details, see Testing and adjusting,
Releasing pressure from hydraulic tank.
3. Drain the hydraulic oil.

6 Hydraulic oil: 19 l
4. Drain the coolant.

6 Coolant: 3.0 l

a Pull cover (9) out towards front at an angle.
k Disconnect the negative () wiring har-
ness (ground cable) of the battery from
the chassis.
11. Loosen plate (18) and remove battery (19).

a When removing the bracket, take care not to
damage the core.
13. Disconnect reservoir tank hose (21).
14. Remove the mounting bolts of bracket (22).
6. Remove air hose (10) and air cleaner assembly

(11). [*3]
8. Remove fan guard (13).
PC20MR-3 50-200 5
SEN04875-00 Removal and installation of radiator and hydraulic oil cooler assembly
15. Disconnect hoses (23) and (24) from the 20. Lift off radiator and hydraulic oil cooler assembly
hydraulic oil cooler. (28).
4 Radiator and hydraulic oil cooler assem-
16. Loosen the clamp of air hose (25). [*6] bly: 30 kg
a While lifting up the radiator assembly a little, a When removing the assembly, take care
disconnect the air hose. not to damage the core.
17. Disconnect hoses (26) and (27) from the control

valve.
18. Sling radiator and hydraulic oil cooler assembly

(28) temporarily.
19. Remove 4 mounting bolts (29) from the under-

side of the radiator.
50-200 6 PC20MR-3
Removal and installation of radiator and hydraulic oil cooler assembly SEN04875-00
Installation q Refilling with water

q Carry out installation in the reverse order to re- a Add water through the water filler to the specified
moval. level. Run the engine to circulate the water
through the system. Then, check the water level
[*1] again.
a Close bolts (6). 5 Coolant: 3.0 l
3 Bolt (6): 157 196 Nm {16 20 kgm}
q Refilling with oil (Hydraulic tank)
a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic oil:
19 l (Engine oil: EO10W30-DH)
q Bleeding air
a Bleed air.
For details, see Testing and adjusting, Bleeding
air from each part.
[*2]
q While pulling lever B toward the rear with your
left hand, grasp knob with your right hand and
lower the floor frame slowly. (If the floor frame
does not lower, pull lever B further with your left
hand to unlock it.)
[*3] [*6]
3 Air hose clamp:
5.9 0.49 Nm {60 5 kgcm}
[*4]
3 Radiator hose clamp:
4.4 0.5 Nm {45 5 kgcm}
[*5]
a Adjust the belt tension.
For details, see Testing and adjusting, Testing
and adjusting alternator belt tension.
PC20MR-3 50-200 7
SEN04875-00 Removal and installation of engine and hydraulic pump assembly
Removal and installation of engine 10. Remove the carburetor and disconnect engine
and hydraulic pump assembly oil pressure sensor (11) and ground wire (12).
Removal
2. Close fuel valve A.
4. Disconnect heater hose (2).
11. Remove 3 deck covers (13) together.
5. Disconnect fuel return hose (3) and fuel supply

hose (4).
12. Remove grommet (14) and disconnect connec-
6. Disconnect water separator (5). tors (15) and (16).
7. Remove pin (6) and disconnect bracket (7). [*1] 13. Remove cover (17).
8. Remove the clip (which is in the lower part and

not easy to see) and disconnect fuel control
cable (8).
9. Disconnect connectors (9) and (10).
50-200 8 PC20MR-3
Removal and installation of engine and hydraulic pump assembly SEN04875-00
14. Remove clip (18) and cover (19).
22. Lift off engine and hydraulic pump assembly

15. Disconnect terminal (20) and connectors (21) (27).
and (22) from the alternator. a Check that all the wires and pipes are discon-
nected.
16. Disconnect terminal (23) from the starting motor. a When removing the assembly, take care that
it will not interfere with the peripheral parts.
4 Engine and hydraulic pump assembly:
17. Disconnect connector (24).
180 kg
18. Disconnect clip (25).
19. Disconnect hoses (26) (30) from the hydraulic

pump.
20. Sling the engine and hydraulic pump assembly

temporarily.
21. Remove 4 mounting bolts (31).
PC20MR-3 50-200 9
SEN04875-00 Removal and installation of engine and hydraulic pump assembly
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
a Adjust the cable tension. For details, see Testing
and adjusting, Testing and adjusting fuel control
lever.
q Refilling with coolant

a Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
5 Coolant : 3.0 l

5 Hydraulic oil:
19 l (Engine oil: EO10W30-DH)
q Bleeding air
a Bleed air.
air from each part.
50-200 10 PC20MR-3
Removal and installation of engine and hydraulic pump assembly SEN04875-00
PC20MR-3 50-200 11
SEN04875-00
2009 KOMATSU
All Rights Reserved
50-200 12
SEN04876-00
PC20MR-3
SEN04876-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


300 Power train
Removal and installation of swing circle assembly ..................................................................................... 2
PC20MR-3 50-300 1
300 Power train
SEN04876-00 Removal and installation of swing circle assembly
Removal and installation of swing Installation

circle assembly q Carry out installation in the reverse order to re-
moval.
Removal [*1]
1. Remove the revolving frame assembly. For 2 Mounting bolt: Adhesive (LT-2)
details, see Removal and installation of 3 Mounting bolt:
revolving frame assembly. 117.6 137.2 Nm {12 14 kgm}
(Target: 127.4 Nm {13 kgm})
2. Remove 18 mounting bolts (1). [*1]
[*2]
3. Install the hanging bolts and lift off swing circle a Set oil filler G of the outer race on the left side of
assembly (2). [*2] the chassis and set the pin on the front right side.
4 Swing circle assembly: 25 kg Set inner race soft zone a (mark S) and outer
race soft zone b as shown below.
2 Inner race tooth surface: Grease (G2-LI)
50-300 2 PC20MR-3
300 Power train
Removal and installation of swing circle assembly SEN04876-00
PC20MR-3 50-300 3
SEN04876-00
2009 KOMATSU
All Rights Reserved
50-300 4
SEN04877-00
PC20MR-3
SEN04877-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


Removal and installation of track shoe assembly ....................................................................................... 2

Disassembly and assembly of idler assembly ............................................................................................ 3
Disassembly and assembly of recoil spring ................................................................................................ 5
Disassembly and assembly of track roller assembly .................................................................................. 8
Removal and installation of floor frame assembly ...................................................................................... 9
Removal and installation of revolving frame assembly ............................................................................... 13
PC20MR-3 50-400 1
SEN04877-00 Removal and installation of track shoe assembly
Removal and installation of track 4. Sling track shoe assembly (3) and pull it out
shoe assembly toward this side.
4 Rubber shoe: 80 kg
Steel shoe: 130 kg
Removal
1. Swing the upper structure by 180 and raise the
machine by using the work equipment and
blade.
2. Loosen valve (1) to discharge grease and loosen

the track shoe tension. [*1]
k Since valve (1) may jump out because of
the high-pressure grease, do not loosen it
more than 1 turn.
Installation
moval.
[*1]
a For details, see Testing and adjusting, Testing
and adjusting track shoe tension.
50-400 2 PC20MR-3
Disassembly and assembly of idler assembly SEN04877-00
Disassembly and assembly of

idler assembly
Special tools
New/Remodel
Symbol
Necessity
Part No. Part Name
Sketch
Q'ty
790-101-5001 Pushtool kit q 1
790-101-5081 q Plate 1
1
L 790-101-5021 q Grip 1
01010-50816 q Bolt 1
2 791-430-3230 Installer t 1 3. Using tool L2, install floating seals (7) to support
a In this section, only the assembly procedure is (3) and (6).
explained. a Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
Assembly a Coat the sliding surface of the floating seal
1. Using tool L1, press fit 2 bushings (10) to idler with engine oil (EO30-DH) before installing,
(9). and be careful not to let any dirt or dust stick
to it.
2. Using tool L2, install 2 floating seals (8) to idler 4. Fit O-ring and install shaft (5) to support (6).
(9).
a Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
a Coat the sliding surface of the floating seal
with engine oil (EO30-DH) before installing,
and be careful not to let any dirt or dust stick
to it.
PC20MR-3 50-400 3
SEN04877-00 Disassembly and assembly of idler assembly
5. Install support and shaft assembly (4) to idler.
6. Fill inside of idler with engine oil.

5 Inside portion of idler: 20 cc (EO30-DH)
7. Install support (3).

2 Mounting bolt: Thread tighener (LT-2)
8. Install bracket (2).

2 Mounting bolt: Thread tighener (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
50-400 4 PC20MR-3
Disassembly and assembly of recoil spring SEN04877-00

recoil spring
Special tools
New/Remodel
Symbol
Necessity
Part No. Part Name
Sketch
Q'ty
M 792-371-1400 Sleeve t 1
Disassembly
1. Piston
1) Remove valve (1).
2) Remove piston (2).
3) Release the hydraulic pressure slowly and

2. Recoil spring
allow spring to extend, then remove stopper
1) Using tool M, set recoil spring to press.
k The recoil spring is under large in-
(5) and spring (6) from cylinder assembly (7).
a Free length of spring : 257 mm
stalled load, so be sure to set the tool
properly. Failure to do this is danger-
ous.
2) Apply hydraulic pressure slowly to compress
spring, then remove screw (3) and remove
nut (4).
a Compress the spring until the nut be-
comes loose.
a Installed load of spring
Rubber shoe specification:
30.9 kN {3,153 kg}
Steel shoe specification:
19.7 kN {2,012 kg}
PC20MR-3 50-400 5
SEN04877-00 Disassembly and assembly of recoil spring
3. Cylinder Assembly
1) Remove snap ring (8), then remove spacer 1. Cylinder
(9) from cylinder (10). 1) Install O-ring (12) to cylinder (10).
2) Remove dust seal (11) 2) Install dust seal (11).
3) Remove O-ring (12). 3) Fit spacer (9) and secure with snap ring (8).
2. Recoil spring
1) Assemble cylinder assembly (7), spring (6),
and stopper (5).
50-400 6 PC20MR-3
Disassembly and assembly of recoil spring SEN04877-00
2) Using tool M, set recoil spring to press. a After assembling the recoil spring, check
k The recoil spring is under large in- that the out-of -parallel between surface a
stalled load, so be sure to set the tool of cylinder (7) and surface b of stopper (5)
properly. Failure to do this is danger- is less than 0.5 mm.
ous.
3) Apply hydraulic pressure slowly to compress
spring, then fit nut (4) and install screw (3).
a Installed height of spring
Rubber shoe specification: 188 mm
Steel shoe specification: 213 mm
a Installed load of spring
Rubber shoe specification:
30.9 kN {3,153 kg}
Steel, shoe specification:
19.7 kN {2,012 kg}
3. Piston
1) Tighten plug (1) temporarily.
a Grease will come out from grease hole c,
so tighten completely, then turn back ap-
prox. 2 turns.
2) Add approx. 120 cc of grease (G2-LI) inside
cylinder.
3) Assembly cylinder (2) and push in until
grease come out from grease hole c.
4) When grease come out, tighten valve (1).
a After tightening the valve, check that the
grease fitting is facing the outside (just
beside) of the chassis.
PC20MR-3 50-400 7
SEN04877-00 Disassembly and assembly of track roller assembly
Disassembly and assembly of 3. Set the floating seal (4) in the collars (1) and (2)
track roller assembly by using the tool L4.
a Clean the O-ring and the O-ring contact sur-
face to degrease completely and dry them.
Special tools a Apply engine oil (EO30-DH) to the floating
New/Remodel
seal sliding surface and keep it free from
dust.
Symbol
Necessity
Part No. Part Name
Sketch
Q'ty
790-101-5001 Pushtool kit q 1
790-101-5051 q Plate 1
3
L 790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 791-434-1660 Installer t 1
a In this section, only the assembly procedure is
explained.
Assembly
1. Press fit two pieces of the bushing (7) in the
roller (6) using the tool L3.
4. Set the O-ring and install the shaft (3) in the
roller.
5. Set the collar (2) on the roller and fix it with a

snap ring.
6. Fill engine oil in the roller.

5 Roller inside: 50 cc (EO30-DH)
7. Set the collar (1) on the roller and fix it with a

snap ring.
2. Set two pieces of the floating seal (5) in the roller

(6) using the tool L4.
a Clean the O-ring and the O-ring contact sur-
face to degrease completely and dry them.
a Apply engine oil (EO30-DH) to the floating
seal sliding surface and keep it free from
dust.
50-400 8 PC20MR-3
Removal and installation of floor frame assembly SEN04877-00
Removal and installation of floor 4. Remove 3 left covers (4) together.

frame assembly
Removal
a The operator's cab and the floor frame are made

in one unit.
1. Remove roof (1).

a Perform this step for only the model with the
canopy specification.

k When disconnecting the work equipment
PPC hose, take care not to touch locking
part B of the floor tilt lock pin from under-
side. (If you touch the lock pin, it may
come out, and that is dangerous.)
6. Disconnect work equipment PPC hoses (6) (9),

10 pieces in total. [*1]
a Hose band colors:
q Hoses (6) on this side from above:
2. Remove floor mat (2) and bar (3). "Black, yellow, blue and red"
a Perform this step for only the model with the q Near side of control valve (7):
canopy specification. "Yellow, Blue"
q Hoses (8) on the deeper side from above:
"Brown, green, white and orange"
q Far side of control valve (9):
"Red, Yellow"

PC20MR-3 50-400 9
SEN04877-00 Removal and installation of floor frame assembly
7. Disconnect PPC hoses (10) and (11).

a Before disconnecting the hoses, prepare
plugs.
a Prepare tags to record the destination of
each hose.
8. Disconnect 4 travel PPC hoses (12). [*2]

a Hose band colors:
Right front: "Black, yellow"
Right rear: "Yellow, green"
Left front: "Yellow, brown"
Left rear: "Yellow, orange"
11. Disconnection of fuel control cable (19)

1) Remove pin (17).
2) Loosen locknut (18). [*5]
a Before loosening the locknut, check the
installed dimension.
3) Remove the clip (which is in the lower part
and not easy to see) and disconnect fuel
control cable (19) from the engine.
a Check the route of the cable in advance.
9. Disconnect PPC hoses (13) and (14). [*3]

a Colors of hose bands:
(13): "Red, Green"
(14): "White, Blue"
10. Disconnect 2 swing PPC hoses (15) and (16).

[*4]
a Identification tape colors of hoses:
Right side: "Blue, white"
Left side: "Red, white"
4) Remove clip (20) from the underside of the

floor frame.
a C: Oil pan
50-400 10 PC20MR-3
Removal and installation of floor frame assembly SEN04877-00
5) Remove cover (21). 16. Remove 2 upper mounting bolts (29) of damper
6) Remove fuel control cable (19) from the (28).
revolving frame. k Since damper (28) is pressed strongly, it
may jump out to right and left. Do not ap-
proach it after removing the upper mount-
ing bolts.
12. Disconnect connectors (22) and (23) at the front

of the revolving frame.
13. Remove bracket (24). 17. Pull out lock pin (30) and remove pin (31).
14. Disconnect connectors (25) and (26). 18. Lift up the operator's cab and floor frame
(canopy and floor frame) assembly a little further
until damper (28) expands to the end (until
damper (28) projects and a space is made in part
D), and then remove the damper.
19. Disconnect windshield washer hose (32).
20. Remove right and left bolts (33) and pull out pin
(34).
a Pull out the right pin first (since the force of
spring (35) is applied).
15. Sling operator's cab and floor frame (canopy and

floor frame) assembly (27) temporarily.
PC20MR-3 50-400 11
SEN04877-00 Removal and installation of floor frame assembly
21. Sling operator's cab and floor frame (canopy and Installation
floor frame) assembly (27) horizontally.
4 Canopy and floor frame assembly: 290 1. Using lever block [1] and block [2], pull spring
kg (36) and install pin (34).
Cab and floor frame assembly: 420 kg
q Carry out the rest of installation in the reverse

22. Disconnect heater hose (35) through the space order to removal.
between the fuel tank and the operator's cab and
floor frame (canopy and floor frame) assembly. [*1] [*2] [*3] [*4]
k Since operator's cab and floor frame (can- a When connecting, check the identification
opy and floor frame) assembly (27) is not colors.
fixed, take care not to catch your hands in
it. [*5]
a Adjust the cable tension. For details, see
Testing and adjusting, Adjusting fuel control
lever.
Refilling with coolant

a Add water through the water filler to the spec-
ified level. Run the engine to circulate the
water through the system. Then, check the
water level again.
5 Coolant: 3.0l
Refilling with oil (Hydraulic tank)

a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
a Before removing the assembly, check that all
again.
5 Hydraulic oil:
the wires and pipes are disconnected.
a Remove operator's cab and floor frame (can-
19l (Engine oil: EO10W30-DH)
opy and floor frame) assembly (27), taking
care of its balance.
Bleeding air
a For details, see Testing and adjusting, Bleed-
ing air from each part.
50-400 12 PC20MR-3
Removal and installation of revolving frame assembly SEN04877-00
Removal and installation of

revolving frame assembly
Removal
1. Remove the work equipment assembly. For
details, see Removal and installation of work
equipment assembly.
2. Remove the operators cab and floor frame

(canopy and floor frame) assembly. For details,
see Removal and installation of floor frame
assembly.
3. Pull out pin (1) and remove boom cylinder 5. Disconnect hoses (6) and (A) (F) from the
assembly (2). [*1]
4 Boom cylinder: 25 kg
control valve.
a Hoses (A) (F) are labeled.
a A F of the hoses are the names of the des-
tination ports of the center swivel joint.
a General drawing of hoses
6. Disconnect drain hose (7) and hose (8) from

center swivel joint J.
7. Remove lever (9) from the center swivel joint.

[*2]
4. Disconnect hoses (3) and (4) and drain hose (5)

from swing motor S.
plugs.
each hose.
a J: Center swivel joint
PC20MR-3 50-400 13
SEN04877-00 Removal and installation of revolving frame assembly
8. Sling the revolving frame assembly temporarily Installation

and remove mounting bolts (10). [*3]
a Leave 2 bolts each on the front and rear q Carry out installation in the reverse order to re-
sides. moval.
[*1]
k When aligning the pin holes, never insert
your fingers in them.
2 Sliding surfaces of pin and swing bracket:
Molybdenum disulfide grease (LM-P)
2 Greasing after installation:
Grease (Hyper white grease)
[*2]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
157 196 Nm {16 20 kgm}
[*3]
2
9. Remove the remaining mounting bolts and lift off Revolving frame assembly mounting bolt:
revolving frame assembly (11). Adhesive (LT-2)
3
a Balancing the revolving frame assembly with Revolving frame assembly mounting bolt:
lever blocks, etc., remove the remaining 117.6 137.2 Nm {12 14 kgm}
mounting bolts. (Target: 127.4 Nm {13 kgm})
a When removing the revolving frame assem-
bly, check that all the pipes have been dis- Refilling with oil (Hydraulic tank)
connected and take care not to damage the a Add oil through the oil filler to the specified level.
center swivel joint.
4 Revolving frame assembly: 770 kg
5 Hydraulic oil:
Bleeding air
a For details, see Testing and adjusting, Bleeding
air from each part.
a Wind the sling onto the right rear part.
50-400 14 PC20MR-3
Removal and installation of revolving frame assembly SEN04877-00
PC20MR-3 50-400 15
SEN04877-00
2009 KOMATSU
All Rights Reserved
50-400 16
SEN04878-00
PC20MR-3
SEN04878-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


500 Hydraulic system
Disassembly and assembly of control valve assembly ............................................................................... 2

Removal and installation of center swivel joint assembly ........................................................................... 6
Disassembly and assembly of center swivel joint assembly ....................................................................... 8
Removal and installation of swing motor and swing machinery assembly ................................................. 10
Disassembly and assembly of hydraulic cylinder assembly ....................................................................... 11
PC20MR-3 50-500 1
SEN04878-00 Disassembly and assembly of control valve assembly

control valve assembly
In this section, only the precautions for assembling

the control valve assembly are explained.
a Work in a clean indoor place where there is no

dirt and dust.
a Clean the parts in clear solvent, and then dry

them with compressed air.
a Replace a part having burrs with new one.
a Coat the sliding surfaces of each part with en-

gine oil before installing.
a Degrease the threads of each plug and spool

thoroughly with denatured alcohol and dry them.
Do not apply pressure for 2 hours after tightening
the plug and spool.
2 Mating face of cover (*1):

Apply sealend 242 or equivalent
50-500 2 PC20MR-3
Disassembly and assembly of control valve assembly SEN04878-00
q Section B-B q Section C-C

a Take care of the installed direction of each spool. a Take care not to tighten the bolt of each 013-
a Install 07-1L to the right and left side, 8 places in 017L too strongly. If it is tightened too strongly it
total, as shown below. will interfere with the pressure reducing valve.
a When tightening or loosening the bolt of each 2 013-017L,15-2L:
07-1L, be sure keep the spool in the valve cham- Apply a drop (about 0.02 g) of Loctite (No.
ber. 638) to the threads.
2 07-1L: 3 013-017L: 1.3 1.7 Nm {0.13 0.17 kgm}
Apply a drop (about 0.02 g) of Loctite (No. 15-2L: 14.7 19.6 Nm {1.5 2.0 kgm}
638) to the threads.
3 07-1L: 6.9 9.8 Nm {0.7 1.0 kgm} a After orifice (1) is installed, its head must not
project from the mating face of the block.
PC20MR-3 50-500 3
SEN04878-00 Disassembly and assembly of control valve assembly
a Sections K-K, L-L, and M-M: See section B-B.

2 15-2L :
Apply a drop (about 0.02 g) of Loctite (No. 638) to the threads.
3 15-2L : 14.7 19.6 Nm {1.5 2.0 kgm}
50-500 4 PC20MR-3
Disassembly and assembly of control valve assembly SEN04878-00
a All sections: See section B-B.

a 013-017L: See section C-C.
2 15-2L :
Apply a drop (about 0.02 g) of Loctite (No. 638) to the threads.
3 15-2L :14.7 19.6 Nm {1.5 2.0 kgm}
PC20MR-3 50-500 5
SEN04878-00 Removal and installation of center swivel joint assembly
Removal and installation of center 4. Disconnect hoses (14), (A) (F), (1), (4), and (6)
swivel joint assembly from the control valve.
a All the hoses, except hose (14), are labeled.
a A F of the hoses are the names of the des-
Removal tination ports of the center swivel joint.

2. Remove partition covers (2 pieces) between the

deck cover and engine. For details, see
Removal and installation of engine and hydraulic
pump assembly, steps 11 14.
q Center swivel joint (28) is at the rear of swing

motor S.
5. Disconnect drain hose (15) and hose (16) from

center swivel joint (28).
6. Remove lever (17) from the center swivel joint.

[*1]
3. Disconnect hoses (11) and (12) and drain hose

(13) from swing motor S.
plugs.
each hose.
50-500 6 PC20MR-3
Removal and installation of center swivel joint assembly SEN04878-00
7. Disconnect hoses (18) (26) from the center Installation

swivel joint.
8. Remove T joint (27). moval.
[*1]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
157 196 Nm {16 20 kgm}

5 Hydraulic oil:
Bleeding air
9. Remove center swivel joint assembly (28). air from each part.
PC20MR-3 50-500 7
SEN04878-00 Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of 4. Remove dust seal (6), 3 plugs (7), and 4 plugs
center swivel joint assembly (8) from the swivel shaft (5).
5. Remove ring (10), O-ring (11), backup ring (12),

Special tools and 7 slipper seals (13) from rotor (9).
New/Remodel
Symbol
Necessity
Part No. Part Name
Sketch
Q'ty
790-101-2501 Push puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1
T 790-101-2540 q Washer 1
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2660 q Adapter 2
Disassembly
1. Remove bolts (1) and plate (2).
2. Remove O-ring (3) and snap ring (4).
3. Using tool T, pull rotor (9) out of swivel shaft (5).
50-500 8 PC20MR-3
Disassembly and assembly of center swivel joint assembly SEN04878-00
Assembly
1. Install O-ring (11), backup ring (12), and 7
slipper seals (13) to rotor (9).
2. Install dust seal (6) to swivel shaft (5).

2 Dust seal lip: Grease (G2-LI)
3. Install 3 plugs (7) and 4 plugs (8) to swivel shaft

(5).
a Degrease, clean, and dry the threaded parts
sufficiently.
a After installing, check that the plug ends are
lower than the shaft end.
3 Plug (8): 16.7 2.9 Nm {1.7 0.3 kgm}
4. Set swivel shaft (5) to the block. Using the push

tool and hitting with a plastic hammer, etc., install
rotor (9).
a Take care extremely not to damage the slip-
per seals and O-ring.
2 Contact surfaces of rotor and swivel
shaft: Grease (G2-LI)
5. Install ring (10), snap ring (4), and O-ring (3).
6. Install plate (2).

3 Mounting bolt (1):
11.8 14.7 Nm {1.2 1.5 kgm}
PC20MR-3 50-500 9
SEN04878-00 Removal and installation of swing motor and swing machinery assembly
Removal and installation of swing

motor and swing machinery
assembly
Removal
1. Remove the operators cab and floor frame

(canopy and floor frame) assembly. For details,
see Removal and installation of floor frame
assembly.
2. Disconnect hoses (1) (3).

plugs. 6. Lift off swing motor and swing machinery
a Prepare tags to record the destination of assembly (9).
each hose. 3 Swing motor and swing machinery as-
sembly: 25 kg
3. Disconnect hose (4) from the front side.
Installation

moval.

5 Hydraulic oil:
Bleeding air
4. Disconnect hoses (5) - (7). air from each part.
5. Remove 4 mounting bolts (8).
50-500 10 PC20MR-3
Disassembly and assembly of hydraulic cylinder assembly SEN04878-00
Disassembly and assembly of a In this section, only the assembly procedure is

hydraulic cylinder assembly explained.
Assembly
Special tools a The contents of this section are common to all
the cylinders, unless otherwise specified.
New/Remodel
a Take care not to damage the packings, dust
Symbol
Necessity
Part No. Part Name seals, O-rings, etc.
Sketch
a Clean the all parts. After installing them, cover
Q'ty
the piping ports and pin holes to prevent dirt from
790-502-1003 Cylinder repair stand t 1 entering.
1
790-101-1102 Hydraulic pump t 1 a Do not insert each backup ring forcibly, but warm
2 790-330-1100 Wrench assembly t 1 it in water at 50 60C and then insert it.
Commer-
Socket (Width across
cially avail- t 1 1. Cylinder
flats: 32 mm)
able
Commer- 1) Press fit bushing (24).
cially avail- t 1 2) Press fit 2 dust seals (23).
flats: 41 mm)
able
3
Commer-
cially avail- t 1
flats: 46 mm)
able
Socket
790-302-1390 (Width across flats: 46 t 1
mm, long type)
790-101-5021 q Grip 1
U 01010-50816 q Bolt 1
4 q Push tool
790-201-1741 1
(arm, swing)
790-201-1721 q Push tool (bucket) 1
790-201-1731 q Push tool (blade) 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1 2. Piston rod
5 q Plate
790-201-1550 1 1) Press fit bushing (22) to piston rod (6).
(boom, arm, swing)
790-201-1530 q Plate (bucket) 1 2) Press fit 2 dust seals (21).
790-201-1540 q Plate (blade) 1
6 790-720-1000 Expander q 1
Ring (boom, arm,
796-720-1740 q 1
blade, swing)
Clamp (boom, arm,
7 07281-00809 q 1
blade, swing)
796-720-1620 Ring (bucket) q 1
07281-00609 Clamp (bucket) q 1
PC20MR-3 50-500 11
SEN04878-00 Disassembly and assembly of hydraulic cylinder assembly
3. Cylinder head assembly a Boom cylinder

1) Using tool U4, press fit bushing (20) to
cylinder head (14).
a Except boom cylinder
8) Install cylinder head assembly (11) to piston

rod (6).
2) Using tool U5, press fit dust seal (18).
3) Install snap ring (17).

4) Install rod packing (19).
5) Install O-ring (15) and backup ring (16).
6) Install O-ring (30).
7) Install O-ring (12) and 2 backup rings (13).
a Boom cylinder only
50-500 12 PC20MR-3
4. Piston assembly 6) Install piston assembly (5) to piston rod (6).

1) Install cushion plunger (10) to piston rod (6).
a Boom cylinder only
7) Set piston rod assembly (2) to tool U1.

8) Using tool U3, install piston nut (4).
2) Set the piston ring (9) on tool U6 and turn the q Width across flats of piston nut
handle 8 to 10 times to expand the ring. Boom cylinder: 41 mm
Arm cylinder: 46 mm
Bucket cylinder: 32 mm
Swing cylinder: 46 mm
Blade cylinder: 41 mm
2 Piston nut:
Thread tightener (Loctite 262 or
equivalent)
3 Piston nut:
Boom cylinder:
618 61.8 Nm {63 6.3 kgm}
Arm cylinder:
785 78.5 Nm {80 8.0 kgm}
Bucket cylinder:
3) Install piston ring (9) to piston (8). 343 34.0 Nm {35 3.5 kgm}
Swing cylinder:
4) Using tool U7, compress piston ring (9).
785 78.5 Nm {80 8.0 kgm}
5) Install wear ring (7). Blade cylinder:
618 61.8 Nm {63 6.3 kgm}
PC20MR-3 50-500 13
SEN04878-00 Disassembly and assembly of hydraulic cylinder assembly
5. Piston rod assembly

1) Install piston rod assembly (2) to cylinder (3).
2) Set cylinder assembly (1) to tool U1.

3) Using tool U2, tighten cylinder head.
3 Cylinder head:
Boom cylinder:
539 54.0 Nm {55 5.5 kgm}
Arm cylinder:
677 67.5 Nm {69 6.9 kgm}
Bucket cylinder:
539 54.0 Nm {55 5.5 kgm}
Swing cylinder:
539 54.0 Nm {55 5.5 kgm}
Blade cylinder:
490 49.0 Nm {50 5.0 kgm}
50-500 14 PC20MR-3
PC20MR-3 50-500 15
SEN04878-00
2009 KOMATSU
All Rights Reserved
50-500 16
SEN04879-00
PC20MR-3
SEN04879-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


600 Work equipment
Removal and installation of work equipment assembly .............................................................................. 2
PC20MR-3 50-600 1
600 Work equipment
SEN04879-00 Removal and installation of work equipment assembly
Removal and installation of work

equipment assembly
k Release the residual pressure in the hydrau-

lic circuit. For details, see Testing and ad-
justing, Releasing residual pressure in
hydraulic circuit.
k Extend the boom cylinder and bucket cylin-
der to the stroke end and lower the work
equipment to the ground.
k Set the lock lever in the Lock position.
Removal
1. Disconnect connector (1) and remove the wiring
4. Sling the work equipment assembly temporarily.
harness from the boom.
5. Remove boom foot pin (5). [*2]
2. Disconnect 6 hoses (2).

6. Lift off work equipment assembly (6).
4 Work equipment assembly: 240 kg
3. Sling boom cylinder (3) temporarily and remove

the plate and head-side pin (4). [*1]
a Lower the boom cylinder onto a block, etc.
50-600 2 PC20MR-3
600 Work equipment
Removal and installation of work equipment assembly SEN04879-00
Installation
moval.
[*1]
2 Sliding surfaces of pin and boom:
[*2]
2 Sliding surfaces of pin and swing bracket:

5 Hydraulic oil:
q Bleeding air
a Bleed air.
air from each part.
PC20MR-3 50-600 3
SEN04879-00
2009 KOMATSU
All Rights Reserved
50-600 4
SEN04880-00
PC20MR-3
SEN04880-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


Removal and installation of front window assembly ................................................................................... 2

Removal and installation of operator's cab glass (stuck glass)................................................................... 3
PC20MR-3 50-700 1
SEN04880-00 Removal and installation of front window assembly
Removal and installation of front

window assembly
k Lower the work equipment to the ground and

stop the engine.
a To replace the front window glass, the front win-

dow assembly must be removed from the opera-
tor's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
Removal
1. Lower the front window assembly.
5. Holding the handle, release the latch and
remove the front window assembly (6).
2. Remove wiper motor (1) and wiper blade (2).
a Remove the coiled cable for the wiper from
the sash and secure it in the operator's cab.
Installation
moval.
3. Remove rollers (3) (right and left) from the
bottom of the sash.
4. Remove bolt (4) and separate pull-up link (5)

from the sash and set it up toward the ceiling.
50-700 2 PC20MR-3
Removal and installation of operator's cab glass (stuck glass) SEN04880-00
Removal and installation of operator's cab glass (stuck glass)
a On the 5 faces of the operators cab, including (1) Right sash window glass assembly
the ceiling, panes (1) - (9) are stuck. (Ceiling (9) (2) Right front lower triangular window glass
is a clear plate.) (3) Right rear window glass
a When replacing front window glass (8), remove (4) Rear window glass
front window assembly. (It is impossible to re- (5) Left rear window glass
place only the front window glass while the front (6) Door upper window glass
window assembly is installed to the operatos (7) Door lower window glass
cab.) (8) Front window glass
a For the procedure for replacing the front window (9) Clear plate
assembly, see Removal and installation of front (10) Both-sided adhesive tape
window assembly. (11) Center trim seal
PC20MR-3 50-700 3
SEN04880-00 Removal and installation of operator's cab glass (stuck glass)
a Precautions for removing and installing glass (The figure shows the operator's cab of a
q When removing and installing the glass, be sure wheel loader.)
to put on protective goggles.
q When using primer or degreasing solvent, take
care of fire and ventilation extremely.
q If a shock is given to an edge of the glass, the
glass is broken easily. Handle the glass with
care.
q If primer, caulking material, or adhesive gets in
your eye, wash your eye with much water, and
then consult an eye doctor.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part Name Sketch a If the window glass is broken finely, it may
be removed with knife [4] and a screw-
Q'ty
driver.
X 1 7934981210 Lifter (Suction cup) t 2 a Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
Removal tape with knife [4].
a Remove the window glass to be replaced ac-
cording to the following procedure. (The figure shows the operator's cab of a
wheel loader.)
1. Using seal cutter [1], cut the adhesive between
broken window glass (12) and operators cab
(metal sheet) (13).
2. Remove the window glass.
a When seal cutter is not available

1) Make holes on the adhesive and both-sided
adhesive tape with a drill and pass a fine wire
(piano wire, etc.) [2] through the holes.
2) Grip both ends of the wire with pliers [3], etc.

(or hold them by winding them onto some-
thing) and move the wire to the right and left
to cut the adhesive and both-sided adhesive
tape.
a Since the wire may be broken by the fric-
tional heat, apply lubricant to it.
50-700 4 PC20MR-3
Installation 3. Apply primer (15).

1. Using a knife and scraper [5], remove the a Since the primer has a large effect on the ad-
remaining adhesive and both-sided adhesive hesion of the glass, never apply a wrong
tape from the metal sheets (glass sticking primer. If you have applied a wrong primer
surfaces) of the operator's cab. by mistake, wipe it off with cleaning solvent.
a Remove the adhesive and both-sided adhe- a The using limit of primer is 4 months after the
sive tape to a degree that they will not affect date of manufacture. Do not use primer after
adhesion of the new adhesive. Take care not this limit.
to scratch the painted surfaces. a Use the primer within 2 hours after unpacking
(If the painted surfaces are scratched, adhe- it.
sion will be lowered.) a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
(The figure shows the operator's cab of a unpacked for the first time.
wheel loader.) (Discard the primer 24 hours after it is
packed.)
1) Stir the primers for paint and glass sufficiently
before using them.
a If the primer has been stored in a refriger-
ator, leave it at the room temperature for
at least half a day before stirring it.
(If the primer is unpacked just after taken
out of the refrigerator, water will be
condensed. Accordingly, leave the
primer at the room temperature for a suffi-
cient time.)
2) When reusing primer brush (16), wash it in
white gasoline.
a After washing the brush, check it again for
2. Remove oil, dust, dirt, etc. from the sticking dirt and foreign matter.
surfaces of operators cab (13) and window a Prepare respective brushes for the paint
glass (14) with white gasoline. primer glass primer.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
3) Evenly apply paint primer to the surfaces to

stick both-sided adhesive tapes (10) and the
surfaces out of those surfaces on operator's
cab (13) which will be coated with the adhe-
sive.
2 Paint primer:
Sunstar paint primer 435-95
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
PC20MR-3 50-700 5
a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window
glass (14) and all over dimension (b)
which will be on both-sided adhesive tape
(10) and operator's cab (13).
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Parts to be coated with primer: Apply the

primer all over dimension (a).
q Dimension to apply primer (a): 25 mm
4. Stick both-sided adhesive tape (10) along the

inside edge of the glass sticking section.
a The both-sided adhesive tape is used to stop
the adhesive from flowing out, finish the ap-
pearance neatly, apply the adhesive evenly
a After applying the primer, leave it for at and stabilize its strength, and protect the
least 5 minutes (within 8 hours) to dry. glass until the adhesive is set.
a The both-sided adhesive tape is classified
4) Evenly apply glass primer to the sticking into 2 types by the sectional dimensions.
surfaces of window glass (14). Use those types according to the following
2 Glass primer:
table.
Sunstar glass primer 435-41 Both-sided adhesive tape Sectional size of
both-sided adhesive tape
a Do not apply the primer more than 2
For general use 5 mm thick 7 mm wide
times. For front sash 5 mm thick 5 mm wide
(If it is applied more than 2 times, its
performance will be lowered.) a Do not remove the release tape of the
both-sided adhesive tape on the glass stick-
ing side before sticking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
50-700 6 PC20MR-3
Pipe
a Install the both-sided adhesive tape from the
end of the round part of each corner of the
pipe.
a When sticking both-sided adhesive tape

around a frame, do not lap its finishing end
over the starting end, or you may make a
clearance of about 5 mm between them.
a Referring to the following, install the both-sid-
ed adhesive tape to each glass sticking part. Front sash (Glass sticking side)
q Right and left frames
Sliding sash
a Install the both-sided adhesive tape along
the periphery of the sticking face of the sash.
q Bottom frame
q Dimension (c): 2.4 mm
Sheet metal part

the edge of the sheet metal part.
Door (Glass sticking side)

the outer end of the door.
q d: Inner, e: Outer
PC20MR-3 50-700 7
2) Cut the tip of the adhesive nozzle (19) so that

dimensions (q) and (r) will be as follows.
q Dimension (q): 10 mm
q Dimension (r): 15 mm
5. Apply adhesive.
a The using limit of the adhesive is 6 months
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the 3) Set adhesive cartridge (17) to caulking gun
temperature is below 25C. [7].
a Never heat the adhesive higher than 30C. a An electric caulking gun is more efficient.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (18) of the outlet of
adhesive cartridge (17) and install the
nozzle.
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (20) to the outside of
both-sided adhesive tape (10) of the oper-
ator's cab.
2 Adhesive:
Sunstar penguine super 560
50-700 8 PC20MR-3
a Apply adhesive (20) to dimensions (s)

and (t) of both-sided adhesive tape (10) of
operator's cab (13).
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (20) higher than both-sid-
ed adhesive tape (10).
a Apply the adhesive evenly.
4) Apply the adhesive according to step 5

above.
a Do not apply the adhesive to the above
water draining area.
5) Install sliding sash assembly (1) to operator's
cab (13).
a Press the sash assembly firmly to elimi-
nate clearance from its periphery.
6. Install the sliding sash assembly. a If the adhesive is projected, wipe it off im-
1) Clean the sash sticking face on the cab side mediately before it is set.
and the sash flange sticking face with
cleaning solvent according to steps 1 and 2
above.
2) Apply the primer according step 3 above.
a Use the right primer for the right sash.
2 Primer (When sash has metallic
shine):
Sunstar primer GP-402 for sash
2 Primer (When sash is painted black
and does not have metallic shine):
Sunstar primer 435-95 for painted
surface
a Do not apply the primer to the following
water draining area.
3) Install the both-sided adhesive tape
6) After installing the sliding sash assembly, fix
according to step 4 above.
it with bands, etc. for about 10 hours.
a To drain water from around the sash,
avoid installing both-sided adhesive tape
7. Install the window glass and clear plate.
(10) of the bottom side to the area of di-
mension (v). 1) Clean the glass sticking face on the cab side
q Dimension (u): 150 mm (v): 50 mm
and the sticking face of the glass with
cleaning solvent according to step 2 above.
2) Apply the primer according step 3 above.
3) Install the both-sided adhesive tape
according to step 4 above.
4) Apply the adhesive according to step 5
above.
5) Stick the glass to the cab.
a Since the window glass cannot be re-
moved and stuck again, stick it very care-
fully.
a Stick the glass within 5 minutes after ap-
plying the adhesive.
PC20MR-3 50-700 9
6) After sticking the window glass, press all a After installing front window glass (8), in-
around it until it is stuck to the both-sided stall the center trim seal to its bottom.
adhesive tape. a When caulking, neatly arrange the form of
a Press the corners of the window glass the adhesive at the right and left ends with
firmly, in particular. a rubber spatula.
a You can perform this work efficiently by 2 Adhesive:
pulling the window glass from inside of Sikaflex 256HV manufactured by Sika
the operator's cab with lifter X1. Japan
(The figure shows the operator's cab of
PC200-7.)
a Apply caulking material all around the

a Make a clearance of the following dimen- glass to fill part (x) between the glass
sion in each corner joint of the rear glass and center trim seal.
and fix the joint with caulking material
(21).
q Dimension (w): 3 mm
2 Caulking material:
GE toshiba silicone tos seal 381
7) After sticking the glass, fix it with bands, etc.

for about 10 hours.
8. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
50-700 10 PC20MR-3
PC20MR-3 50-700 11
SEN04880-00
2009 KOMATSU
All Rights Reserved
50-700 12
SEN04881-00
PC20MR-3
SEN04881-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3


800 Electric system
Removal and installation of KOMTRAX terminal ........................................................................................ 2
PC20MR-3 50-800 1
800 Electric system
SEN04881-00 Removal and installation of KOMTRAX terminal
Removal and installation of Installation

KOMTRAX terminal q Carry out installation in the reverse order to re-
moval.
Removal
1. Turn the starting switch to the OFF position.
2. Remove the cover, garnish (1), etc. to expose

KOMTRAX terminal.
3. Remove the cab wiring harness from KOMTRAX

terminal.
a Be sure to remove the cab wiring harness be-
fore the antenna cable (described in step 4).
4. Remove the communication antenna cable and

GPS antenna cable from KOMTRAX terminal.
5. Remove all mounting bolts (3) and washers (4)

of the KOMTRAX terminal.
Reference: The mounting bolt size is M8.
6. Remove KOMTRAX terminal from bracket (4).

a When handling the KOMTRAX terminal, take
care not to give an impact on it.
(Never hit it against another part or drop it.)
50-800 2 PC20MR-3
800 Electric system
Removal and installation of KOMTRAX terminal SEN04881-00
PC20MR-3 50-800 3
SEN04881-00
2009 KOMATSU
All Rights Reserved
50-800 4
SEN04788-00
HYDRAULIC EXCAVATOR
PC20MR-3

90 Diagrams and drawings 1

100 Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
PC20MR-3 90-100 1
SEN04788-00 Hydraulic circuit diagram
Hydraulic circuit diagram 1
90-100 2 PC20MR-3
Hydraulic circuit diagram
Hydraulic circuit diagram PC20MR-3
PC20MR-3
SEN04788-00
PC20MR-3
90-100 3
Hydraulic circuit diagram SEN04788-00
PC20MR-3 90-100 5
SEN04788-00

2009 KOMATSU
All Rights Reserved
90-100 6
SEN04789-01
PC20MR-3
SEN04789-00
HYDRAULIC EXCAVATOR
Shop Manual
PC20MR-3

90 Diagrams and Drawings

200 Electrical diagrams and drawings
Electrical circuit diagram (1/2)..................................................................................................................... 3

Electrical circuit diagram (2/2)..................................................................................................................... 5
Connector arrangement diagram ................................................................................................................ 7
PC20MR-3 90-200 1
90-200 2 PC20MR-3
Electrical circuit diagram (1/2)
Electrical circuit diagram (1/2) PC20MR-3
SEN04789-01
PC20MR-3
90-200 3
Electrical circuit diagram (2/2)
Electrical circuit diagram (2/2) PC20MR-3
SEN04789-01
PC20MR-3
90-200 5
Connector list and stereogram PC20MR-3 Connector list and stereogram
PC20MR-3
Address of stereogram
Connector Number
No. Model of pins Component name Canopy Cab
specification specification
D1 2 Diode F-6 R-6
D2 2 Diode L-7 X-6
F1 X 4 Intermediate connector H-1 T-1
F2 YAZAKI 2 Intermediate connector H-1 T-1
F3 SWP 6 Intermediate connector H-1 T-1
F4 SWP 8 Intermediate connector H-1 T-1
F5 DT 2 PPC lock switch (left) L-5 X-5
F7 DT 4 Wiper motor and switch [Cab specification] S-1
F8 M 2 Intermediate connector [Cab specification] W-9
F9 DT 2 Intermediate connector [Canopy specification] G-5
F11 KES 3 Heater [Cab specification] S-2
F12 KES 4 Heater switch [Cab specification] X-4
F13 M 2 Horn switch G-5 S-5
F14 DT 2 PPC lock switch [Canopy specification] G-4
F15 AMP 20 Machine monitor G-5 S-6
F16 KES0 2 Speaker (right) [Cab specification] X-7
F17 PA 9 Radio [Cab specification] X-8
F18 KES0 2 Speaker (left) [Cab specification] X-6
F19 SUMITOMO 3 Room lamp [Cab specification] U-9
F20 SWP 12 Intermediate connector (main option harness)
F21 M 2 Revolving warning lamp [Cab specification, if equipped]
F22 M 2 Intermediate connector [Cab specification] U-9
F22A DT 2 Additional working lamp [Cab specification, if equipped] X-9
F22B DT 2 Additional working lamp [Cab specification, if equipped] T-9
F22C DT 2 Additional working lamp [Cab specification, if equipped] V-9
F23 M 3 Intermediate connector [Cab specification] W-9
F24 M 3 Intermediate connector [Cab specification] U-9
F25 Terminal 2 Cigarette lighter [Cab specification] X-8
F26 KES 4 Heater switch [Canopy specification, if equipped]
F27 KES 3 Heater [Canopy specification, if equipped]
F28 M 2 Alarm buzzer G-4 S-4
F29 10 Working lamp switch L-4 X-4
F30 18 KOMTRAX terminal L-6 X-6
F32 12 KOMTRAX terminal L-6 X-5
F33 1 KOMTRAX test connector L-6 X-5
F34 1 KOMTRAX test connector L-6 X-5
F36 DT 3 Resistor L-7 X-6
F37 12 Service connector L-3 X-3
F38 2 Speedup switch G-5 S-4
FB1 Fuse box L-3 X-2
M1 YAZAKI 2 Horn B-1 N-1
M2 X 3 Fuel level sensor A-6 M-6
M3 YAZAKI 4 Timer B-8 N-8
M4 2 Fusible link (45A) C-9 O-9
M5 X 4 Connector (for option) [Cab specification] M-5
M6 KES0 2 Window washer motor [Cab specification] O-9
M7 SUMITOMO 3 Alternator D-9 P-9
M8 DT 2 Engine coolant temperature sensor D-9 P-9
M9 X 3 Engine stop solenoid F-9 R-9
M10 X 2 Fuel pump F-9 R-9
M11 DT 2 Intermediate connector F-5 R-5
M12 DT 2 PPC lock solenoid A-1 M-1
M13 DT 2 Travel speedup solenoid B-1 N-1
M15 YAZAKI 1 Air intake heater F-9 R-9
M16 DT 1 Starting motor (S terminal) C-1 O-1
R1 R 5 Starting motor relay L-1 X-1
R2 R 5 PPC lock solenoid relay L-2 X-2
R4 R 5 Travel speedup solenoid relay K-1 W-1
R5 R 5 Starting motor cut relay K-1 W-1
RM1 YAZAKI 2 Engine stop solenoid relay A-8 M-8
RM4 SUMITOMO 6 Engine safety relay B-8 N-9
RM5 SUMITOMO 2 Engine safety relay B-8 N-9
T1 DT 2 Travel alarm buzzer F-5 R-5
T2 X 2 Travel oil pressure switch (left foward) E-2 Q-2
T3 X 2 Travel oil pressure switch (right foward) E-1 Q-1
T4 X 2 Travel oil pressure switch (right backward) F-2 R-2
T5 X 2 Travel oil pressure switch (left backward) E-2 Q-2
T-F1 Terminal 1 Starting switch (B terminal) G-9 S-9
T-F2 Terminal 1 Starting switch (BR terminal) G-8 S-8
T-F3 Terminal 1 Starting switch (ACC terminal) G-9 S-9
T-F4 Terminal 1 Starting switch (C terminal) G-9 S-9
T-F5 Terminal 1 Starting switch (R1 terminal) H-9 T-9
T-F6 Terminal 1 Starting switch (R2 terminal) H-8 T-8
T-M1 Terminal 1 Battery (+ terminal) C-9 O-9
T-M2 Terminal 1 Alternator (B terminal) D-9 P-9
T-M3 Terminal 1 Engine oil pressure switch E-9 Q-9
T-M5 Terminal 2 Starting motor (B terminal) C-1 O-1
T-M7 Terminal 1 Ground (revolving frame) E-9 Q-9
W1 DT 2 Intermediate connector A-6 M-6
W1A DT 2 Intermediate connector [Canopy specification] A-6
W1B DT 2 Intermediate connector [Canopy specification] A-5
W2 DT 3 Working lamp A-6 M-6
W6 DT 3 Additional working lamp [Canopy specification] A-4
SEN04789-01
PC20MR-3
90-200 7
Connector arrangement diagram SEN04789-01
PC20MR-3 90-200 9
SEN04789-01
2009 KOMATSU
All Rights Reserved
90-200 10

Pc20mr-3 Shop Manual

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Pc20mr-3 Shop Manual

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SEN04767-02

Machine model Serial number

00 Index and foreword 00

Composition of shop manual .......................................................................................................................... 2

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04768-02

01 Specification ............................................................................................................................... SEN04771-00

10 Structure, function and maintenance standard........................................................................... SEN04773-00

20 Standard value table................................................................................................................... SEN04783-01

30 Testing and adjusting ................................................................................................................. SEN04784-00

50 Disassembly and assembly........................................................................................................ SEN04786-00

300 Power train .........................................................................................................................SEN04876-00

90 Diagrams and drawings ..............................................................................................................SEN04787-01

10 Structure, function and maintenance standard

403 Hydraulic system, Part 3 SEN04779-00

20 Standard value table

30 Testing and adjusting

M- 1 When starting switch is turned ON, no monitor/gauge operates ........................................................... 5

50 Disassembly and assembly

90 Diagrams and drawings

PC20MR-3 Hydraulic excavator

Machine model Serial number

00 Index and foreword 00

200 Foreword and general information

Safety notice (Rev. 2008/08)1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during