Komatsu PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR Shop Manual WENBM00060 PDF

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Komatsu PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR Shop Manual WENBM00060 – PDF DOWNLOAD

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Komatsu PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR Shop Manual WENBM00060 – PDF DOWNLOAD

Language : English
Pages : 720
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR Shop Manual WENBM00060 – PDF DOWNLOAD 

SERIAL NUMBERS

PC30MR- F30001 and up
PC35MR- F30001 and up

How to read the shop manual
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 disassembly
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.

TABLE OF CONTENTS:

Komatsu PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR Shop Manual WENBM00060 – PDF DOWNLOAD 

SERIAL NUMBERS

PC30MR- F30001 and up
PC35MR- F30001 and up

00 Index and foreword 3
Composition of shop manual 4
Table of contents 6
00 Index and foreword 13
Safety notice 14
How to read the shop manual 19
Explanation of terms for maintenance standard 21
Handling of electric equipment and hydraulic component 23
Handling of connectors newly used for engines 32
How to read electric wire code 35
Precautions when carrying out operation 38
Method of disassembling and connecting push-pull type coupler 41
Standard tightening torque table 44
Conversion table 48
01 Specification 55
Specification dimension drawing 56
Working range drawing 57
Specifications 58
Weight table 65
Table of fuel, coolant and lubricants 69
10 Structure, function and maintenance standard 71
PTO 72
Cooling system 74
10 Structure, function and maintenance standard 77
Power train 78
Swing circle 80
Swing machinery 81
10 Structure, function and maintenance standard 85
Track frame 86
Idler cushion 87
Idler 88
Track roller 90
Carrier roller 91
Sprocket 92
Track shoe 93
10 Structure, function and maintenance standard 99
Hydraulic components layout drawing 100
Hydraulic tank, filter 101
Center swivel joint 103
Travel motor 104
Hydraulic cylinder 112
Solenoid valve 116
10 Structure, function and maintenance standard 123
Hydraulic pump 124
Control valve 140
10 Structure, function and maintenance standard 165
CLSS 166
Operation for each function and valve 170
Swing motor 204
PPC valve 209
10 Structure, function and maintenance standard 221
Work equipment 222
Dimensions of each part of work equipment 226
10 Structure, function and maintenance standard 231
Floor 232
Air conditioner 233
10 Structure, function and maintenance standard 235
Engine control system 236
Electric control system 240
Auto-deceleration function 250
Attachment proportional switch, breaker operation switch, work mode selection, flow control function 252
KOMTRAX system 260
Component parts of system 263
Monitor system 264
Sensors 268
20 Standard value table 273
Standard service value table for engine related parts 274
Standard service value table for chassis related parts 275
30 Testing and adjusting 293
Tools for testing, adjusting, and troubleshooting 295
Testing engine speed 298
Testing exhaust gas color 299
Testing and adjusting valve clearance 300
Testing compression pressure 301
Testing engine oil pressure 302
Testing and adjusting fuel injection timing 303
Testing and adjusting alternator belt tension 307
Testing and adjusting air conditioner compressor belt tension 308
Adjusting fuel control lever 309
Testing clearance in swing circle bearings 310
Testing and adjusting track shoe tension 311
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits 312
Testing and adjusting LS differential pressure 317
Adjusting PC valve 320
Testing and adjusting control pump circuit oil pressure 321
Testing solenoid valve output pressure 323
Testing PPC valve output pressure 324
Adjusting PPC valve 327
Testing swing holding brake release pressure 328
Testing and adjusting travel deviation 329
Testing oil leakage from work equipment cylinder 331
Bleeding air from each part 333
Releasing residual pressure from hydraulic circuit 335
Releasing residual pressure from hydraulic tank 336
Pressurizing hydraulic tank 336
How to open and close (tilt) floor 337
Inspection procedures for diode 342
Function and flow of operator and service mode 344
How to start operation of KOMTRAX terminal 368
Lamp display of KOMTRAX terminal 372
Removal and installation of KOMTRAX terminal 375
Preparation work for troubleshooting of electrical system 376
40 Troubleshooting 379
User code and failure code list 380
Fuse locations 381
40 Troubleshooting 385
Points to remember when troubleshooting 386
Sequence of events in troubleshooting 387
Checks before troubleshooting 388
Classification and procedures of troubleshooting 389
Information contained in troubleshooting table 390
Connection table for connector pin numbers 394
T- branch box and T- branch adapter table 430
40 Troubleshooting 435
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller 438
Failure code [DBH1KK] Unswitched power supply error 440
Failure code [DBH2KK] Solenoid power supply error 442
Failure code [DBH5KP] 5V sensor power supply output 0 error 444
Failure code [DBH6KP] 5V sensor power supply output 1 error 445
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit) 446
Failure code [DDWLKB] Breaker switch error (Hot short circuit) 447
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault) 448
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit) 450
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error 451
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault) 452
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit) 454
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault) 456
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit) 458
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit) 460
Failure code [D1E0KB] Motor power supply relay error (Ground fault) 462
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit) 464
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault) 466
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit) 468
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault) 470
Failure code [DY10MA] Fuel control motor operation error 472
Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side) 474
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side) 476
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection) 478
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault) 480
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit) 481
40 Troubleshooting 483
Before carrying out troubleshooting of electrical system 484
E-1 Engine does not start 485
E-2 Engine does not stop 493
E-3 When starting switch is turned ON, any item does not operate 496
E-4 When starting switch is turned ON, some items do not operate 498
E-5 Alarm buzzer is abnormal 499
E-6 Engine oil pressure caution is turned ON 501
E-7 Charge level caution is turned ON 502
E-8 Preheating system does not operate or preheater does not become hot 504
E-9 Coolant temperature gauge is abnormal 506
E-10 Fuel level gauge is abnormal 510
E-11 Service meter does not operate while engine is running 514
E-12 2nd travel speed is not selected 516
E-13 Working lamp does not light up 520
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves 522
E-15 Windshield wiper does not operate 524
E-16 Windshield washer does not operate 526
E-17 Defective air conditioner 528
E-18 KOMTRAX system does not operate normally 536
40 Troubleshooting 539
Information contained in troubleshooting table 541
H1 Speed or power of whole work equipment, travel, swing, and blade is low 542
H-2 Engine speed lowers extremely or engine stalls 546
H-3 Whole work equipment, travel system, swing system, and blade do not work 547
H-4 Abnormal sound comes out from around hydraulic pump 551
H-5 Fine control performance or response is low 551
H-6 Speed or power of boom is low 552
H-7 Speed or power of arm is low 553
H-8 Speed or power of bucket is low 554
H-9 Speed or power of boom swing is low 555
H-10 Work equipment does not move singly 555
H-11 Work equipment hydraulic drift is large 556
H-12 Time lag of work equipment is large 558
H-13 In compound operation of work equipment, speed of part loaded more is low 558
H-14 Machine deviates during travel 559
H-15 Travel speed or travel power is low (while work equipment is normal) 561
H-16 Machine is not steered well or steering power is low 562
H-17 Travel speed does not change 563
H-18 Travel motor does not work 564
H-19 Speed or power of swing is low 566
H-20 Machine does not swing 568
H-21 Swing acceleration performance is low 570
H-22 Machine overruns when it stops swinging 572
H-23 Large shock is made when machine stops swinging 573
H-24 When upper structure stops swinging, it makes large sound 573
H-25 Hydraulic drift of swing is large 574
H-26 Speed or power of blade is low 575
H-27 Blade does not move 576
H-28 Hydraulic drift of blade is large 577
40 Troubleshooting 579
Method of using troubleshooting charts 580
S-1 Starting performance is poor 583
S-2 Engine does not start 584
S-3 Engine does not pick up smoothly 587
S-4 Engine stops during operations 588
S-5 Engine does not rotate smoothly 589
S-6 Engine lacks output (or lacks power) 590
S-7 Exhaust smoke is black (incomplete combustion) 591
S-8 Oil consumption is excessive (or exhaust smoke is blue) 592
S-9 Oil becomes contaminated quickly 593
S-10 Fuel consumption is excessive 594
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 595
S-12 Oil pressure drops 596
S-13 Oil level rises (Entry of coolant/fuel) 597
S-14 Coolant temperature becomes too high (overheating) 598
S-15 Abnormal noise is made 599
S-16 Vibration is excessive 600
50 Disassembly and assembly 603
How to read this manual 604
Coating materials list 606
Special tool list 609
Sketches of special tools 613
50 Disassembly and assembly 615
Removal and installation of fuel injection pump assembly 616
Removal and installation of radiator and hydraulic oil cooler assembly 619
Removal and installation of engine and hydraulic pump assembly 623
50 Disassembly and assembly 627
Removal and installation of swing motor and swing machinery assembly 628
Disassembly and assembly of swing motor and swing machinery assembly 629
Removal and installation of swing circle assembly 634
50 Disassembly and assembly 637
Removal and installation of track shoe assembly 638
Disassembly and assembly of idler assembly 639
Disassembly and assembly of recoil spring assembly 641
Disassembly and assembly of track roller assembly 644
Disassembly and assembly of carrier roller assembly 645
Removal and installation of revolving frame assembly 646
50 Disassembly and assembly 649
Removal and installation of center swivel joint assembly 650
Disassembly and assembly of center swivel joint assembly 652
Disassembly and assembly of control valve assembly 654
Disassembly and assembly of hydraulic cylinder assembly 655
50 Disassembly and assembly 661
Removal and installation of work equipment assembly 662
50 Disassembly and assembly 665
Removal and installation of operator’s cab glass (stuck glass) 666
Removal and installation of front window assembly 675
Removal and installation of floor frame assembly 676
50 Disassembly and assembly 681
Removal and installation of air conditioner unit assembly (If equipped) 682
90 Diagrams and drawings 687
Hydraulic circuit diagram 689
Hydraulic circuit diagram 691
Hydraulic circuit diagram 693
Hydraulic circuit diagram 695
90 Diagrams and drawings 699
Electrical circuit diagram (1st attachment) (1/4) 701
Electrical circuit diagram (1st attachment) (2/4) 703
Electrical circuit diagram (1st attachment) (3/4) 705
Electrical circuit diagram (1st attachment) (4/4) 707
Electrical circuit diagram (2nd attachment) (1/4) 709
Electrical circuit diagram (2nd attachment) (2/4) 711
Electrical circuit diagram (2nd attachment) (3/4) 713
Electrical circuit diagram (2nd attachment) (4/4) 715
Connector list and stereogram 717

S.V 12/12/24