Komatsu Hydraulic Excavator Galeo PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PCMR50-2 Shop Manual PDF

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Komatsu Hydraulic Excavator Galeo PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PCMR50-2 Shop Manual – PDF DOWNLOAD

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Komatsu Hydraulic Excavator Galeo PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PCMR50-2 Shop Manual – PDF DOWNLOAD

Language : English
Pages :618
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator Galeo PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PCMR50-2 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER
PC27MR-2 15001 and up PCS0MR-2 20001 and up PCS5MR-2 5001 and up PC40MR-2 8001 and up
PC50MR-2 5001 and up

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator Galeo PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PCMR50-2 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER
PC27MR-2 15001 and up PCS0MR-2 20001 and up PCS5MR-2 5001 and up PC40MR-2 8001 and up
PC50MR-2 5001 and up

COVER 3
CONTENTS 4
01 GENERAL 28
SPECIFICATION DIMENSION DRAWING 29
WORKING RANGE DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 46
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS 50
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 52
PTO 53
COOLING SYSTEM 54
POWER TRAIN 57
SWING CIRCLE 59
SWING MACHINERY 60
TRACK FRAME 64
IDLER CUSHION 66
IDLER 67
TRACK ROLLER 69
CARRIER ROLLER 71
SPROCKET 72
TRACK SHOE 73
HYDRAULIC COMPONENTS LAYOUT DRAWING 80
HYDRAULIC TANK 82
CENTER SWIVEL JOINT 85
TRAVEL MOTOR 88
HYDRAULIC CYLINDER 96
SOLENOID VALVE103
MULTI-CONTROL VALVE107
HYDRAULIC PUMP108
CONTROL VALVE126
CLSS163
OPERATION FOR EACH FUNCTION AND VALVE166
SWING MOTOR208
PPC VALVE220
WORK EQUIPMENT228
DIMENSIONS OF EACH PART OF WORK EQUIPMENT231
FLOOR242
AIR CONDITIONER243
ENGINE CONTROL244
ELECTRIC CONTROL SYSTEM246
COMPONENT PARTS OF SYSTEM254
MONITOR SYSTEM255
MONITOR PANEL256
SENSORS258
20 TESTING AND ADJUSTING260
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS261
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS265
TESTING AND ADJUSTING291
LIST OF TESTING,ADJUSTING, AND TROUBLESHOOTING TOOLS292
MEASURING ENGINE SPEED294
MEASUREMENT OF EXHAUST GAS COLOR295
ADJUSTING VALVE CLEARANCE296
MEASURING COMPRESSION PRESSURE299
MEASURING ENGINE OIL PRESSURE300
TESTING AND ADJUSTING FUEL INJECTION TIMING301
TESTING AND ADJUSTING ALTERNATOR BELT TENSION304
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION305
ADJUSTING FUEL CONTROL LEVER306
TESTING WEAR OF SPROCKET307
TESTING AND ADJUSTING TRACK SHOE TENSION308
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS309
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING,AND BLADE CIRCUITS310
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE316
ADJUSTING PC VALVE320
MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE)321
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE322
MEASURING SOLENOID VALVE OUTPUT PRESSURE324
MEASURING PPC VALVE OUTPUT PRESSURE326
ADJUSTING PPC VALVE330
MEAURING SWING HOLDING BRAKE RELEASE PRESSURE331
TESTING AND ADJUSTING TRAVEL DEVIATION332
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER334
BLEEDING AIR FROM EACH PART336
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT339
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK339
PRESSURIZING HYDRAULIC TANK340
INSPECTION PROCEDURES FOR DIODE341
TROUBLESHOOTING342
POINTS TO REMEMBER WHEN TROUBLESHOOTING343
SEQUENCE OF EVENTS IN TROUBLESHOOTING344
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE345
CHECKS BEFORE TROUBLESHOOTING353
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING354
TYPES AND LOCATIONS OF CONNECTORS357
CONNECTOR ARRANGEMENT DIAGRAM363
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS371
T-ADAPTER-BOXES AND T-ADAPTER TABLE393
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)396
BEFORE STARTING E-MODE TROUBLESHOOTING397
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE398
E-1 ENGINE DOES NOT START399
E-2 ENGINE DOES NOT STOP407
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION,WORK EQUIPMENT STILL MOVES411
E-4 WINDSHIELD WIPER DOES NOT OPERATE415
E-5 WINDSHIELD WASHER DOES NOT OPERATE417
E-6 TRAVEL ALARM DOES NOT SOUND421
E-7 DEFECTIVE AIR CONDITIONER425
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)433
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE434
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL,SWING,AND BLADE IS LOW435
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS439
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK440
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP444
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW444
H-6 SPEED OR POWER OF BOOM IS LOW445
H-7 SPEED OR POWER OF ARM IS LOW446
H-8 SPEED OR POWER OF BUCKET IS LOW447
H-9 SPEED OR POWER OF BOOM SWING IS LOW448
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY448
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE449
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE450
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW450
H-14 MACHINE DEVIATES DURING TRAVEL451
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL)453
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW454
H-17 TRAVEL SPEED DOES NOT CHANGE455
H-18 TRAVEL MOTOR DOES NOT WORK456
H-19 SPEED OR POWER OF SWING IS LOW458
H-20 MACHINE DOES NOT SWING460
H-21 SWING ACCELERATION PERFORMANCE IS LOW462
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING464
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING465
H-24 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING,IT MAKES LARGE SOUND465
H-25 HYDRAULIC DRIFT OF SWING IS LARGE466
H-26 SPEED OR POWER OF BLADE IS LOW467
H-27 BLADE DOES NOT MOVE468
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE468
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE)469
BEFORE STARTING M-MODE TROUBLESHOOTING470
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE471
SYSTEM DIAGRAM RELATED TO MONITOR PANEL472
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE474
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE476
M-3 ALARM BUZZER IS ABNORMAL477
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON479
M-5 CHARGE LEVEL CAUTION IS TURNED ON480
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT484
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL486
M-8 FUEL LEVEL GAUGE IS ABNORMAL491
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING 495
M-10 2ND TRAVEL SPEED IS NOT SELECTED497
M-11 WORKING LAMP DOES NOT LIGHT UP502
TROUBLESHOOTING OF ENGINE (S-MODE)505
METHOD OF USING TROUBLESHOOTING CHARTS506
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)510
S-2 ENGINE DOES NOT START512
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)515
S-4 ENGINE STOPS DURING OPERATIONS516
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)517
S-6 ENGINE LACKS OUTPUT OR LACKS POWER518
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)519
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE520
S-9 OIL BECOMES CONTAMINATED QUICKLY521
S-10 FUEL CONSUMPTION IS EXCESSIVE522
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN523
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)524
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)525
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)526
S-15 ABNORMAL NOISE IS MADE527
S-16 VIBRATION IS EXCESSIVE528
30 DISASSEMBLY AND ASSEMBLY529
HOW TO READ THIS MANUAL530
PRECAUTIONS WHEN PERFORMING OPERATION532
SPECIAL TOOL LIST534
SKETCHES OF SPECIAL TOOLS538
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY539
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY541
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY550
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY557
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY558
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY560
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY563
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY565
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOIT ASSEMBLY566
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOIT ASSEMBLY569
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY571
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY575
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY576
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY582
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY584
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY586
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY587
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY588
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY592
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)595
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY603
90 OTHERS604
HYDRAULIC CIRCUIT DIAGRAM PC27MR-2605
HYDRAULIC CIRCUIT DIAGRAM PC30MR-2606
HYDRAULIC CIRCUIT DIAGRAM PC35MR-2607
HYDRAULIC CIRCUIT DIAGRAM PC40,50MR-2608
HYDRAULIC CIRCUIT DIAGRAM (ADDITIONAL ATTACHMENT CIRCUIT) PC40,50MR-2609
ELECTRICAL CIRCUIT DIAGRAM PC27,30MR-2(1/2)610
ELECTRICAL CIRCUIT DIAGRAM PC27,30MR-2(2/2)611
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2(1/2)612
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2(2/2)613
ELECTRICAL CIRCUIT DIAGRAM PC40,50MR-2(1/2)614
ELECTRICAL CIRCUIT DIAGRAM PC40,50MR-2(2/2)615

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24