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

Description

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

FILE DETAILS:

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

Language : English
Pages :630
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

MACHINE MODEL SERIAL NUMBER
PC27MR-2 15001 and up
PC30MR-2 20001 and up
PC35MR-2 5001 and up
PC40MR-2 8001 and up
PC50MR-2 5001 and up

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.

TABLE OF CONTENTS:

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

MACHINE MODEL SERIAL NUMBER
PC27MR-2 15001 and up
PC30MR-2 20001 and up
PC35MR-2 5001 and up
PC40MR-2 8001 and up
PC50MR-2 5001 and up

COVER 1
CONTENTS 2
01 GENERAL 27
SPECIFICATION DIMENSION DRAWING 28
WORKING RANGE DRAWING 30
SPECIFICATIONS 32
WEIGHT TABLE 51
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 59
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 62
PTO 63
COOLING SYSTEM 64
POWER TRAIN 67
SWING CIRCLE 69
SWING MACHINERY 70
TRACK FRAME 74
IDLER CUSHION 76
IDLER 77
TRACK ROLLER 79
CARRIER ROLLER 81
SPROCKET 82
TRACK SHOE 83
HYDRAULIC COMPONENTS LAYOUT DRAWING 90
HYDRAULIC TANK 92
CENTER SWIVEL JOINT 95
TRAVEL MOTOR 98
HYDRAULIC CYLINDER106
SOLENOID VALVE113
MULTI-CONTROL VALVE117
HYDRAULIC PUMP118
CONTROL VALVE136
CLSS173
OPERATION FOR EACH FUNCTION AND VALVE176
SWING MOTOR218
PPC VALVE230
WORK EQUIPMENT238
DIMENSIONS OF EACH PART OF WORK EQUIPMENT241
FLOOR252
AIR CONDITIONER254
ENGINE CONTROL255
ELECTRIC CONTROL SYSTEM257
COMPONENT PARTS OF SYSTEM265
MONITOR SYSTEM266
MONITOR PANEL267
SENSORS269
20 TESTING AND ADJUSTING271
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS272
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS277
TESTING AND ADJUSTING303
LIST OF TESTING,ADJUSTING, AND TROUBLESHOOTING TOOLS304
MEASURING ENGINE SPEED306
MEASUREMENT OF EXHAUST GAS COLOR307
ADJUSTING VALVE CLEARANCE308
MEASURING COMPRESSION PRESSURE310
MEASURING ENGINE OIL PRESSURE311
TESTING AND ADJUSTING FUEL INJECTION TIMING312
TESTING AND ADJUSTING ALTERNATOR BELT TENSION315
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION316
ADJUSTING FUEL CONTROL LEVER317
TESTING AND ADJUSTING TRACK SHOE TENSION318
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS319
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING,AND BLADE CIRCUITS320
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE326
ADJUSTING PC VALVE330
MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE)331
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE332
MEASURING SOLENOID VALVE OUTPUT PRESSURE334
MEASURING PPC VALVE OUTPUT PRESSURE336
ADJUSTING PPC VALVE340
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE341
TESTING AND ADJUSTING TRAVEL DEVIATION342
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER344
BLEEDING AIR FROM EACH PART346
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT349
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK349
PRESSURIZING HYDRAULIC TANK350
HOW TO OPEN AND CLOSE (TILT) FLOOR351
INSPECTION PROCEDURES FOR DIODE355
TROUBLESHOOTING356
POINTS TO REMEMBER WHEN TROUBLESHOOTING357
SEQUENCE OF EVENTS IN TROUBLESHOOTING358
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE359
CHECKS BEFORE TROUBLESHOOTING367
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING368
TYPES AND LOCATIONS OF CONNECTORS371
CONNECTOR ARRANGEMENT DIAGRAM377
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS385
T-ADAPTER-BOXES AND T-ADAPTER TABLE408
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)411
BEFORE STARTING E-MODE TROUBLESHOOTING412
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE413
E-1 ENGINE DOES NOT START414
E-2 ENGINE DOES NOT STOP422
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES426
E-4 WINDSHIELD WIPER DOES NOT OPERATE430
E-5 WINDSHIELD WASHER DOES NOT OPERATE432
E-6 TRAVEL ALARM DOES NOT SOUND436
E-7 DEFECTIVE AIR CONDITIONER440
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)448
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE449
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL,SWING,AND BLADE IS LOW450
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS454
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK455
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP459
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW459
H-6 SPEED OR POWER OF BOOM IS LOW460
H-7 SPEED OR POWER OF ARM IS LOW461
H-8 SPEED OR POWER OF BUCKET IS LOW462
H-9 SPEED OR POWER OF BOOM SWING IS LOW463
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY463
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE464
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE465
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW465
H-14 MACHINE DEVIATES DURING TRAVEL466
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL)468
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW469
H-17 TRAVEL SPEED DOES NOT CHANGE470
H-18 TRAVEL MOTOR DOES NOT WORK471
H-19 SPEED OR POWER OF SWING IS LOW473
H-20 MACHINE DOES NOT SWING475
H-21 SWING ACCELERATION PERFORMANCE IS LOW477
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING479
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING480
H-24 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING,IT MAKES LARGE SOUND480
H-25 HYDRAULIC DRIFT OF SWING IS LARGE481
H-26 SPEED OR POWER OF BLADE IS LOW482
H-27 BLADE DOES NOT MOVE483
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE483
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE)484
BEFORE STARTING M-MODE TROUBLESHOOTING485
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE486
SYSTEM DIAGRAM RELATED TO MONITOR PANEL487
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE489
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE491
M-3 ALARM BUZZER IS ABNORMAL492
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON494
M-5 CHARGE LEVEL CAUTION IS TURNED ON495
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT499
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL501
M-8 FUEL LEVEL GAUGE IS ABNORMAL506
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING 510
M-10 2ND TRAVEL SPEED IS NOT SELECTED512
M-11 WORKING LAMP DOES NOT LIGHT UP517
TROUBLESHOOTING OF ENGINE (S-MODE)520
METHOD OF USING TROUBLESHOOTING CHARTS521
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)525
S-2 ENGINE DOES NOT START527
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)530
S-4 ENGINE STOPS DURING OPERATIONS531
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)532
S-6 ENGINE LACKS OUTPUT OR LACKS POWER533
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)534
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE535
S-9 OIL BECOMES CONTAMINATED QUICKLY536
S-10 FUEL CONSUMPTION IS EXCESSIVE537
S-11 OIL IS IN COOLANT, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN538
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)539
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)540
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)541
S-15 ABNORMAL NOISE IS MADE542
S-16 VIBRATION IS EXCESSIVE543
30 DISASSEMBLY AND ASSEMBLY544
HOW TO READ THIS MANUAL545
PRECAUTIONS WHEN PERFORMING OPERATION547
SPECIAL TOOL LIST551
SKETCHES OF SPECIAL TOOLS555
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY556
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY558
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY565
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY572
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY573
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY575
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY578
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY580
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY581
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY584
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY586
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY590
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY591
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY597
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY599
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY601
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY602
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY603
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY607
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)610
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY618
90 OTHERS619
HYDRAULIC CIRCUIT DIAGRAM PC27MR-2620
HYDRAULIC CIRCUIT DIAGRAM PC30MR-2621
HYDRAULIC CIRCUIT DIAGRAM PC35MR-2622
HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2623
HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2 (ADDITIONAL ATTACHMENT CIRCUIT) 624
ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (1/2)625
ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (2/2)626
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (1/2)627
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (2/2)628
ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (1/2)629
ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (2/2)630

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24