Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-10 PDF

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Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-10 –  PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-10 –  PDF DOWNLOAD

Language : English
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Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-10 –  PDF DOWNLOAD

• SERIAL NUMBERS
  PC27MR-20002 and up
  PC30MR-30001 and up
  PC35MR-15001 and up

COVER . 1
00 Index and foreword . 3
100 Index . 3
Composition of shop manual 4
Table of contents . 6
200 Foreword and general information 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
100 Specification and technical data 55
Specification dimension drawing . 56
Working range drawing . 57
Specifications 58
Weight table 68
Table of fuel, coolant and lubricants . 72
10 Structure, function and maintenance standard . 75
100 Engine and cooling system . 75
PTO . 76
Cooling system 78
200 Power train . 81
Power train . 82
Swing circle 84
Swing machinery . 85
300 Undercarriage and frame . 89
Track frame . 90
Idler cushion . 91
Idler . 92
Track roller 94
Carrier roller 95
Sprocket 96
Track shoe 97
410 Hydraulic system, Part 1 103
Hydraulic components layout drawing .104
Hydraulic tank, filter 105
Center swivel joint .107
Travel motor 109
Hydraulic cylinder 117
Solenoid valve 122
Multi-control valve .128
420 Hydraulic system, Part 2 131
Hydraulic pump 132
Control valve .148
430 Hydraulic system, Part 3 181
CLSS 182
Operation for each function and valve .186
Swing motor .226
PPC valve .231
500 Work equipment 243
Work equipment 244
Dimensions of each part of work equipment .248
600 Cab and its attachments .257
Floor .258
Air conditioner .259
700 Electrical system .261
Engine control system .262
Electric control system .266
Auto-deceleration function 276
Attachment proportional switch, breaker operation switch, work mode selection, flow control function 280
KOMTRAX system 290
Component parts of system .293
Monitor system 294
Sensors .298
20 Standard value table .303
100 Standard service value table 303
Standard service value table for engine related parts .304
Standard service value table for chassis related parts 306
30 Testing and adjusting 331
100 Testing and adjusting .331
Tools for testing, adjusting, and troubleshooting .333
Testing engine speed 336
Testing exhaust gas color .337
Testing and adjusting valve clearance .338
Testing compression pressure 339
Testing engine oil pressure .340
Testing and adjusting fuel injection timing .341
Testing and adjusting alternator belt tension .345
Testing and adjusting air conditioner compressor belt tension .346
Adjusting fuel control lever 347
Testing clearance in swing circle bearings 348
Testing and adjusting track shoe tension 349
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits 350
Testing and adjusting LS differential pressure 355
Adjusting PC valve 358
Testing and adjusting control pump circuit oil pressure .359
Testing solenoid valve output pressure 361
Testing PPC valve output pressure .362
Adjusting PPC valve .366
Testing swing holding brake release pressure 367
Testing and adjusting travel deviation 368
Testing oil leakage from work equipment cylinder 370
Bleeding air from each part .372
Releasing residual pressure from hydraulic circuit 374
Releasing residual pressure from hydraulic tank .375
Pressurizing hydraulic tank .375
How to open and close (tilt) floor 376
Inspection procedures for diode .381
Function and flow of operator and service mode 382
How to start operation of KOMTRAX terminal 406
Lamp display of KOMTRAX terminal 410
Removal and installation of KOMTRAX terminal 413
Preparation work for troubleshooting of electrical system .414
40 Troubleshooting 417
010 Failure code table and fuse locations .417
User code and failure code list .418
Fuse locations 419
100 General information on troubleshooting 425
Points to remember when troubleshooting .426
Sequence of events in troubleshooting .427
Checks before troubleshooting .428
Classification and procedures of troubleshooting 429
Information contained in troubleshooting table 430
Connection table for connector pin numbers 434
T- branch box and T- branch adapter table .470
110 Troubleshooting by failure code .475
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller 478
Failure code [DBH1KK] Unswitched power supply error .480
Failure code [DBH2KK] Solenoid power supply error .482
Failure code [DBH5KP] 5V sensor power supply output 0 error .484
Failure code [DBH6KP] 5V sensor power supply output 1 error .485
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit) .486
Failure code [DDWLKB] Breaker switch error (Hot short circuit) 487
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault) 488
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit) 490
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error .491
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault) .492
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit) .494
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault) 496
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit) 498
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit) .500
Failure code [D1E0KB] Motor power supply relay error (Ground fault) .502
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit) 504
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault) 506
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit) 508
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault) 510
Failure code [DY10MA] Fuel control motor operation error 512
Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side) 514
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side) 516
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection) .518
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault) 520
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit) .521
200 Troubleshooting of electrical system (E-mode) .523
Before carrying out troubleshooting of electrical system 524
E-1 Engine does not start .526
E-2 Engine does not stop 542
E-3 When starting switch is turned ON, any item does not operate 546
E-4 When starting switch is turned ON, some items do not operate 550
E-5 Alarm buzzer is abnormal 551
E-6 Engine oil pressure caution is turned ON 553
E-7 Charge level caution is turned ON .554
E-8 Preheating system does not operate or preheater does not become hot1 556
E-9 Coolant temperature gauge is abnormal .558
E-10 Fuel level gauge is abnormal .566
E-11 Service meter does not operate while engine is running .574
E-12 2nd travel speed is not selected .578
E-13 Working lamp does not light up .582
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves 586
E-15 Windshield wiper does not operate 590
E-16 Windshield washer does not operate .594
E-17 Defective air conditioner 597
E-18 KOMTRAX system does not operate normally .605
300 Troubleshooting of hydraulic and mechanical system (H-mode) .609
Information contained in troubleshooting table 611
H1 Speed or power of whole work equipment, travel, swing, and blade is low 612
H-2 Engine speed lowers extremely or engine stalls 616
H-3 Whole work equipment, travel system, swing system, and blade do not work 617
H-4 Abnormal sound comes out from around hydraulic pump .621
H-5 Fine control performance or response is low .621
H-6 Speed or power of boom is low .622
H-7 Speed or power of arm is low 623
H-8 Speed or power of bucket is low .624
H-9 Speed or power of boom swing is low .625
H-10 Work equipment does not move singly 625
H-11 Work equipment hydraulic drift is large 626
H-12 Time lag of work equipment is large 628
H-13 In compound operation of work equipment, speed of part loaded more is low 628
H-14 Machine deviates during travel .629
H-15 Travel speed or travel power is low (while work equipment is normal) .631
H-16 Machine is not steered well or steering power is low .632
H-17 Travel speed does not change .633
H-18 Travel motor does not work .634
H-19 Speed or power of swing is low .636
H-20 Machine does not swing .638
H-21 Swing acceleration performance is low 640
H-22 Machine overruns when it stops swinging 642
H-23 Large shock is made when machine stops swinging 643
H-24 When upper structure stops swinging, it makes large sound 643
H-25 Hydraulic drift of swing is large 644
H-26 Speed or power of blade is low .645
H-27 Blade does not move 646
H-28 Hydraulic drift of blade is large 647
400 Troubleshooting of engine (S-mode) 649
Method of using troubleshooting charts 651
S-1 Starting performance is poor 654
S-2 Engine does not start .655
S-3 Engine does not pick up smoothly 658
S-4 Engine stops during operations 659
S-5 Engine does not rotate smoothly .660
S-6 Engine lacks output (or lacks power) 661
S-7 Exhaust smoke is black (incomplete combustion) 662
S-8 Oil consumption is excessive (or exhaust smoke is blue) .663
S-9 Oil becomes contaminated quickly 664
S-10 Fuel consumption is excessive 665
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 666
S-12 Oil pressure drops .667
S-13 Oil level rises (Entry of coolant/fuel) 668
S-14 Coolant temperature becomes too high (overheating) .669
S-15 Abnormal noise is made .670
S-16 Vibration is excessive .671
50 Disassembly and assembly .673
100 General information on disassembly and assembly .673
How to read this manual .674
Coating materials list 676
Special tool list .679
Sketches of special tools .683
200 Engine and cooling system .685
Removal and installation of fuel injection pump assembly 686
Removal and installation of radiator and hydraulic oil cooler assembly 689
Removal and installation of engine and hydraulic pump assembly 693
300 Power train .697
Removal and installation of swing motor and swing machinery assembly 698
Disassembly and assembly of swing motor and swing machinery assembly 699
Removal and installation of swing circle assembly .704
400 Undercarriage and frame .707
Removal and installation of track shoe assembly .708
Disassembly and assembly of idler assembly 709
Disassembly and assembly of recoil spring assembly 711
Disassembly and assembly of track roller assembly .714
Disassembly and assembly of carrier roller assembly .715
Removal and installation of revolving frame assembly 716
500 Hydraulic system 719
Removal and installation of center swivel joint assembly 720
Disassembly and assembly of center swivel joint assembly 722
Disassembly and assembly of control valve assembly 724
Disassembly and assembly of hydraulic cylinder assembly .725
600 Work equipment 731
Removal and installation of blade assembly 732
Removal and installation of work equipment assembly .733
700 Cab and its attachments .737
Removal and installation of operator’s cab glass (stuck glass) 738
Removal and installation of front window assembly .747
Removal and installation of floor frame assembly 748
800 Electrical system .753
Removal and installation of air conditioner unit assembly (If equipped) .754
90 Diagrams and drawings 759
100 Hydraulic diagrams and drawings .759
Hydraulic circuit diagram .761
200 Electrical diagrams and drawings 775
Electrical circuit diagram 777
Connector list and stereogram .793

DESCRIPTION:

Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-10 –  PDF DOWNLOAD

• SERIAL NUMBERS
  PC27MR-20002 and up
  PC30MR-30001 and up
  PC35MR-15001 and up

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.
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.

G.B 25/12/24