Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-C8 PDF

Description

Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-C8 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-C8 – PDF DOWNLOAD

Language : English
Pages :780
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-C8 – PDF DOWNLOAD

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

1. General precautions

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC27MR-3 PC30MR-3 PC35MR-3 Shop Manual SEN04063-C8 – PDF DOWNLOAD

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

Cover 1
00 Index and foreword 0
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 0
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 0
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 1103
Hydraulic components layout drawing104
Hydraulic tank, filter105
Center swivel joint107
Travel motor109
Hydraulic cylinder117
Solenoid valve122
Multi-control valve128
420 Hydraulic system, Part 2131
Hydraulic pump132
Control valve148
430 Hydraulic system, Part 3181
CLSS182
Operation for each function and valve186
Swing motor226
PPC valve231
500 Work equipment243
Work equipment244
Dimensions of each part of work equipment248
600 Cab and its attachments257
Floor258
Air conditioner259
700 Electrical system261
Engine control system262
Electric control system266
Auto-deceleration function276
Attachment proportional switch, breaker operation switch, work mode selection, flow control function280
KOMTRAX system290
Component parts of system293
Monitor system294
Sensors298
20 Standard value table 0
100 Standard service value table303
Standard service value table for engine related parts304
Standard service value table for chassis related parts306
30 Testing and adjusting 0
100 Testing and adjusting331
Tools for testing, adjusting, and troubleshooting333
Testing engine speed336
Testing exhaust gas color337
Testing and adjusting valve clearance338
Testing compression pressure339
Testing engine oil pressure340
Testing and adjusting fuel injection timing341
Testing and adjusting alternator belt tension345
Testing and adjusting air conditioner compressor belt tension346
Adjusting fuel control lever347
Testing clearance in swing circle bearings348
Testing and adjusting track shoe tension349
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits350
Testing and adjusting LS differential pressure355
Adjusting PC valve358
Testing and adjusting control pump circuit oil pressure359
Testing solenoid valve output pressure361
Testing PPC valve output pressure362
Adjusting PPC valve366
Testing swing holding brake release pressure367
Testing and adjusting travel deviation368
Testing oil leakage from work equipment cylinder370
Bleeding air from each part372
Releasing residual pressure from hydraulic circuit374
Releasing residual pressure from hydraulic tank375
Pressurizing hydraulic tank375
How to open and close (tilt) floor376
Inspection procedures for diode381
Function and flow of operator and service mode382
How to start operation of KOMTRAX terminal406
Lamp display of KOMTRAX terminal410
Removal and installation of KOMTRAX terminal413
Preparation work for troubleshooting of electrical system414
40 Troubleshooting 0
010 Failure code table and fuse locations417
User code and failure code list418
Fuse locations419
100 General information on troubleshooting425
Points to remember when troubleshooting426
Sequence of events in troubleshooting427
Checks before troubleshooting428
Classification and procedures of troubleshooting429
Information contained in troubleshooting table430
Connection table for connector pin numbers434
T- branch box and T- branch adapter table470
110 Troubleshooting by failure code475
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller478
Failure code [DBH1KK] Unswitched power supply error480
Failure code [DBH2KK] Solenoid power supply error482
Failure code [DBH5KP] 5V sensor power supply output 0 error484
Failure code [DBH6KP] 5V sensor power supply output 1 error485
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 error491
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 error512
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 system524
E-1 Engine does not start526
E-2 Engine does not stop542
E-3 When starting switch is turned ON, any item does not operate546
E-4 When starting switch is turned ON, some items do not operate550
E-5 Alarm buzzer is abnormal551
E-6 Engine oil pressure caution is turned ON553
E-7 Charge level caution is turned ON554
E-8 Preheating system does not operate or preheater does not become hot1556
E-9 Coolant temperature gauge is abnormal558
E-10 Fuel level gauge is abnormal566
E-11 Service meter does not operate while engine is running574
E-12 2nd travel speed is not selected578
E-13 Working lamp does not light up582
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves586
E-15 Windshield wiper does not operate590
E-16 Windshield washer does not operate594
E-17 Defective air conditioner597
E-18 KOMTRAX system does not operate normally605
300 Troubleshooting of hydraulic and mechanical system (H-mode)609
Information contained in troubleshooting table611
H1 Speed or power of whole work equipment, travel, swing, and blade is low612
H-2 Engine speed lowers extremely or engine stalls616
H-3 Whole work equipment, travel system, swing system, and blade do not work617
H-4 Abnormal sound comes out from around hydraulic pump621
H-5 Fine control performance or response is low621
H-6 Speed or power of boom is low622
H-7 Speed or power of arm is low623
H-8 Speed or power of bucket is low624
H-9 Speed or power of boom swing is low625
H-10 Work equipment does not move singly625
H-11 Work equipment hydraulic drift is large626
H-12 Time lag of work equipment is large628
H-13 In compound operation of work equipment, speed of part loaded more is low628
H-14 Machine deviates during travel629
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 low632
H-17 Travel speed does not change633
H-18 Travel motor does not work634
H-19 Speed or power of swing is low636
H-20 Machine does not swing638
H-21 Swing acceleration performance is low640
H-22 Machine overruns when it stops swinging642
H-23 Large shock is made when machine stops swinging643
H-24 When upper structure stops swinging, it makes large sound643
H-25 Hydraulic drift of swing is large644
H-26 Speed or power of blade is low645
H-27 Blade does not move646
H-28 Hydraulic drift of blade is large647
400 Troubleshooting of engine (S-mode)649
Method of using troubleshooting charts651
S-1 Starting performance is poor654
S-2 Engine does not start655
S-3 Engine does not pick up smoothly658
S-4 Engine stops during operations659
S-5 Engine does not rotate smoothly660
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 quickly664
S-10 Fuel consumption is excessive665
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)666
S-12 Oil pressure drops667
S-13 Oil level rises (Entry of coolant/fuel)668
S-14 Coolant temperature becomes too high (overheating)669
S-15 Abnormal noise is made670
S-16 Vibration is excessive671
50 Disassembly and assembly 0
100 General information on disassembly and assembly673
How to read this manual674
Coating materials list676
Special tool list679
Sketches of special tools683
200 Engine and cooling system685
Removal and installation of fuel injection pump assembly686
Removal and installation of radiator and hydraulic oil cooler assembly689
Removal and installation of engine and hydraulic pump assembly693
300 Power train697
Removal and installation of swing motor and swing machinery assembly698
Disassembly and assembly of swing motor and swing machinery assembly699
Removal and installation of swing circle assembly704
400 Undercarriage and frame707
Removal and installation of track shoe assembly708
Disassembly and assembly of idler assembly709
Disassembly and assembly of recoil spring assembly711
Disassembly and assembly of track roller assembly714
Disassembly and assembly of carrier roller assembly715
Removal and installation of revolving frame assembly716
500 Hydraulic system719
Removal and installation of center swivel joint assembly720
Disassembly and assembly of center swivel joint assembly722
Disassembly and assembly of control valve assembly724
Disassembly and assembly of hydraulic cylinder assembly725
600 Work equipment731
Removal and installation of work equipment assembly732
700 Cab and its attachments735
Removal and installation of operator’s cab glass (stuck glass)736
Removal and installation of front window assembly745
Removal and installation of floor frame assembly746
800 Electrical system751
Removal and installation of air conditioner unit assembly (If equipped)752
90 Diagrams and drawings 0
100 Hydraulic diagrams and drawings757
Hydraulic circuit diagram759
200 Electrical diagrams and drawings767
Electrical circuit diagram769
Connector list and stereogram777

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24