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KOMATSU PC20-6 PC30-6 PC40-6 SERVICE REPAIR MANUAL (SEBM020R0604) KOMATSU PC20-6 PC30-6 PC40-6 – PDF DOWNLOAD
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- KOMATSU PC20-6 PC30-6 PC40-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM020R0604
- SERIAL NUMBER:PC20-G 24001 and up
PC30-6 10001 and up
PC40-6 10001 and up
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Description
KOMATSU PC20-6 PC30-6 PC40-6 SERVICE REPAIR MANUAL (SEBM020R0604) KOMATSU PC20-6 PC30-6 PC40-6
KOMATSU PC20-6 PC30-6 PC40-6 SERVICE REPAIR MANUAL (SEBM020R0604) KOMATSU PC20-6 PC30-6 PC40-6 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC20-6 PC30-6 PC40-6 SERVICE REPAIR MANUAL (SEBM020R0604) KOMATSU PC20-6 PC30-6 PC40-6
- 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 PC20-6 PC30-6 PC40-6 SERVICE REPAIR MANUAL (SEBM020R0604) KOMATSU PC20-6 PC30-6 PC40-6
COVER..................................................................................................................... 1 CONTENTS.................................................................................................................. 2 10 STRUCTURE AND FUNCTION................................................................................................. 17 POWER TRAIN........................................................................................................... 18 SWING CIRCLE.......................................................................................................... 19 SWING MACHINERY....................................................................................................... 20 SPROCKET.............................................................................................................. 22 TRACK FRAME AND RECOIL SPRING......................................................................................... 23 IDLER................................................................................................................. 24 TRACK ROLLER.......................................................................................................... 24 TRACK SHOE............................................................................................................ 25 HYDRAULIC PIPING...................................................................................................... 27 HYDRAULIC CIRCUIT SCHEMATICS.......................................................................................... 29 HYDRAULIC CIRCUIT DIAGRAM............................................................................................. 32 HYDRAULIC TANK........................................................................................................ 39 HYDRAULIC TRIPLE GEAR PUMP............................................................................................ 41 6-SPOOL CONTROL VALVE................................................................................................. 43 2-SPOOL CONTROL VALVE................................................................................................. 45 3-SPOOL CONTROL VALVE................................................................................................. 46 CENTER SWIVEL JOINT................................................................................................... 49 SWING MOTOR........................................................................................................... 51 TRAVEL MOTOR (WITH REDUCTION GEAR).................................................................................... 52 VALVE CONTROL......................................................................................................... 57 WORK EQUIPMENT........................................................................................................ 58 ELECTRICAL CIRCUIT DIAGRAM............................................................................................ 59 20 TESTING AND ADJUSTING.................................................................................................. 63 TABLE OF JUDGEMENT STANDARD VALVE..................................................................................... 64 TESTING AND ADJUSTING TOOL LIST....................................................................................... 74 ADJUSTING VALVE CLEARANCE (PC20,30-6)................................................................................. 75 ADJUSTING VALVE CLEARANCE (PC40-6).................................................................................... 76 MEASURING COMPRESSION PRESSURE........................................................................................ 77 TESTING AND ADJUSTING FUEL INJECTION TIMING (PC20,30-6)............................................................... 78 TESTING AND ADJUSTING FUEL INJECTION TIMING (PC40-6).................................................................. 79 BLEEDING AIR FROM HYDRAULIC CYLINDERS................................................................................. 80 MEASURING AND ADJUSTING HYDRAULIC PRESSURE............................................................................ 81 MEASURING HYDRAULIC PRESSURE OF ACCELERATION CIRCUIT (PC30,40-6)...................................................... 84 MEASURING DISCHARGE AMOUNT OF PUMP.................................................................................... 85 MEASURING OIL LEAKAGE FROM SWING, TRAVEL MOTORS....................................................................... 86 TESTING FOR LEAKAGE OF OIL FROM CENTER SWIVEL JOINT (PC20-6).......................................................... 87 TESTING FOR LEAKAGE OF OIL FROM CENTER SWIVEL JOINT (PC30-6).......................................................... 88 TESTING FOR LEAKAGE OF OIL FROM CENTER SWIVEL JOINT (PC40-6).......................................................... 89 MEASURING LEAKAGE FROM HYDRAULIC CYLINDERS............................................................................ 90 TROUBLESHOOTING....................................................................................................... 91 PREPARATION OF TROUBLESHOOTING.................................................................................... 92 HOW TO USE DIAGNOSTIC TABLE....................................................................................... 94 PREVENTING RECURRENCE OF THE SAME TROUBLE......................................................................... 96 1.WORK EQUIPMENT, SWING, AND TRAVEL DO NOT MOVE, OR SPEED IS EXTREMELY SLOW................................... 97 2.ARM IN (OUT) LACKS POWER (INCLUDING LACK OF SPEED).......................................................... 98 3.BUCKET CURL (DUMP), BOOM RAISE (PUSHING UP CHASSIS), AND BOOM SWING LACK POWER (INCLUDING LACK OF SPEED).... 99 4.ARM IN (OUT) OPERATION IS IMPOSSIBLE........................................................................100 5.BUCKET CURL (DUMP), BOOM RAISE (LOWER), BOOM SWING OPERATION IS IMPOSSIBLE..................................101 6.EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT (BOOM, ARM, BUCKET, BLADE, BOOM SWING)..........................102 7.BLADE LACKS POWER (INCLUDING LACK OF SPEED).................................................................103 8.BLADE OPERATION IS IMPOSSIBLE...............................................................................104 9.LEFT (RIGHT) BOOM SWING LACKS POWER (INCLUDING LACK OF SPEED)...............................................105 10.SWING OPERATION IS IMPOSSIBLE TO LEFT (OR RIGHT)...........................................................106 11.EXCESSIVE OVERRUN OF SWING ON SLOPES (HYDRAULIC DRIFT OF SWING)............................................107 12.EXCESSIVE OVERRUN WHEN SWING IS STOPPED....................................................................108 13.MACHINE NATURALLY DEVIATES TO ONE SIDE WHEN TRAVELING......................................................109 14.MACHINE DOES NOT TRAVEL FORWARD (IN REVERSE)...............................................................110 15.TRAVEL SPEED DOES NOT CHANGE (PC30.40-6)...................................................................111 30 DISASSEMBLY AND ASSEMBLY...............................................................................................112 METHOD OF READING MANUAL..............................................................................................114 TABLE OF SPECIAL TOOLS................................................................................................116 STARTING MOTOR........................................................................................................118 REMOVAL...........................................................................................................118 INSTALLATION......................................................................................................118 ALTERNATOR............................................................................................................118 REMOVAL...........................................................................................................118 INSTALLATION......................................................................................................118 WATER PUMP............................................................................................................120 REMOVAL...........................................................................................................120 INSTALLATION......................................................................................................120 FUEL INJECTION PUMP...................................................................................................122 REMOVAL...........................................................................................................122 INSTALLATION......................................................................................................122 NOZZLE HOLDER.........................................................................................................124 REMOVAL...........................................................................................................124 INSTALLATION......................................................................................................124 CYLINDER HEAD.........................................................................................................126 REMOVAL (PC20.30-6)...............................................................................................126 INSTALLATION (PC20.30-6)..........................................................................................126 REMOVAL (PC40-6)..................................................................................................128 INSTALLATION (PC40-6).............................................................................................128 HYDRAULIC OIL COOLER .................................................................................................130 REMOVAL...........................................................................................................130 INSTALLATION......................................................................................................130 RADIATOR..............................................................................................................130 REMOVAL ..........................................................................................................130 INSTALLATION......................................................................................................130 ENGINE................................................................................................................132 REMOVAL (PC20,30-6)...............................................................................................132 INSTALLATION (PC20,30-6)..........................................................................................132 REMOVAL (PC40-6)..................................................................................................134 INSTALLATION (PC40-6).............................................................................................134 SWING CIRCLE..........................................................................................................136 REMOVAL...........................................................................................................136 INSTALLATION......................................................................................................136 SWING MACHINERY.......................................................................................................138 REMOVAL...........................................................................................................138 INSTALLATION .....................................................................................................138 DISASSEMBLY (PC20.30-6)...........................................................................................140 ASSEMBLY (PC20.30-6)..............................................................................................142 DISASSEMBLY (PC40-6)..............................................................................................144 ASSEMBLY (PC40-6).................................................................................................146 REVOLVING FRAME.......................................................................................................148 REMOVAL...........................................................................................................148 INSTALLATION......................................................................................................148 TRACK SHOE............................................................................................................150 REMOVAL...........................................................................................................150 INSTALLATION......................................................................................................150 TRACK ROLLER..........................................................................................................152 REMOVAL...........................................................................................................152 INSTALLATION......................................................................................................152 IDLER, RECOIL SPRING..................................................................................................152 REMOVAL...........................................................................................................152 INSTALLATION......................................................................................................152 RECOIL SPRING.........................................................................................................154 DISASSEMBLY.......................................................................................................154 ASSEMBLY..........................................................................................................154 SPROCKET..............................................................................................................156 REMOVAL...........................................................................................................156 INSTALLATION......................................................................................................156 HYDRAULIC PUMP........................................................................................................156 REMOVAL...........................................................................................................156 INSTALLATION......................................................................................................156 6-SPOOL CONTROL VALVE.................................................................................................158 REMOVAL...........................................................................................................158 INSTALLATION......................................................................................................158 3-SPOOL CONTROL VALVE.................................................................................................158 REMOVAL...........................................................................................................158 INSTALLATION......................................................................................................158 2-SPOOL CONTROL VALVE.................................................................................................158 REMOVAL...........................................................................................................158 INSTALLATION......................................................................................................158 6-SPOOL CONTROL VALVE.................................................................................................160 DISASSEMBLY.......................................................................................................160 ASSEMBLY..........................................................................................................160 3-SPOOL CONTROL VALVE.................................................................................................162 DISASSEMBLY.......................................................................................................162 ASSEMBLY..........................................................................................................162 SWING MOTOR...........................................................................................................164 REMOVAL...........................................................................................................164 INSTALLATION......................................................................................................164 DISASSEMBLY.......................................................................................................166 ASSEMBLY..........................................................................................................168 CENTER SWIVEL JOINT...................................................................................................170 REMOVAL...........................................................................................................170 INSTALLATION......................................................................................................170 DISASSEMBLY (PC20,30-6)...........................................................................................172 ASSEMBLY (PC20,30-6)..............................................................................................172 DISASSEMBLY (PC40-6)..............................................................................................174 ASSEMBLY (PC40-6).................................................................................................174 TRAVEL MOTOR..........................................................................................................176 REMOVAL...........................................................................................................176 INSTALLATION......................................................................................................176 DISASSEMBLY (PC20-6)..............................................................................................178 ASSEMBLY (PC20-6).................................................................................................190 DISASSEMBLY (PC30,40-6)...........................................................................................208 ASSEMBLY (PC30,40-6)..............................................................................................222 DISASSEMBLY (PC20-6)..............................................................................................240 ASSEMBLY (PC20-6).................................................................................................248 DISASSEMBLY (PC30-6)..............................................................................................258 ASSEMBLY (PC30-6).................................................................................................266 DISASSEMBLY (PC40-6)..............................................................................................278 ASSEMBLY (PC40-6).................................................................................................286 BOOM CYLINDER ........................................................................................................296 REMOVAL...........................................................................................................296 INSTALLATION......................................................................................................296 ARM CYLINDER .........................................................................................................298 REMOVAL...........................................................................................................298 INSTALLATION......................................................................................................298 BUCKET CYLINDER.......................................................................................................298 REMOVAL...........................................................................................................298 INSTALLATION......................................................................................................298 BLADE CYLINDER........................................................................................................300 REMOVAL...........................................................................................................300 INSTALLATION......................................................................................................300 BOOM SWING CYLINDER...................................................................................................300 REMOVAL...........................................................................................................300 INSTALLATION......................................................................................................300 HYDRAULIC CYLINDER....................................................................................................302 DISASSEMBLY.......................................................................................................302 ASSEMBLY..........................................................................................................304 REPLACING HYDRAULIC CYLINDER PISTON RING..............................................................................306 WORK EQUIPMENT........................................................................................................308 REMOVAL...........................................................................................................308 INSTALLATION......................................................................................................308 BLADE ...............................................................................................................308 REMOVAL...........................................................................................................308 INSTALLATION......................................................................................................308 BUCKET................................................................................................................310 REMOVAL...........................................................................................................310 INSTALLATION......................................................................................................310 ARM .................................................................................................................310 REMOVAL...........................................................................................................310 INSTALLATION......................................................................................................310 ARM, BUCKET...........................................................................................................312 REMOVAL...........................................................................................................312 INSTALLATION......................................................................................................312 BOOM..................................................................................................................312 REMOVL............................................................................................................312 INSTALLATION......................................................................................................312 FLOOR FRAME...........................................................................................................314 REMOVAL...........................................................................................................314 INSTALLATION......................................................................................................314 40 MAINTENANCE STANDARD...................................................................................................316 SWING CIRCLE..........................................................................................................317 SWING MACHINERY.......................................................................................................318 SPROCKET..............................................................................................................320 TRACK FRAME AND RECOIL SPRING.........................................................................................321 IDLER.................................................................................................................322 TRACK ROLLER..........................................................................................................323 TRACK SHOE............................................................................................................324 TRIPLE GEAR PUMP......................................................................................................326 CENTER SWIVEL JOINT...................................................................................................328 SWING MOTOR...........................................................................................................330 TRAVEL MOTOR BRAKE VALVE..............................................................................................331 6-SPOOL CONTROL VALVE.................................................................................................333 2-SPOOL CONTROL VALVE.................................................................................................334 3-SPOOL CONTROL VALVE.................................................................................................335 HYDRAULIC CYLINDER....................................................................................................336 WORK EQUIPMENT........................................................................................................342
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
