Komatsu PC25-1 PC30-1 PC40-1 PC45-1 Shop Manual SEBM020S07070 – PDF DOWNLOAD
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Komatsu PC25-1 PC30-1 PC40-1 PC45-1 Shop Manual SEBM020S07070 – PDF DOWNLOAD
MACHINE MODEL
PC25-1 PC30-7 PC40-7 PC45-1
SERIAL.·No.
-1001 ·and up
18001 and up
18001 and up
1001 and up
Description
Komatsu PC25-1 PC30-1 PC40-1 PC45-1 Shop Manual SEBM020S07070 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC25-1 PC30-1 PC40-1 PC45-1 Shop Manual SEBM020S07070 – PDF DOWNLOAD
Language : English
Pages :387
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu PC25-1 PC30-1 PC40-1 PC45-1 Shop Manual SEBM020S07070 – PDF DOWNLOAD
FOREWORD
GENERAL
- This shop manual has been prepared as an aid to improve the quality of repairs by g1vmg 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.
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.
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” to “Causes” are also included in this
section.
or assembling each component, as well as precautions to be taken for these operations.
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC25-1 PC30-1 PC40-1 PC45-1 Shop Manual SEBM020S07070 – PDF DOWNLOAD
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 5
SAFETY NOTICE 5
FOREWARD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 11
ELECTRIC WIRE CODE 13
CONVERSION TABLE 14
WEIGHT TABLE 21
WEIGHT TABLE 22
LIST OF LUBRICANT AND WATER 25
10 STRUCTURE AND FUNCTION 28
POWER TRAIN 29
SWING CIRCLE 30
SWING MACHINERY 31
TRACK FRAME AND RECOIL SPRING 33
HYDRAULIC PIPING 36
HYDRAULIC CIRCUIT DIAGRAM 37
HYDRAULIC TANK AND FUEL TANK 41
HYDRAULIC PUMP 42
CONTROL PUMP 50
7 – SPOOL CONTROL VALVE 51
2 – SPOOL CONTROL VALVE 55
SWING MOTOR 59
CENTER SWIVEL JOINT 62
TRAVEL MOTOR 63
HYDRAULIC CYLINDER 68
VALVE CONTROL 72
PPC VALVE 73
SOLENOID VALVE 79
WORK EQUIPMENT 81
HYDRAULIC BREAKER 82
ELECTRICAL CIRCUIT DIAGRAM 85
MONITOR SYSTEM 88
20 TESTING AND ADJUSTING 97
TABLE OF JUDGEMENT STANDARD VALUE 98
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM116
TOOL FOR TESTING, ADJUSTING, AND TROUBLESHOOTING118
ADJUSTING VALVE CLEARANCE119
MEASURING COMPRESSION PRESSURE121
ADJUSTING FUEL INJECTION TIMING122
MEASURING ENGINE OIL PRESSURE123
ADJUSTING FUEL CONTROL LEVER125
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT126
TESTING CONTROL CIRCUIT PRESSURE129
MEASURING OUTPUT PRESSURE OF PPC VALVE130
ADJUSTING PPC VALVE131
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE132
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE134
ADJUSTING BLADE CONTROL LEVER135
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT136
BLEEDING AIR FROM HYDRAULIC CIRCUIT137
RELEASING REMAINING FROM HYDRAULIC CIRCUIT139
TESTING HYDRAULIC BREAKER GAS PRESSURE140
TROUBLESHOOTING142
SEQUENCE OF EVENTS IN TROUBLESHOOTING143
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE144
CHECKS BEFORE TROUBLESHOOTING151
ELECTRICAL CIRCUIT DIAGRAM152
POSITION OF CONNECTORS FOR TROUBLESHOOTING155
CONNECTION TABLE FOR CONNECTOR159
METHOD OF USING TROUBLESHOOTING CHARTS166
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)168
E-1 THE ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF169
E-2 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELEASED172
E-3 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED173
E-4 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS DEPRESSED174
E-5 TRAVEL SPEED INCREASES EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS NOT DEPRESSED175
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)176
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW177
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS178
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW179
a) NONE OF WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS SLOW179
b) ONLY TRAVEL IS NORMAL, OR DROP IN SPEED IS COMPARATIVELY SMALL180
H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER180
H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)180
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW181
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER182
H-8 EXCESSIVE HYDRAULIC DRIFT182
H-9 EXCESSIVE TIME LAG182
H-10 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE183
a) DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND REVERSE183
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE187
H-11 EXCESSIVE DEVIATION WHEN STARTING (PC30, 40)188
H-12 TRAVEL LACKS POWER (OR SPEED IS SLOW)189
H-13 TRAVEL SPEED DOES NOT SWITCH190
H-14 MACHINE DOES NOT MOVE (ONE SIDE ONLY)190
H-15 TRAVEL LEVER IS HEAVY191
H-16 DOES NOT SWING191
H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR193
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING193
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING194
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING194
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING195
H-22 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING196
TABLE OF FAILURE MODES AND CAUSES197
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)198
M-1 MONITOR PANEL DOES NOT WORK199
M-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON, OR ALL LAMPS STAY200
M-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)201
M-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)201
M-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING202
M-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)202
M-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)203
M-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING203
M-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY204
a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE204
b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY ENTERS RED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING204
M-10 ABNORMALITY IN FUEL GAUGE DISPLAY205
a) ALL SEGMENTS OF FUEL GAUGE GO OUT205
b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN205
c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED206
M-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND206
M-12 ABNORMALITY IN SERVICE METER DISPLAY207
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING207
b) SERVICE METER PILOT LAMP DOES NOT FLASH207
M-13 NIGHT LIGHTING DOES NOT LIGHT UP208
a) WHEN LAMP SWITCH IS AT POSITION 1 OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP208
b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP IS NOT BLOWN BEFORE STARTING TROUBLESHOOTING208
M-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)209
TROUBLESHOOTING OF HYDRAULIC BREAKER210
30 DISASSEMBLY AND ASSEMBLY213
METHOD OF USING MANUAL214
PRECAUTIONS WHEN CARRYING OUT OPERATION215
SPECIAL TOOL LIST217
WEIGHT TABLE222
TIGHTENING TORQUES AND STANDARD VALUES TABLE223
LUBRICANT AND COOLANT TABLE224
ENGINE, HYDRAULIC PUMP ASSEMBLY226
REMOVAL226
INSTALLATION229
HYDRAULIC PUMP ASSEMBLY230
HYDRAULIC PUMP ASSEMBLY (PC30-7)230
DISASSEMBLY230
ASSEMBLY232
HYDRAULIC PUMP ASSEMBLY (PC45-1)238
DISASSEMBLY238
ASSEMBLY242
GEAR PUMP ASSEMBLY249
DISASSEMBLY AND ASSEMBLY249
CENTER SWIVEL JOINT ASSEMBLY250
REMOVAL AND INSTALLATION250
DISASSEMBLY AND ASSEMBLY251
TRAVEL MOTOR ASSEMBLY 252
TRAVEL MOTOR ASSEMBLY (PC25-1, PC30-7, PC40-7)252
DISASSEMBLY252
ASSEMBLY258
TRAVEL MOTOR ASSEMBLY (PC45-1)264
DISASSEMBLY264
ASSEMBLY273
SWING MOTOR ASSEMBLY284
DISASSEMBLY284
ASSEMBLY286
SWING MACHINERY ASSEMBLY290
DISASSEMBLY290
ASSEMBLY292
REVOLVING FRAME ASSEMBLY294
REMOVAL AND INSTALLATION294
RECOIL SPRING ASSEMBLY295
DISASSEMBLY295
ASSEMBLY297
2 SPOOL CONTROL VALVE ASSEMBLY300
DISASSEMBLY300
ASSEMBLY301
7 SPOOL CONTROL VALVE ASSEMBLY302
DISASSEMBLY302
ASSEMBLY304
PPC VALVE ASSEMBLY306
DISASSEMBLY306
ASSEMBLY307
HYDRAULIC CYLINDER ASSEMBLY308
DISASSEMBLY308
ASSEMBLY310
WORK EQUIPMENT ASSEMBLY312
REMOVAL AND INSTALLATION312
BUCKET ASSEMBLY313
REMOVAL AND INSTALLATION313
HYDRAULIC BREAKER ASSEMBLY314
REMOVAL AND INSTALLATION314
DISASSEMBLY315
ASSEMBLY318
HYDRAULIC BREAKER BUSHING322
REMOVAL322
CHISEL323
REMOVAL AND INSTALLATION323
40 MAINTENANCE STANDARD326
SWING CIRCLE327
SWING MACHINERY328
SPROCKET330
TRACK FRAME AND RECOIL FRAME333
IDLER337
TRACK ROLLER343
CARRIER ROLLER349
TRACK SHOE351
HYDRAULIC PUMP355
7 SPOOL CONTROL VALVE357
2 SPOOL CONTROL VALVE359
SWING MOTOR360
CENTER SWIVEL JOINT361
PPC VALVE362
HYDRAULIC CYLINDER365
WORK EQUIPMENT369
HYDRAULIC BREAKER373
PISTON, CHISEL375
IMAGES PREVIEW OF THE MANUAL:
S.M 20/12/24
