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Komatsu PC25 130-7, PC40-7, PC4-1 Shop Manual – PDF DOWNLOAD
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Komatsu PC25 130-7, PC40-7, PC4-1 Shop Manual
MACHINE MODEL SERIAL-No.
- PC25-1 1001 and up
- PC30-7 18001 and up
- PC40-7 18001 and up
- PC45-1 1001 and up
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Description
Komatsu PC25 130-7, PC40-7, PC4-1 Shop Manual
FILE DETAILS:
Komatsu PC25 130-7, PC40-7, PC4-1 Shop Manual
Size : 22.4MB
Format : PDF
Language : English
Number of pages : 387 pages
Language : English
Number of pages : 387 pages
KOMATSU PC25 130-7, PC40-7, PC4-1 SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC25 130-7, PC40-7, PC4-1 Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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.
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” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC25 130-7, PC40-7, PC4-1 Shop Manual
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 SYSTEM...............................................................................................116 TOOL FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.........................................................................................118 ADJUSTING VALVE CLEARANCE................................................................................................................119 MEASURING COMPRESSION PRESSURE...........................................................................................................121 ADJUSTING FUEL INJECTION TIMING..........................................................................................................122 MEASURING ENGINE OIL PRESSURE............................................................................................................123 ADJUSTING FUEL CONTROL LEVER.............................................................................................................125 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT........................................................126 TESTING CONTROL CIRCUIT PRESSURE.........................................................................................................129 MEASURING OUTPUT PRESSURE OF PPC VALVE...................................................................................................130 ADJUSTING PPC VALVE......................................................................................................................131 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE................................................................................................132 MEASURING SOLENOID VALVE OUTLET PORT PRESSURE............................................................................................134 ADJUSTING BLADE CONTROL LEVER............................................................................................................135 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..............................................................................136 BLEEDING AIR FROM HYDRAULIC CIRCUIT......................................................................................................137 RELEASING REMAINING FROM HYDRAULIC CIRCUIT...............................................................................................139 TESTING HYDRAULIC BREAKER GAS PRESSURE...................................................................................................140 TROUBLESHOOTING..........................................................................................................................142 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................143 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................144 CHECKS BEFORE TROUBLESHOOTING........................................................................................................151 ELECTRICAL CIRCUIT DIAGRAM...........................................................................................................152 POSITION OF CONNECTORS FOR TROUBLESHOOTING...........................................................................................155 CONNECTION TABLE FOR CONNECTOR.......................................................................................................159 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................166 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................168 E-1 THE ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF..............................................................169 E-2 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELEASED.................................................172 E-3 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED...........................................................173 E-4 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS DEPRESSED........................................174 E-5 TRAVEL SPEED INCREASES EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS NOT DEPRESSED............................................175 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................................................176 H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW.........................................................................177 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....................................................................178 H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW........................................................179 a) NONE OF WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS SLOW.......................................................179 b) ONLY TRAVEL IS NORMAL, OR DROP IN SPEED IS COMPARATIVELY SMALL............................................................180 H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER.................................................................................180 H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)..................................................................................180 H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW.............................................................................181 H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER...............................................................................182 H-8 EXCESSIVE HYDRAULIC DRIFT....................................................................................................182 H-9 EXCESSIVE TIME LAG...........................................................................................................182 H-10 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE................................................................183 a) DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND REVERSE................................................................183 b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE....................................................................187 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 SWITCH................................................................................................190 H-14 MACHINE DOES NOT MOVE (ONE SIDE ONLY).......................................................................................190 H-15 TRAVEL LEVER IS HEAVY.......................................................................................................191 H-16 DOES NOT SWING..............................................................................................................191 H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR.................................................................................193 H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING.......................................................................................193 H-19 EXCESSIVE SHOCK WHEN STOPPING SWING.........................................................................................194 H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING................................................................................194 H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING..........................................................................................195 H-22 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING.....................................................................................196 TABLE OF FAILURE MODES AND CAUSES................................................................................................197 TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)..........................................................................................198 M-1 MONITOR PANEL DOES NOT WORK..................................................................................................199 M-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON, OR ALL LAMPS STAY....200 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 PREHEATING....................................................................202 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 RUNNING.......................................................................203 M-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY.............................................................................204 a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE....................................................204 b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY. ENTERS RED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING....................204 M-10 ABNORMALITY IN FUEL GAUGE DISPLAY...........................................................................................205 a) ALL SEGMENTS OF FUEL GAUGE GO OUT.........................................................................................205 b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN...................................205 c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED.......................................................206 M-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND.......................................................206 M-12 ABNORMALITY IN SERVICE METER DISPLAY........................................................................................207 a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING........................................................................207 b) SERVICE METER PILOT LAMP DOES NOT FLASH...................................................................................207 M-13 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................................208 a) WHEN LAMP SWITCH IS AT POSITION 1 OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP...........208 b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP IS NOT BLOWN BEFORE STARTING TROUBLESHOOTING..............................208 M-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION).......................................209 TROUBLESHOOTING OF HYDRAULIC BREAKER.................................................................................................210 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................213 METHOD OF USING MANUAL...................................................................................................................214 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................215 SPECIAL TOOL LIST........................................................................................................................217 WEIGHT TABLE.............................................................................................................................222 TIGHTENING TORQUES AND STANDARD VALUES TABLE.............................................................................................223 LUBRICANT AND COOLANT TABLE..............................................................................................................224 ENGINE, HYDRAULIC PUMP ASSEMBLY..........................................................................................................226 REMOVAL..............................................................................................................................226 INSTALLATION.........................................................................................................................229 HYDRAULIC PUMP ASSEMBLY..................................................................................................................230 HYDRAULIC PUMP ASSEMBLY (PC30-7).....................................................................................................230 DISASSEMBLY......................................................................................................................230 ASSEMBLY.........................................................................................................................232 HYDRAULIC PUMP ASSEMBLY (PC45-1).....................................................................................................238 DISASSEMBLY......................................................................................................................238 ASSEMBLY.........................................................................................................................242 GEAR PUMP ASSEMBLY.......................................................................................................................249 DISASSEMBLY AND ASSEMBLY.............................................................................................................249 CENTER SWIVEL JOINT ASSEMBLY.............................................................................................................250 REMOVAL AND INSTALLATION.............................................................................................................250 DISASSEMBLY AND ASSEMBLY.............................................................................................................251 TRAVEL MOTOR ASSEMBLY ...................................................................................................................252 TRAVEL MOTOR ASSEMBLY (PC25-1, PC30-7, PC40-7).......................................................................................252 DISASSEMBLY......................................................................................................................252 ASSEMBLY.........................................................................................................................258 TRAVEL MOTOR ASSEMBLY (PC45-1).......................................................................................................264 DISASSEMBLY......................................................................................................................264 ASSEMBLY.........................................................................................................................273 SWING MOTOR ASSEMBLY.....................................................................................................................284 DISASSEMBLY..........................................................................................................................284 ASSEMBLY.............................................................................................................................286 SWING MACHINERY ASSEMBLY.................................................................................................................290 DISASSEMBLY..........................................................................................................................290 ASSEMBLY.............................................................................................................................292 REVOLVING FRAME ASSEMBLY.................................................................................................................294 REMOVAL AND INSTALLATION.............................................................................................................294 RECOIL SPRING ASSEMBLY...................................................................................................................295 DISASSEMBLY..........................................................................................................................295 ASSEMBLY.............................................................................................................................297 2 SPOOL CONTROL VALVE ASSEMBLY...........................................................................................................300 DISASSEMBLY..........................................................................................................................300 ASSEMBLY.............................................................................................................................301 7 SPOOL CONTROL VALVE ASSEMBLY...........................................................................................................302 DISASSEMBLY..........................................................................................................................302 ASSEMBLY.............................................................................................................................304 PPC VALVE ASSEMBLY.......................................................................................................................306 DISASSEMBLY..........................................................................................................................306 ASSEMBLY.............................................................................................................................307 HYDRAULIC CYLINDER ASSEMBLY..............................................................................................................308 DISASSEMBLY..........................................................................................................................308 ASSEMBLY.............................................................................................................................310 WORK EQUIPMENT ASSEMBLY..................................................................................................................312 REMOVAL AND INSTALLATION.............................................................................................................312 BUCKET ASSEMBLY..........................................................................................................................313 REMOVAL AND INSTALLATION.............................................................................................................313 HYDRAULIC BREAKER ASSEMBLY...............................................................................................................314 REMOVAL AND INSTALLATION.............................................................................................................314 DISASSEMBLY..........................................................................................................................315 ASSEMBLY.............................................................................................................................318 HYDRAULIC BREAKER BUSHING................................................................................................................322 REMOVAL..............................................................................................................................322 CHISEL...................................................................................................................................323 REMOVAL AND INSTALLATION.............................................................................................................323 40 MAINTENANCE STANDARD......................................................................................................................326 SWING CIRCLE.............................................................................................................................327 SWING MACHINERY..........................................................................................................................328 SPROCKET.................................................................................................................................330 TRACK FRAME AND RECOIL FRAME.............................................................................................................333 IDLER....................................................................................................................................337 TRACK ROLLER.............................................................................................................................343 CARRIER ROLLER...........................................................................................................................349 TRACK SHOE...............................................................................................................................351 HYDRAULIC PUMP...........................................................................................................................355 7 SPOOL CONTROL VALVE....................................................................................................................357 2 SPOOL CONTROL VALVE....................................................................................................................359 SWING MOTOR..............................................................................................................................360 CENTER SWIVEL JOINT......................................................................................................................361 PPC VALVE................................................................................................................................362 HYDRAULIC CYLINDER.......................................................................................................................365 WORK EQUIPMENT...........................................................................................................................369 HYDRAULIC BREAKER........................................................................................................................373 PISTON, CHISEL...........................................................................................................................375
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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