Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 EXCAVATOR Shop Manual – PDF
$31.95
Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR Shop Manual SEBM032406 – PDF DOWNLOAD
SERIAL NUMBERS PC27MR-2 15001 and up
PC30MR-2 20001 and up
PC35MR-2 5001 and up
PC40MR-2 8001 and up
PC50MR-2 5001 and up
Description
Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR Shop Manual SEBM032406 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR Shop Manual SEBM032406 – PDF DOWNLOAD
Language : English
Pages :622
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR Shop Manual SEBM032406 – PDF DOWNLOAD
SERIAL NUMBERS PC27MR-2 15001 and up
PC30MR-2 20001 and up
PC35MR-2 5001 and up
PC40MR-2 8001 and up
PC50MR-2 5001 and up
GENERAL
- 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 judge ments. 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 fur ther 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 under standing of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte nance standards.
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.
This section explains the procedures for removing, installing, disassembling and assembling each com ponent, as well as precautions for them.
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE Af’IJD FUNCTION.
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 PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR Shop Manual SEBM032406 – PDF DOWNLOAD
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWORD 8
GENERAL 8
HOW TO READ THE SHOP MANUAL 9
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
SPECIFICATION DIMENSION DRAWING 27
WORKING RANGE DRAWING 28
SPECIFICATIONS 29
WEIGHT TABLE 45
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 49
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 52
PTO 53
COOLING SYSTEM 54
POWER TRAIN 57
SWING CIRCLE 59
SWING MACHINERY 60
TRACK FRAME 64
IDLER CUSHION 66
IDLER 67
TRACK ROLLER 69
CARRIER ROLLER 71
SPROCKET 72
TRACK SHOE 73
HYDRAULIC COMPONENTS LAYOUT DRAWING 81
HYDRAULIC TANK 83
CENTER SWIVEL JOINT 86
TRAVEL MOTOR 89
HYDRAULIC CYLINDER 97
SOLENOID VALVE104
MULTI-CONTROL VALVE108
HYDRAULIC PUMP109
CONTROL VALVE127
CLSS164
OPERATION FOR EACH FUNCTION AND VALVE167
SWING MOTOR212
PPC VALVE224
WORK EQUIPMENT232
DIMENSIONS OF EACH PART OF WORK EQUIPMENT235
FLOOR246
AIR CONDITIONER247
ENGINE CONTROL248
ELECTRIC CONTROL SYSTEM250
COMPONENT PARTS OF SYSTEM258
MONITOR SYSTEM259
MONITOR PANEL260
SENSORS262
20 TESTING AND ADJUSTING264
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS265
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS269
TESTING AND ADJUSTING295
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS296
MEASURING ENGINE SPEED298
MEASUREMENT OF EXHAUST GAS COLOR299
ADJUSTING VALVE CLEARANCE300
MEASURING COMPRESSION PRESSURE302
MEASURING ENGINE OIL PRESSURE303
TESTING AND ADJUSTING FUEL INJECTION TIMING304
TESTING AND ADJUSTING ALTERNATOR BELT TENSION307
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION308
ADJUSTING FUEL CONTROL LEVER309
TESTING AND ADJUSTING TRACK SHOE TENSION310
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS311
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING, AND BLADE CIRCUITS312
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE318
ADJUSTING PC VALVE322
MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE)323
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE324
MEASURING SOLENOID VALVE OUTPUT PRESSURE326
MEASURING PPC VALVE OUTPUT PRESSURE328
ADJUSTING PPC VALVE332
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE333
TESTING AND ADJUSTING TRAVEL DEVIATION334
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER336
BLEEDING AIR FROM EACH PART338
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT341
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK341
PRESSURIZING HYDRAULIC TANK342
HOW TO OPEN AND CLOSE (TILT) FLOOR343
INSPECTION PROCEDURES FOR DIODE347
TROUBLESHOOTING349
POINTS TO REMEMBER WHEN TROUBLESHOOTING350
SEQUENCE OF EVENTS IN TROUBLESHOOTING351
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE352
CHECKS BEFORE TROUBLESHOOTING360
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING361
TYPES AND LOCATIONS OF CONNECTORS364
CONNECTOR ARRANGEMENT DIAGRAM370
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS378
T-ADAPTER BOXES AND T-ADAPTER TABLE401
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)404
BEFORE STARTING E-MODE TROUBLESHOOTING405
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE406
E-1 ENGINE DOES NOT START407
E-2 ENGINE DOES NOT STOP415
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES419
E-4 WINDSHIELD WIPER DOES NOT OPERATE423
E-5 WINDSHIELD WASHER DOES NOT OPERATE425
E-6 TRAVEL ALARM DOES NOT SOUND429
E-7 DEFECTIVE AIR CONDITIONER433
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)442
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE443
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW444
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS448
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK449
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP452
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW452
H-6 SPEED OR POWER OF BOOM IS LOW453
H-7 SPEED OR POWER OF ARM IS LOW454
H-8 SPEED OR POWER OF BUCKET IS LOW455
H-9 SPEED OR POWER OF BOOM SWING IS LOW456
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY457
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE458
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE459
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW459
H-14 MACHINE DEVIATES DURING TRAVEL460
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL)462
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW463
H-17 TRAVEL SPEED DOES NOT CHANGE464
H-18 TRAVEL MOTOR DOES NOT WORK465
H-19 SPEED OR POWER OF SWING IS LOW467
H-20 MACHINE DOES NOT SWING469
H-21 SWING ACCELERATION PERFORMANCE IS LOW471
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING473
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING474
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND474
H-25 HYDRAULIC DRIFT OF SWING IS LARGE475
H-26 SPEED OR POWER OF BLADE IS LOW476
H-27 BLADE DOES NOT MOVE477
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE477
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE)478
BEFORE STARTING M-MODE TROUBLESHOOTING479
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE480
SYSTEM DIAGRAM RELATED TO MONITOR PANEL481
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE483
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE485
M-3 ALARM BUZZER IS ABNORMAL486
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON488
M-5 CHARGE LEVEL CAUTION IS TURNED ON489
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT493
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL495
M-8 FUEL LEVEL GAUGE IS ABNORMAL500
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING504
M-10 2ND TRAVEL SPEED IS NOT SELECTED506
M-11 WORKING LAMP DOES NOT LIGHT UP511
TROUBLESHOOTING OF ENGINE (S-MODE)514
METHOD OF USING TROUBLESHOOTING CHARTS515
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)519
S-2 ENGINE DOES NOT START521
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)524
S-4 ENGINE STOPS DURING OPERATIONS525
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)526
S-6 ENGINE LACKS OUTPUT OR LACKS POWER527
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)528
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE529
S-9 OIL BECOMES CONTAMINATED QUICKLY530
S-10 FUEL CONSUMPTION IS EXCESSIVE531
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN532
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)533
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)534
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)535
S-15 ABNORMAL NOISE IS MADE536
S-16 VIBRATION IS EXCESSIVE537
30 DISASSEMBLY AND ASSEMBLY538
HOW TO READ THIS MANUAL539
PRECAUTIONS WHEN PERFORMING OPERATION541
SPECIAL TOOL LIST543
SKETCHES OF SPECIAL TOOLS547
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY548
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY550
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY557
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY564
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY565
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY567
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY570
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY572
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY573
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY576
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY578
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY582
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY583
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY589
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY591
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY593
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY594
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY595
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY599
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)602
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY610
90 OTHERS611
HYDRAULIC CIRCUIT DIAGRAM612
HYDRAULIC CIRCUIT DIAGRAM PC27MR-2612
HYDRAULIC CIRCUIT DIAGRAM PC30MR-2613
HYDRAULIC CIRCUIT DIAGRAM PC35MR-2614
HYDRAULIC CIRCUIT DIAGRAM PC40, 50MR-2615
HYDRAULIC CIRCUIT DIAGRAM PC40, 50MR-2 (ADDITIONAL ATTACHMENT CIRCUIT)616
ELECTRICAL CIRCUIT DIAGRAM617
ELECTRICAL CIRCUIT DIAGRAM PC27, PC30MR-2 (1/2)617
ELECTRICAL CIRCUIT DIAGRAM PC27, PC30MR-2 (2/2)618
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (1/2)619
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (2/2)620
ELECTRICAL CIRCUIT DIAGRAM PC40, 50MR-2 (1/2)621
ELECTRICAL CIRCUIT DIAGRAM PC40, 50MR-2 (2/2)622
IMAGES PREVIEW OF THE MANUAL:
S.M 12/12/24
