Komatsu PC27MR-2,PC30MR-2,PC35MR-2,PC40MR-2,PC50MR-2 Shop Manual PDF

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

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 VALVE 104
MULTI-CONTROL VALVE .108
HYDRAULIC PUMP 109
CONTROL VALVE .127
CLSS 164
OPERATION FOR EACH FUNCTION AND VALVE .167
SWING MOTOR .212
PPC VALVE .224
WORK EQUIPMENT 232
DIMENSIONS OF EACH PART OF WORK EQUIPMENT .235
FLOOR .246
AIR CONDITIONER .247
ENGINE CONTROL 248
ELECTRIC CONTROL SYSTEM .250
COMPONENT PARTS OF SYSTEM .258
MONITOR SYSTEM 259
MONITOR PANEL .260
SENSORS .262
20 TESTING AND ADJUSTING 264
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS .265
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 269
TESTING AND ADJUSTING .295
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS .296
MEASURING ENGINE SPEED 298
MEASUREMENT OF EXHAUST GAS COLOR 299
ADJUSTING VALVE CLEARANCE .300
MEASURING COMPRESSION PRESSURE 302
MEASURING ENGINE OIL PRESSURE .303
TESTING AND ADJUSTING FUEL INJECTION TIMING .304
TESTING AND ADJUSTING ALTERNATOR BELT TENSION .307
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION .308
ADJUSTING FUEL CONTROL LEVER 309
TESTING AND ADJUSTING TRACK SHOE TENSION 310
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS .311
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING, AND BLADE CIRCUITS 312
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE 318
ADJUSTING PC VALVE 322
MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE) 323
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE .324
MEASURING SOLENOID VALVE OUTPUT PRESSURE 326
MEASURING PPC VALVE OUTPUT PRESSURE .328
ADJUSTING PPC VALVE .332
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE 333
TESTING AND ADJUSTING TRAVEL DEVIATION 334
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER .336
BLEEDING AIR FROM EACH PART .338
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 341
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK .341
PRESSURIZING HYDRAULIC TANK .342
HOW TO OPEN AND CLOSE (TILT) FLOOR 343
INSPECTION PROCEDURES FOR DIODE .347
TROUBLESHOOTING .349
POINTS TO REMEMBER WHEN TROUBLESHOOTING .350
SEQUENCE OF EVENTS IN TROUBLESHOOTING .351
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 352
CHECKS BEFORE TROUBLESHOOTING .360
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 361
TYPES AND LOCATIONS OF CONNECTORS .364
CONNECTOR ARRANGEMENT DIAGRAM .370
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 378
T-ADAPTER BOXES AND T-ADAPTER TABLE .401
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .404
BEFORE STARTING E-MODE TROUBLESHOOTING 405
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 406
E-1 ENGINE DOES NOT START .407
E-2 ENGINE DOES NOT STOP 415
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES 419
E-4 WINDSHIELD WIPER DOES NOT OPERATE .423
E-5 WINDSHIELD WASHER DOES NOT OPERATE 425
E-6 TRAVEL ALARM DOES NOT SOUND .429
E-7 DEFECTIVE AIR CONDITIONER .433
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) .442
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 443
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW .444
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS 448
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK 449
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP .452
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW .452
H-6 SPEED OR POWER OF BOOM IS LOW .453
H-7 SPEED OR POWER OF ARM IS LOW 454
H-8 SPEED OR POWER OF BUCKET IS LOW .455
H-9 SPEED OR POWER OF BOOM SWING IS LOW .456
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY 457
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE 458
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE 459
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW 459
H-14 MACHINE DEVIATES DURING TRAVEL .460
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 LOW .463
H-17 TRAVEL SPEED DOES NOT CHANGE .464
H-18 TRAVEL MOTOR DOES NOT WORK .465
H-19 SPEED OR POWER OF SWING IS LOW .467
H-20 MACHINE DOES NOT SWING .469
H-21 SWING ACCELERATION PERFORMANCE IS LOW 471
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING 473
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING 474
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND 474
H-25 HYDRAULIC DRIFT OF SWING IS LARGE 475
H-26 SPEED OR POWER OF BLADE IS LOW .476
H-27 BLADE DOES NOT MOVE 477
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE 477
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE) 478
BEFORE STARTING M-MODE TROUBLESHOOTING 479
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 480
SYSTEM DIAGRAM RELATED TO MONITOR PANEL .481
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE 483
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE 485
M-3 ALARM BUZZER IS ABNORMAL 486
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON 488
M-5 CHARGE LEVEL CAUTION IS TURNED ON .489
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT .493
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL .495
M-8 FUEL LEVEL GAUGE IS ABNORMAL 500
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING 504
M-10 2ND TRAVEL SPEED IS NOT SELECTED .506
M-11 WORKING LAMP DOES NOT LIGHT UP .511
TROUBLESHOOTING OF ENGINE (S-MODE) 514
METHOD OF USING TROUBLESHOOTING CHARTS 515
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) .519
S-2 ENGINE DOES NOT START .521
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR) 524
S-4 ENGINE STOPS DURING OPERATIONS 525
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) .526
S-6 ENGINE LACKS OUTPUT OR LACKS POWER 527
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 528
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE .529
S-9 OIL BECOMES CONTAMINATED QUICKLY 530
S-10 FUEL CONSUMPTION IS EXCESSIVE 531
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 532
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 MADE .536
S-16 VIBRATION IS EXCESSIVE .537
30 DISASSEMBLY AND ASSEMBLY .538
HOW TO READ THIS MANUAL .539
PRECAUTIONS WHEN PERFORMING OPERATION .541
SPECIAL TOOL LIST .543
SKETCHES OF SPECIAL TOOLS .547
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 548
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 550
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY 557
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY .564
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 565
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 567
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY .570
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY .572
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 573
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 576
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 578
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 582
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 583
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY .589
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY 591
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY .593
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 594
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY .595
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY .599
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) 602
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY .610
90 OTHERS .611
HYDRAULIC CIRCUIT DIAGRAM .612
HYDRAULIC CIRCUIT DIAGRAM PC27MR-2 612
HYDRAULIC CIRCUIT DIAGRAM PC30MR-2 613
HYDRAULIC CIRCUIT DIAGRAM PC35MR-2 614
HYDRAULIC CIRCUIT DIAGRAM PC40, 50MR-2 .615
HYDRAULIC CIRCUIT DIAGRAM PC40, 50MR-2 (ADDITIONAL ATTACHMENT CIRCUIT) 616
ELECTRICAL CIRCUIT DIAGRAM 617
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

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

G.B 27/12/24