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KOMATSU PC27MR-3 PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SEN04063-07) – PDF DOWNLOAD
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- KOMATSU PC27MR-3 PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SEN04063-07)
- PUBLICATION NUMBER:SEN04063-07
- SERIAL NUMBERS:
PC27MR-20002 and up
PC30MR-30001 and up
PC35MR-15001 and up
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Description
KOMATSU PC27MR-3 PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SEN04063-07)
KOMATSU PC27MR-3 PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SEN04063-07) – PDF DOWNLOAD:
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KOMATSU PC27MR-3 PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SEN04063-07)
- This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
- 00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information. - 01. Specification
This section explains the specifications of the machine. - 10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. - 20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. - 30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. - 40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. - 50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. - 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
KOMATSU PC27MR-3 PC30MR-3 PC35MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SEN04063-07)
COVER .............................................................................................................. 1 00 Index and foreword............................................................................................... 0 100 Index....................................................................................................... 2 Composition of shop manual.................................................................................. 3 Table of contents........................................................................................... 5 200 Foreword and general information............................................................................ 12 Safety notice............................................................................................... 13 How to read the shop manual................................................................................. 18 Explanation of terms for maintenance standard............................................................... 20 Handling of electric equipment and hydraulic component...................................................... 22 Handling of connectors newly used for engines............................................................... 31 How to read electric wire code.............................................................................. 34 Precautions when carrying out operation..................................................................... 37 Method of disassembling and connecting push-pull type coupler............................................... 40 Standard tightening torque table............................................................................ 43 Conversion table............................................................................................ 47 01 Specification.................................................................................................... 0 100 Specification and technical data............................................................................ 54 Specification dimension drawing............................................................................. 55 Working range drawing....................................................................................... 56 Specifications.............................................................................................. 57 Weight table................................................................................................ 67 Table of fuel, coolant and lubricants....................................................................... 71 10 Structure, function and maintenance standard..................................................................... 0 100 Engine and cooling system................................................................................... 74 PTO......................................................................................................... 75 Cooling system.............................................................................................. 77 200 Power train................................................................................................. 80 Power train................................................................................................. 81 Swing circle................................................................................................ 83 Swing machinery............................................................................................. 84 300 Undercarriage and frame..................................................................................... 88 Track frame................................................................................................. 89 Idler cushion............................................................................................... 90 Idler....................................................................................................... 91 Track roller................................................................................................ 93 Carrier roller.............................................................................................. 94 Sprocket.................................................................................................... 95 Track shoe.................................................................................................. 96 410 Hydraulic system, Part 1....................................................................................102 Hydraulic components layout drawing.........................................................................103 Hydraulic tank, filter......................................................................................104 Center swivel joint.........................................................................................106 Travel motor................................................................................................108 Hydraulic cylinder..........................................................................................116 Solenoid valve..............................................................................................121 Multi-control valve.........................................................................................127 420 Hydraulic system, Part 2....................................................................................130 Hydraulic pump..............................................................................................131 Control valve...............................................................................................147 430 Hydraulic system, Part 3....................................................................................180 CLSS........................................................................................................181 Operation for each function and valve.......................................................................185 Swing motor.................................................................................................225 PPC valve...................................................................................................230 500 Work equipment..............................................................................................242 Work equipment..............................................................................................243 Dimensions of each part of work equipment...................................................................247 600 Cab and its attachments.....................................................................................256 Floor.......................................................................................................257 Air conditioner.............................................................................................258 700 Electrical system...........................................................................................260 Engine control system.......................................................................................261 Electric control system.....................................................................................265 Auto-deceleration function..................................................................................275 Attachment proportional switch, breaker operation switch, work mode selection, flow control function........279 KOMTRAX system..............................................................................................289 Component parts of system...................................................................................292 Monitor system..............................................................................................293 Sensors.....................................................................................................297 20 Standard value table............................................................................................. 0 100 Standard service value table................................................................................302 Standard service value table for engine related parts.......................................................303 Standard service value table for chassis related parts......................................................305 30 Testing and adjusting............................................................................................ 0 100 Testing and adjusting.......................................................................................330 Tools for testing, adjusting, and troubleshooting...........................................................332 Testing engine speed........................................................................................335 Testing exhaust gas color...................................................................................336 Testing and adjusting valve clearance.......................................................................337 Testing compression pressure................................................................................338 Testing engine oil pressure.................................................................................339 Testing and adjusting fuel injection timing.................................................................340 Testing and adjusting alternator belt tension...............................................................344 Testing and adjusting air conditioner compressor belt tension...............................................345 Adjusting fuel control lever................................................................................346 Testing clearance in swing circle bearings..................................................................347 Testing and adjusting track shoe tension....................................................................348 Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits........349 Testing and adjusting LS differential pressure..............................................................354 Adjusting PC valve..........................................................................................357 Testing and adjusting control pump circuit oil pressure.....................................................358 Testing solenoid valve output pressure......................................................................360 Testing PPC valve output pressure...........................................................................361 Adjusting PPC valve.........................................................................................365 Testing swing holding brake release pressure................................................................366 Testing and adjusting travel deviation......................................................................367 Testing oil leakage from work equipment cylinder............................................................369 Bleeding air from each part.................................................................................371 Releasing residual pressure from hydraulic circuit..........................................................373 Releasing residual pressure from hydraulic tank.............................................................374 Pressurizing hydraulic tank.................................................................................374 How to open and close (tilt) floor..........................................................................375 Inspection procedures for diode.............................................................................380 Function and flow of operator and service mode..............................................................381 How to start operation of KOMTRAX terminal..................................................................405 Lamp display of KOMTRAX terminal............................................................................409 Removal and installation of KOMTRAX terminal................................................................412 Preparation work for troubleshooting of electrical system...................................................413 40 Troubleshooting.................................................................................................. 0 010 Failure code table and fuse locations.......................................................................416 User code and failure code list.............................................................................417 Fuse locations..............................................................................................418 100 General information on troubleshooting......................................................................424 Points to remember when troubleshooting.....................................................................425 Sequence of events in troubleshooting.......................................................................426 Checks before troubleshooting...............................................................................427 Classification and procedures of troubleshooting............................................................428 Information contained in troubleshooting table..............................................................429 Connection table for connector pin numbers..................................................................433 T- branch box and T- branch adapter table...................................................................469 110 Troubleshooting by failure code.............................................................................474 Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller............477 Failure code [DBH1KK] Unswitched power supply error.........................................................479 Failure code [DBH2KK] Solenoid power supply error...........................................................481 Failure code [DBH5KP] 5V sensor power supply output 0 error.................................................483 Failure code [DBH6KP] 5V sensor power supply output 1 error.................................................484 Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit).................................485 Failure code [DDWLKB] Breaker switch error (Hot short circuit)..............................................486 Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)........................487 Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)....................................489 Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error.................................490 Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault).................491 Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit).............................493 Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)..........................495 Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)......................................497 Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)...................499 Failure code [D1E0KB] Motor power supply relay error (Ground fault).........................................501 Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)......................503 Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)............................................505 Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)......................507 Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)............................................509 Failure code [DY10MA] Fuel control motor operation error....................................................511 Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side)......................513 Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)......................515 Failure code [DXEAKA] EPC valve (port A side) error (Disconnection).........................................517 Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)..........................................519 Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit).....................................520 200 Troubleshooting of electrical system (E-mode)...............................................................522 Before carrying out troubleshooting of electrical system....................................................523 E-1 Engine does not start...................................................................................525 E-2 Engine does not stop....................................................................................541 E-3 When starting switch is turned ON, any item does not operate............................................545 E-4 When starting switch is turned ON, some items do not operate............................................549 E-5 Alarm buzzer is abnormal................................................................................550 E-6 Engine oil pressure caution is turned ON................................................................552 E-7 Charge level caution is turned ON.......................................................................553 E-8 Preheating system does not operate or preheater does not become hot1....................................555 E-9 Coolant temperature gauge is abnormal...................................................................557 E-10 Fuel level gauge is abnormal...........................................................................565 E-11 Service meter does not operate while engine is running.................................................573 E-12 2nd travel speed is not selected.......................................................................577 E-13 Working lamp does not light up.........................................................................581 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves....585 E-15 Windshield wiper does not operate......................................................................589 E-16 Windshield washer does not operate.....................................................................593 E-17 Defective air conditioner..............................................................................596 E-18 KOMTRAX system does not operate normally...............................................................604 300 Troubleshooting of hydraulic and mechanical system (H-mode).................................................608 Information contained in troubleshooting table..............................................................610 H1 Speed or power of whole work equipment, travel, swing, and blade is low..................................611 H-2 Engine speed lowers extremely or engine stalls..........................................................615 H-3 Whole work equipment, travel system, swing system, and blade do not work................................616 H-4 Abnormal sound comes out from around hydraulic pump.....................................................620 H-5 Fine control performance or response is low.............................................................620 H-6 Speed or power of boom is low...........................................................................621 H-7 Speed or power of arm is low............................................................................622 H-8 Speed or power of bucket is low.........................................................................623 H-9 Speed or power of boom swing is low.....................................................................624 H-10 Work equipment does not move singly....................................................................624 H-11 Work equipment hydraulic drift is large................................................................625 H-12 Time lag of work equipment is large....................................................................627 H-13 In compound operation of work equipment, speed of part loaded more is low..............................627 H-14 Machine deviates during travel.........................................................................628 H-15 Travel speed or travel power is low (while work equipment is normal)...................................630 H-16 Machine is not steered well or steering power is low...................................................631 H-17 Travel speed does not change...........................................................................632 H-18 Travel motor does not work.............................................................................633 H-19 Speed or power of swing is low.........................................................................635 H-20 Machine does not swing.................................................................................637 H-21 Swing acceleration performance is low..................................................................639 H-22 Machine overruns when it stops swinging................................................................641 H-23 Large shock is made when machine stops swinging........................................................642 H-24 When upper structure stops swinging, it makes large sound..............................................642 H-25 Hydraulic drift of swing is large......................................................................643 H-26 Speed or power of blade is low.........................................................................644 H-27 Blade does not move....................................................................................645 H-28 Hydraulic drift of blade is large......................................................................646 400 Troubleshooting of engine (S-mode)..........................................................................648 Method of using troubleshooting charts......................................................................650 S-1 Starting performance is poor............................................................................653 S-2 Engine does not start...................................................................................654 S-3 Engine does not pick up smoothly........................................................................657 S-4 Engine stops during operations..........................................................................658 S-5 Engine does not rotate smoothly.........................................................................659 S-6 Engine lacks output (or lacks power)....................................................................660 S-7 Exhaust smoke is black (incomplete combustion)..........................................................661 S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................662 S-9 Oil becomes contaminated quickly........................................................................663 S-10 Fuel consumption is excessive..........................................................................664 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................665 S-12 Oil pressure drops.....................................................................................666 S-13 Oil level rises (Entry of coolant/fuel)................................................................667 S-14 Coolant temperature becomes too high (overheating).....................................................668 S-15 Abnormal noise is made.................................................................................669 S-16 Vibration is excessive.................................................................................670 50 Disassembly and assembly......................................................................................... 0 100 General information on disassembly and assembly.............................................................672 How to read this manual.....................................................................................673 Coating materials list......................................................................................675 Special tool list...........................................................................................678 Sketches of special tools...................................................................................682 200 Engine and cooling system...................................................................................684 Removal and installation of fuel injection pump assembly....................................................685 Removal and installation of radiator and hydraulic oil cooler assembly......................................688 Removal and installation of engine and hydraulic pump assembly..............................................692 300 Power train.................................................................................................696 Removal and installation of swing motor and swing machinery assembly........................................697 Disassembly and assembly of swing motor and swing machinery assembly........................................698 Removal and installation of swing circle assembly...........................................................703 400 Undercarriage and frame.....................................................................................706 Removal and installation of track shoe assembly.............................................................707 Disassembly and assembly of idler assembly..................................................................708 Disassembly and assembly of recoil spring assembly..........................................................710 Disassembly and assembly of track roller assembly...........................................................713 Disassembly and assembly of carrier roller assembly.........................................................714 Removal and installation of revolving frame assembly........................................................715 500 Hydraulic system............................................................................................718 Removal and installation of center swivel joint assembly....................................................719 Disassembly and assembly of center swivel joint assembly....................................................721 Disassembly and assembly of control valve assembly..........................................................723 Disassembly and assembly of hydraulic cylinder assembly.....................................................724 600 Work equipment..............................................................................................730 Removal and installation of work equipment assembly.........................................................731 700 Cab and its attachments.....................................................................................734 Removal and installation of operator’s cab glass (stuck glass)..............................................735 Removal and installation of front window assembly...........................................................744 Removal and installation of floor frame assembly............................................................745 800 Electrical system...........................................................................................750 Removal and installation of air conditioner unit assembly (If equipped).....................................751 90 Diagrams and drawings............................................................................................ 0 100 Hydraulic diagrams and drawings.............................................................................756 Hydraulic circuit diagram...................................................................................758 200 Electrical diagrams and drawings............................................................................766 Electrical circuit diagram..................................................................................768 Connector list and stereogram...............................................................................776
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
