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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF
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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
SERIAL NUMBERS
PC30MR-50001 and up
PC35MR-30001 and up
PC35MR-30001 and up
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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 1400
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
PC30MR-50001 and up
PC35MR-30001 and up
PC35MR-30001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
COVER................................................................................................................................................... 1 00 INDEX AND FOREWORD.................................................................................................................................. 3 INDEX.............................................................................................................................................. 4 ABBREVIATION LIST.................................................................................................................................. 15 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................................ 21 HOW TO READ THE SHOP MANUAL.................................................................................................................... 21 SAFETY NOTICE FOR OPERATION.................................................................................................................... 23 PRECAUTIONS TO PREVENT FIRE.................................................................................................................... 31 ACTIONS IF FIRE OCCURS......................................................................................................................... 33 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS................................................................................................... 34 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT................................................................................................... 35 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS........................................................................................ 38 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT.................................................................................................. 45 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT................................................................................................. 47 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT............................................................................................... 48 PRACTICAL USE OF KOMTRAX....................................................................................................................... 49 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER.................................................................................................. 50 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...................................................................... 50 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...................................................................... 51 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...................................................................... 52 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS..................................................................................... 54 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...................................................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR.............................................................................. 59 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................................ 61 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................................ 62 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE....................................................................... 64 HOW TO READ ELECTRICAL WIRE CODE............................................................................................................... 65 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................................................................. 69 STANDARD TIGHTENING TORQUE TABLE............................................................................................................... 72 CONVERSION TABLE............................................................................................................................... 79 01 SPECIFICATIONS...................................................................................................................................... 85 CONTENTS........................................................................................................................................... 86 ABBREVIATION LIST.................................................................................................................................. 87 SPECIFICATIONS..................................................................................................................................... 93 SPECIFICATION DRAWING.......................................................................................................................... 93 SPECIFICATION DRAWING: PC30MR-5............................................................................................................ 93 SPECIFICATION DRAWING: PC35MR-5............................................................................................................ 95 WORKING RANGE DRAWINGS......................................................................................................................... 96 WORKING RANGE DRAWINGS: PC30MR-5........................................................................................................... 96 WORKING RANGE DRAWINGS: PC35MR-5........................................................................................................... 97 SPECIFICATIONS................................................................................................................................. 98 SPECIFICATIONS: PC30MR-5................................................................................................................... 98 SPECIFICATIONS: PC35MR-5................................................................................................................... 102 WEIGHT TABLE................................................................................................................................... 106 WEIGHT TABLE: PC30MR-5..................................................................................................................... 106 WEIGHT TABLE: PC35MR-5..................................................................................................................... 108 TABLE OF FUEL, COOLANT, AND LUBRICANTS......................................................................................................... 110 10 STRUCTURE AND FUNCTION.............................................................................................................................. 111 CONTENTS........................................................................................................................................... 112 ABBREVIATION LIST.................................................................................................................................. 114 BOOT-UP SYSTEM..................................................................................................................................... 120 LAYOUT DRAWING OF BOOT-UP SYSTEM............................................................................................................... 120 SYSTEM OPERATING LAMP SYSTEM................................................................................................................... 121 SYSTEM OPERATING LAMP SYSTEM DIAGRAM....................................................................................................... 121 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM................................................................................................... 121 QUICK RELEASE BATTERY TERMINAL (-)............................................................................................................. 123 FUNCTION OF QUICK RELEASE BATTERY TERMINAL (-)............................................................................................. 123 ENGINE SYSTEM...................................................................................................................................... 124 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................................ 124 ENGINE CONTROL SYSTEM.......................................................................................................................... 125 ENGINE CONTROL SYSTEM DIAGRAM.............................................................................................................. 125 FUNCTION OF ENGINE CONTROL SYSTEM.......................................................................................................... 126 AUTO-DECELERATION SYSTEM....................................................................................................................... 133 AUTO-DECELERATION SYSTEM DIAGRAM........................................................................................................... 133 FUNCTION OF AUTO-DECELERATION SYSTEM....................................................................................................... 133 OPERATION OF AUTO-DECELERATION SYSTEM...................................................................................................... 134 OVERHEAT PREVENTION SYSTEM..................................................................................................................... 135 OVERHEAT PREVENTION SYSTEM DIAGRAM......................................................................................................... 135 FUNCTION OF OVERHEAT PREVENTION SYSTEM..................................................................................................... 136 AUTOMATIC IDLE STOP SYSTEM..................................................................................................................... 137 AUTOMATIC IDLE STOP SYSTEM DIAGRAM......................................................................................................... 137 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM..................................................................................................... 137 COMPONENT PARTS OF ENGINE SYSTEM............................................................................................................... 139 PTO........................................................................................................................................ 139 COOLING SYSTEM..................................................................................................................................... 140 LAYOUT DRAWING OF COOLING SYSTEM............................................................................................................... 140 SPECIFICATIONS OF COOLING SYSTEM........................................................................................................... 141 CONTROL SYSTEM..................................................................................................................................... 142 LAYOUT DRAWING OF CONTROL SYSTEM............................................................................................................... 142 MACHINE MONITOR SYSTEM......................................................................................................................... 143 MACHINE MONITOR SYSTEM DIAGRAM............................................................................................................. 143 KOMTRAX SYSTEM................................................................................................................................. 144 KOMTRAX SYSTEM DIAGRAM..................................................................................................................... 144 FUNCTION OF KOMTRAX SYSTEM................................................................................................................. 144 COMPONENT PARTS OF CONTROL SYSTEM.............................................................................................................. 145 MACHINE MONITOR............................................................................................................................ 145 KOMTRAX TERMINAL........................................................................................................................... 153 MACHINE CONTROLLER......................................................................................................................... 155 RESISTOR FOR PC-EPC VALVE.................................................................................................................. 159 FUEL CONTROL DIAL.......................................................................................................................... 160 HYDRAULIC SYSTEM................................................................................................................................... 162 LAYOUT DRAWING OF HYDRAULIC SYSTEM............................................................................................................. 162 CLSS........................................................................................................................................... 165 STRUCTURE OF CLSS.......................................................................................................................... 165 FUNCTION OF CLSS........................................................................................................................... 166 ENGINE AND PUMP COMBINED CONTROL SYSTEM........................................................................................................ 168 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................................ 168 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM........................................................................................ 169 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................................ 171 HYDRAULIC TANK............................................................................................................................. 171 MAIN PUMP.................................................................................................................................. 175 CONTROL VALVE.............................................................................................................................. 186 WORK EQUIPMENT SYSTEM.............................................................................................................................. 227 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM........................................................................................................ 227 STRUCTURE OF VALVE CONTROL..................................................................................................................... 230 PPC LOCK SYSTEM................................................................................................................................ 232 PPC LOCK SYSTEM DIAGRAM.................................................................................................................... 232 FUNCTION OF PPC LOCK SYSTEM................................................................................................................ 233 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................................ 234 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................ 234 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM............................................................................... 234 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................................................................ 235 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................................ 235 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................................................ 236 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM....................................................................................................... 237 WORK EQUIPMENT AND SWING PPC VALVE......................................................................................................... 237 ATTACHMENT PPC VALVE....................................................................................................................... 242 BLADE PPC VALVE............................................................................................................................ 244 BOOM SWING PPC VALVE....................................................................................................................... 246 BIPARTITE SOLENOID VALVE................................................................................................................... 248 MULTI-CONTROL VALVE........................................................................................................................ 251 PILOT CIRCUIT ACCUMULATOR.................................................................................................................. 252 SWING SYSTEM....................................................................................................................................... 253 LAYOUT DRAWING OF SWING SYSTEM................................................................................................................. 253 COMPONENT PARTS OF SWING SYSTEM................................................................................................................ 254 SWING MOTOR................................................................................................................................ 254 SWING MACHINERY............................................................................................................................ 259 SWING CIRCLE............................................................................................................................... 261 TRAVEL SYSTEM...................................................................................................................................... 262 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................................ 262 TRAVEL CONTROL SYSTEM DIAGRAM.................................................................................................................. 264 FUNCTION OF TRAVEL CONTROL SYSTEM.......................................................................................................... 264 COMPONENT PARTS OF TRAVEL SYSTEM............................................................................................................... 266 TRAVEL MOTOR............................................................................................................................... 266 TRAVEL PPC VALVE........................................................................................................................... 274 CENTER SWIVEL JOINT........................................................................................................................ 276 UNDERCARRIAGE AND FRAME............................................................................................................................ 277 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................................ 277 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................................ 277 IDLER CUSHION.................................................................................................................................. 278 STRUCTURE OF IDLER CUSHION................................................................................................................. 278 SPECIFICATIONS OF IDLER CUSHION............................................................................................................ 278 WORK EQUIPMENT..................................................................................................................................... 279 STRUCTURE OF WORK EQUIPMENT.................................................................................................................... 279 FUNCTION OF WORK EQUIPMENT..................................................................................................................... 280 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM....................................................................................................... 281 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM....................................................................................... 281 CAB AND ITS ATTACHMENTS............................................................................................................................ 282 ROPS CAB....................................................................................................................................... 282 STRUCTURE OF ROPS CAB...................................................................................................................... 282 FUNCTION OF ROPS CAB....................................................................................................................... 282 TILT TYPE FLOOR................................................................................................................................ 283 STRUCTURE OF TILT TYPE FLOOR............................................................................................................... 283 FUNCTION OF TILT TYPE FLOOR................................................................................................................ 283 20 STANDARD VALUE TABLE................................................................................................................................ 285 CONTENTS........................................................................................................................................... 286 ABBREVIATION LIST.................................................................................................................................. 287 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................... 293 STANDARD VALUE TABLE FOR ENGINE: PC30MR-5...................................................................................................... 293 STANDARD VALUE TABLE FOR ENGINE: PC35MR-5...................................................................................................... 295 STANDARD VALUE TABLE FOR MACHINE................................................................................................................... 297 STANDARD VALUE TABLE FOR MACHINE: PC30MR-5..................................................................................................... 297 STANDARD VALUE TABLE FOR MACHINE: PC35MR-5..................................................................................................... 311 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE........................................................................................ 325 30 TESTING AND ADJUSTING............................................................................................................................... 329 CONTENTS........................................................................................................................................... 330 ABBREVIATION LIST.................................................................................................................................. 333 RELATED INFORMATION ON TESTING AND ADJUSTING....................................................................................................... 339 TOOLS FOR TESTING AND ADJUSTING................................................................................................................ 339 SKETCH OF TOOLS FOR TESTING AND ADJUSTING...................................................................................................... 343 ENGINE AND COOLING SYSTEM.......................................................................................................................... 345 TEST ENGINE SPEED.............................................................................................................................. 345 METHOD FOR TESTING ENGINE SPEED............................................................................................................ 345 TEST EXHAUST GAS COLOR......................................................................................................................... 348 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................................ 348 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER........................................................................................ 349 TEST AND ADJUST VALVE CLEARANCE................................................................................................................ 350 METHOD FOR TESTING VALVE CLEARANCE......................................................................................................... 350 METHOD FOR ADJUSTING VALVE CLEARANCE....................................................................................................... 351 TEST COMPRESSION PRESSURE...................................................................................................................... 353 METHOD FOR TESTING COMPRESSION PRESSURE.................................................................................................... 353 TEST ENGINE OIL PRESSURE....................................................................................................................... 356 METHOD FOR TESTING ENGINE OIL PRESSURE..................................................................................................... 356 TEST AND ADJUST FUEL INJECTION TIMING.......................................................................................................... 358 METHOD FOR TESTING FUEL INJECTION TIMING................................................................................................... 358 METHOD FOR ADJUSTING FUEL INJECTION TIMING................................................................................................. 360 BLEED AIR FROM FUEL SYSTEM..................................................................................................................... 363 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM................................................................................................... 363 TEST FUEL CIRCUIT FOR LEAKAGE.................................................................................................................. 364 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................................ 364 TEST AND ADJUST ALTERNATOR BELT TENSION........................................................................................................ 365 METHOD FOR TESTING ALTERNATOR BELT TENSION................................................................................................. 365 METHOD FOR ADJUSTING ALTERNATOR BELT TENSION............................................................................................... 365 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION........................................................................................ 366 METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION................................................................................. 366 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION............................................................................... 366 POWER TRAIN........................................................................................................................................ 367 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................................ 367 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE.......................................................................................... 367 UNDERCARRIAGE AND FRAME............................................................................................................................ 368 TEST AND ADJUST TRACK TENSION.................................................................................................................. 368 METHOD FOR TESTING TRACK TENSION........................................................................................................... 368 METHOD FOR ADJUSTING TRACK TENSION......................................................................................................... 368 HYDRAULIC SYSTEM................................................................................................................................... 369 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................................................................... 369 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK................................................................................ 369 METHOD FOR RELEASING REMAINING PRESSURE IN PPC ACCUMULATOR CIRCUIT......................................................................... 369 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT...................................................................... 369 METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT........................................................................... 374 METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT.......................................................................... 374 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS................................................................ 375 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS......................................................... 375 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS....................................................... 385 TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE........................................................................................... 387 METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE.................................................................................... 387 METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE.................................................................................. 392 TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT................................................................................................ 394 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT......................................................................................... 394 METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT....................................................................................... 396 ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT................................................................................................. 398 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT............................................................................... 398 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT........................................................................................ 400 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR............................................................................. 400 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL................................................................................ 402 METHOD FOR ADJUSTING LS VALVE.............................................................................................................. 403 TEST OUTLET PRESSURE OF SOLENOID VALVE......................................................................................................... 405 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR.................................................................... 405 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL....................................................................... 406 OPERATING CONDITION OF SOLENOID VALVE...................................................................................................... 407 TEST PPC VALVE OUTLET PRESSURE................................................................................................................. 409 METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR......................................................................... 409 METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL............................................................................ 412 ADJUST WORK EQUIPMENT AND SWING PPC VALVES..................................................................................................... 414 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES........................................................................... 414 TEST SWING PARKING BRAKE RELEASE PRESSURE...................................................................................................... 415 METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE.................................................................................... 415 TEST AND ADJUST TRAVEL DEVIATION............................................................................................................... 416 METHOD FOR TESTING TRAVEL DEVIATION........................................................................................................ 416 METHOD FOR ADJUSTING TRAVEL DEVIATION...................................................................................................... 416 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT....................................................................................... 419 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER.................................................. 419 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER....................................................................... 419 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE.......................................................................... 420 TEST OIL LEAKAGE............................................................................................................................... 421 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER.......................................................................................... 421 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER........................................................................................... 422 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER........................................................................................ 423 METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER......................................................................................... 423 BLEED AIR FROM HYDRAULIC CIRCUIT............................................................................................................... 425 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT............................................................................................. 426 PRESSURIZE HYDRAULIC TANK...................................................................................................................... 428 METHOD FOR PRESSURIZING HYDRAULIC TANK..................................................................................................... 428 CAB AND ITS ATTACHMENTS............................................................................................................................ 429 OPENING AND CLOSING FLOOR UNIT................................................................................................................. 429 METHOD FOR OPENING FLOOR UNIT.............................................................................................................. 430 METHOD FOR CLOSING FLOOR UNIT.............................................................................................................. 434 ELECTRICAL SYSTEM.................................................................................................................................. 438 SET AND OPERATE MACHINE MONITOR................................................................................................................ 438 OPERATOR MODE.............................................................................................................................. 441 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY).......................................................................................... 441 CHECKING FUNCTION OF SERVICE METER......................................................................................................... 441 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD.................................................................................. 441 SERVICE MODE............................................................................................................................... 444 METHOD FOR OPERATING SERVICE MODE.......................................................................................................... 444 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION..................................................................................... 445 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION..................................................................................... 447 ABNORMALITY RECORD MENU.................................................................................................................... 453 METHOD FOR CONFIRMING MAINTENANCE RECORD................................................................................................... 456 METHOD FOR OPERATING MAINTENANCE MODE SETTING.............................................................................................. 457 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................................ 461 DEFAULT MENU............................................................................................................................... 463 ADJUSTMENT MENU............................................................................................................................ 468 METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING..................................................................................... 472 KOMTRAX SETTINGS MENU...................................................................................................................... 474 METHOD FOR DISPLAYING SERVICE MESSAGE...................................................................................................... 476 METHOD FOR STARTING UP KOMTRAX TERMINAL........................................................................................................ 478 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER.................................................................................................... 483 HANDLE QUICK RELEASE BATTERY TERMINAL (-)...................................................................................................... 484 TEST DIODES.................................................................................................................................... 485 METHOD FOR TESTING DIODE USING DIGITAL TESTER.............................................................................................. 485 METHOD FOR TESTING DIODE USING ANALOG TESTER............................................................................................... 485 Pm CLINIC.......................................................................................................................................... 486 Pm CLINIC SERVICE.............................................................................................................................. 486 Pm CLINIC CHECK SHEET: PC30MR-5............................................................................................................ 487 Pm CLINIC CHECK SHEET: PC35MR-5............................................................................................................ 495 40 TROUBLESHOOTING..................................................................................................................................... 503 CONTENTS........................................................................................................................................... 504 ABBREVIATION LIST.................................................................................................................................. 509 RELATED INFORMATION ON TROUBLESHOOTING............................................................................................................. 515 GENERAL TROUBLESHOOTING POINTS................................................................................................................. 515 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................................... 516 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................. 518 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING.................................................................................................... 520 WALK-AROUND CHECK.......................................................................................................................... 520 TESTING IN ACCORDANCE WITH TESTING PROCEDURE................................................................................................... 522 CHECK FUEL LEVEL AND TYPE.................................................................................................................. 522 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT......................................................................................... 523 TEST FUEL MAIN FILTER CARTRIDGE............................................................................................................ 523 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)............................................................................................. 526 CHECK COOLANT LEVEL (RESERVOIR TANK)....................................................................................................... 526 CHECK CLOGGING OF AIR CLEANER.............................................................................................................. 527 CLEAN OUTER ELEMENT (SINGLE ELEMENT)....................................................................................................... 528 REPLACE SINGLE ELEMENT..................................................................................................................... 530 CHECK HYDRAULIC OIL LEVEL.................................................................................................................. 531 CHECK HYDRAULIC OIL STRAINER............................................................................................................... 535 CHECK HYDRAULIC FILTER..................................................................................................................... 537 CHECK OIL LEVEL IN FINAL DRIVE CASE........................................................................................................ 538 BLEED AIR FROM FUEL SYSTEM................................................................................................................. 538 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................................ 538 ELECTRICAL EQUIPMENT - CHECK METHOD........................................................................................................ 539 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION................................................................................................ 546 PROCEDURE FOR TESTING AND TROUBLESHOOTING...................................................................................................... 550 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................................ 553 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE................................................................................................. 557 CONNECTORS LIST AND LAYOUT..................................................................................................................... 559 CONNECTOR CONTACT IDENTIFICATION............................................................................................................... 570 CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE).......................................................................................... 610 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE........................................................................................................ 612 FUSE LOCATION TABLE............................................................................................................................ 618 FAILURE CODES TABLE............................................................................................................................ 624 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE).................................................................................................. 630 FAILURE CODE [989L00].......................................................................................................................... 630 FAILURE CODE [989M00].......................................................................................................................... 631 FAILURE CODE [989N00].......................................................................................................................... 632 FAILURE CODE [B@BCNS].......................................................................................................................... 633 FAILURE CODE [D19JKZ].......................................................................................................................... 634 FAILURE CODE [D19JKZ].......................................................................................................................... 637 FAILURE CODE [D811MC].......................................................................................................................... 640 FAILURE CODE [D862KA].......................................................................................................................... 641 FAILURE CODE [D8ALKA].......................................................................................................................... 642 FAILURE CODE [D8ALKB].......................................................................................................................... 644 FAILURE CODE [D8AQKR].......................................................................................................................... 646 FAILURE CODE [DAF0KT].......................................................................................................................... 651 FAILURE CODE [DAF0MB].......................................................................................................................... 652 FAILURE CODE [DAF0MC].......................................................................................................................... 653 FAILURE CODE [DAF3KK].......................................................................................................................... 654 FAILURE CODE [DAF9KQ].......................................................................................................................... 659 FAILURE CODE [DAFGMC].......................................................................................................................... 660 FAILURE CODE [DAFLKA].......................................................................................................................... 661 FAILURE CODE [DAFLKB].......................................................................................................................... 663 FAILURE CODE [DAFQKR].......................................................................................................................... 665 FAILURE CODE [DB2QKR].......................................................................................................................... 666 FAILURE CODE [DBH0MC].......................................................................................................................... 671 FAILURE CODE [DBH2KK].......................................................................................................................... 672 FAILURE CODE [DBH2KK].......................................................................................................................... 675 FAILURE CODE [DBH5KP].......................................................................................................................... 678 FAILURE CODE [DBH5KP].......................................................................................................................... 680 FAILURE CODE [DBH9KQ].......................................................................................................................... 682 FAILURE CODE [DBHLKA].......................................................................................................................... 685 FAILURE CODE [DBHLKB].......................................................................................................................... 687 FAILURE CODE [DBHQKR].......................................................................................................................... 689 FAILURE CODE [DBHQKR].......................................................................................................................... 694 FAILURE CODE [DDNRKA].......................................................................................................................... 699 FAILURE CODE [DDNRKY].......................................................................................................................... 702 FAILURE CODE [DDNS00].......................................................................................................................... 705 FAILURE CODE [DDWLKA].......................................................................................................................... 708 FAILURE CODE [DDWLKB].......................................................................................................................... 710 FAILURE CODE [DFB1KZ].......................................................................................................................... 712 FAILURE CODE [DFB3L8].......................................................................................................................... 714 FAILURE CODE [DFB5KZ].......................................................................................................................... 716 FAILURE CODE [DHS1MA].......................................................................................................................... 718 FAILURE CODE [DHS5MA].......................................................................................................................... 720 FAILURE CODE [DKULKA].......................................................................................................................... 722 FAILURE CODE [DKULKB].......................................................................................................................... 725 FAILURE CODE [DKULKY].......................................................................................................................... 728 FAILURE CODE [DV00KB].......................................................................................................................... 731 FAILURE CODE [DV20KB].......................................................................................................................... 732 FAILURE CODE [DW43KA].......................................................................................................................... 734 FAILURE CODE [DW43KB].......................................................................................................................... 736 FAILURE CODE [DW43KY].......................................................................................................................... 738 FAILURE CODE [DW4CKY].......................................................................................................................... 739 FAILURE CODE [DXA8KA].......................................................................................................................... 742 FAILURE CODE [DXA8KB].......................................................................................................................... 746 FAILURE CODE [DXE7KA].......................................................................................................................... 750 FAILURE CODE [DXE7KB].......................................................................................................................... 752 FAILURE CODE [DXE7KY].......................................................................................................................... 754 FAILURE CODE [DXEAKA].......................................................................................................................... 755 FAILURE CODE [DXEAKB].......................................................................................................................... 757 FAILURE CODE [DXEAKY].......................................................................................................................... 759 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...................................................................................................... 760 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK).............................................................................................. 760 E-2 ENGINE DOES NOT START (ENGINE DOES NOT CRANK).............................................................................................. 767 E-3 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM).............................................................................................. 773 E-4 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM).............................................................................................. 775 E-5 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK.................................................................................................. 777 E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING............................................................ 781 E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING............................................................ 784 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING.............................................................. 787 E-9 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.............................................................................. 788 E-10 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING............................................................................... 789 E-11 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING............................................................... 790 E-12 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...................................................................... 791 E-13 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.................................................................................. 792 E-14 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...................................................................................... 794 E-15 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM............................................................ 795 E-16 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE....................................................... 796 E-17 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.................................................................................... 797 E-18 FUNCTION SWITCH DOES NOT OPERATE.......................................................................................................... 798 E-19 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER................................................................................... 799 E-20 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED......................................................... 800 E-21 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE............................................................... 801 E-22 ALARM BUZZER DOES NOT SOUND............................................................................................................... 804 E-23 ALARM BUZZER CANNOT BE CANCELED........................................................................................................... 806 E-24 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.................................................................. 808 E-25 SERVICE MODE CANNOT BE SELECTED........................................................................................................... 809 E-26 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE........................................................................... 810 E-27 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK............................................................................ 814 E-28 ALARM DOES NOT SOUND DURING TRAVEL........................................................................................................ 817 E-29 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..................................................................................... 819 E-30 HORN DOES NOT SOUND....................................................................................................................... 820 E-31 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC)......................................................................................... 824 E-32 HORN DOES NOT STOP SOUNDING............................................................................................................... 828 E-33 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER SPEC)................................................................................. 831 E-34 WORKING LAMP AND HEADLAMP DO NOT LIGHT UP (CANOPY SPEC)................................................................................... 834 E-35 NONE OF WORKING LAMP, HEADLAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP (CAB SPEC)........................................................... 839 E-36 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE.......................................................................... 844 E-37 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE..................................................................... 847 E-38 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................................... 850 E-39 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.......................................................................... 851 E-40 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION........................................................................... 852 E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY.................................................................................................. 854 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...................................................................................... 855 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)........................................................................................ 855 H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE.................................................................................. 856 H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE............................................................................................. 857 H-3 TRAVEL OR BLADE DOES NOT OPERATE........................................................................................................... 858 H-4 SWING OR BLADE DOES NOT OPERATE............................................................................................................ 859 H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW.......................................................................... 860 H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW........................................................................................ 861 H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW..................................................................................................... 862 H-8 SWING AND BLADE SPEED OR POWER IS LOW...................................................................................................... 863 H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................................................................... 864 H-10 UNUSUAL NOISE IS HEARD FROM AROUND MAIN PUMP.............................................................................................. 865 H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS................................................................................................ 866 H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW................................................................................................. 868 H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW....................................................................................... 869 H-14 BLADE DOES NOT OPERATE.................................................................................................................... 870 H-15 ALL WORK EQUIPMENTS DO NOT OPERATE........................................................................................................ 871 H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE............................................................................................... 872 H-17 SPEED OR POWER OF BOOM IS LOW............................................................................................................. 873 H-18 SPEED OR POWER OF BOOM IS LOW (PIPING SPECIFICATION)...................................................................................... 875 H-19 ARM SPEED OR POWER IS LOW................................................................................................................. 877 H-20 BUCKET SPEED OR POWER IS LOW.............................................................................................................. 878 H-21 BLADE SPEED OR POWER IS LOW............................................................................................................... 879 H-22 BOOM SWING SPEED OR POWER IS LOW.......................................................................................................... 881 H-23 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION.......................................................................................... 882 H-24 HYDRAULIC DRIFT OF BOOM IS LARGE.......................................................................................................... 883 H-25 HYDRAULIC DRIFT OF ARM IS LARGE........................................................................................................... 884 H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE........................................................................................................ 885 H-27 HYDRAULIC DRIFT OF BLADE IS LARGE......................................................................................................... 886 H-28 TIME LAG OF WORK EQUIPMENT IS LARGE....................................................................................................... 888 H-29 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER....................................................... 889 H-30 MACHINE DOES NOT TRAVEL STRAIGHT.......................................................................................................... 890 H-31 MACHINE DOES NOT MOVE OFF STRAIGHT........................................................................................................ 892 H-32 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...................................................................................... 893 H-33 TRAVEL SPEED IS LOW....................................................................................................................... 895 H-34 BOTH SIDES OF CRAWLERS DO NOT MOVE........................................................................................................ 897 H-35 ONE OF TRACKS DOES NOT RUN................................................................................................................ 898 H-36 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST......................................................................... 900 H-37 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT................................................................................. 901 H-38 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT (AIR CONDITIONER EQUIPPED MODEL)................................................ 903 H-39 SWINGS ONLY IN ONE DIRECTION.............................................................................................................. 905 H-40 SWINGS ONLY IN ONE DIRECTION (AIR CONDITIONER EQUIPPED MODEL)............................................................................. 907 H-41 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT).............................................................. 909 H-42 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) (AIR CONDITIONER EQUIPPED MODEL)............................. 911 H-43 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION....................................................... 913 H-44 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) (AIR CONDITIONER EQUIPPED MODEL).... 914 H-45 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)......................................................... 915 H-46 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) (AIR CONDITIONER EQUIPPED MODEL)........................ 916 H-47 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)..................................... 917 H-48 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING........................................................................................ 918 H-49 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING.......................................................................... 919 H-50 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).................................................................... 920 H-51 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)................................................................... 921 H-52 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) (AIR CONDITIONER EQUIPPED MODEL).................................. 922 TROUBLESHOOTING OF ENGINE (S-MODE)................................................................................................................. 923 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)........................................................................................ 923 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION..................................................................... 924 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT................................................................................................. 925 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)............................................. 926 S-4 ENGINE STARTABILITY IS POOR................................................................................................................ 927 S-5 ENGINE DOES NOT PICK UP SMOOTHLY........................................................................................................... 929 S-6 ENGINE STOPS DURING OPERATION.............................................................................................................. 930 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE........................................................................................................... 932 S-8 ENGINE LACKS POWER......................................................................................................................... 933 S-9 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................................ 935 S-10 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................................... 936 S-11 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................. 937 S-12 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)..................................................................... 938 S-13 OIL PRESSURE DROPS........................................................................................................................ 939 S-14 FUEL MIXES INTO ENGINE OIL................................................................................................................ 941 S-15 WATER MIXES INTO ENGINE OIL (MILKY)....................................................................................................... 942 S-16 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING).......................................................................................... 943 S-17 UNUSUAL NOISE IS HEARD.................................................................................................................... 944 S-18 VIBRATION IS EXCESSIVE.................................................................................................................... 945 S-19 AIR CANNOT BE BLED FROM FUEL CIRCUIT...................................................................................................... 946 50 DISASSEMBLY AND ASSEMBLY............................................................................................................................ 947 CONTENTS........................................................................................................................................... 948 ABBREVIATION LIST.................................................................................................................................. 951 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.................................................................................................... 957 HOW TO READ THIS MANUAL........................................................................................................................ 957 COATING MATERIALS LIST......................................................................................................................... 959 SPECIAL TOOLS LIST............................................................................................................................. 963 SKETCHES OF SPECIAL TOOLS...................................................................................................................... 969 ENGINE AND COOLING SYSTEM.......................................................................................................................... 970 REMOVE AND INSTALL RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY.................................................................................. 970 METHOD FOR REMOVING RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY............................................................................. 970 METHOD FOR INSTALLING RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY........................................................................... 977 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY............................................................................................... 983 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY.......................................................................................... 983 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY........................................................................................ 991 REMOVE AND INSTALL FUEL COOLER ASSEMBLY........................................................................................................ 999 METHOD FOR REMOVING FUEL COOLER ASSEMBLY................................................................................................... 999 METHOD FOR INSTALLING FUEL COOLER ASSEMBLY.................................................................................................1001 REMOVE AND INSTALL FUEL TANK ASSEMBLY..........................................................................................................1003 METHOD FOR REMOVING FUEL TANK ASSEMBLY.....................................................................................................1003 METHOD FOR INSTALLING FUEL TANK ASSEMBLY...................................................................................................1005 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY..........................................................................................1008 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY.....................................................................................1008 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...................................................................................1009 POWER TRAIN........................................................................................................................................1011 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.......................................................................................1011 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY..................................................................................1011 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY................................................................................1013 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY....................................................................................1015 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY...............................................................................1015 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY.............................................................................1016 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY..............................................................................................1018 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY..........................................................................................1018 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY.............................................................................................1021 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY.......................................................................................................1025 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY..................................................................................................1025 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY................................................................................................1025 UNDERCARRIAGE AND FRAME............................................................................................................................1027 DISASSEMBLE AND ASSEMBLE RECOIL SPRING.........................................................................................................1027 METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING......................................................................................1027 METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY...............................................................................................1028 SEPARATION AND CONNECTION OF TRACK ASSEMBLY....................................................................................................1030 METHOD FOR SEPARATING TRACK ASSEMBLY.......................................................................................................1030 METHOD FOR INSTALLING TRACK ASSEMBLY.......................................................................................................1030 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY........................................................................................................1032 METHOD FOR DISASSEMBLING IDLER ASSEMBLY....................................................................................................1032 METHOD FOR ASSEMBLING IDLER ASSEMBLY.......................................................................................................1033 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY.................................................................................................1036 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY.............................................................................................1036 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY................................................................................................1037 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY................................................................................................1039 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY...........................................................................................1039 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY..............................................................................................1040 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY....................................................................................................1042 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY...............................................................................................1042 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY.............................................................................................1043 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY......................................................................................................1045 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY.................................................................................................1045 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...............................................................................................1048 HYDRAULIC SYSTEM...................................................................................................................................1052 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY................................................................................................1052 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY...........................................................................................1052 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY.........................................................................................1054 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY..........................................................................................1056 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY......................................................................................1057 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.........................................................................................1058 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY.....................................................................................................1059 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY................................................................................................1059 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY..............................................................................................1062 REMOVE AND INSTALL MAIN PUMP ASSEMBLY..........................................................................................................1065 METHOD FOR REMOVING MAIN PUMP ASSEMBLY.....................................................................................................1065 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY...................................................................................................1068 REMOVE AND INSTALL ACCUMULATOR ASSEMBLY........................................................................................................1071 METHOD FOR REMOVING ACCUMULATOR ASSEMBLY...................................................................................................1071 METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY.................................................................................................1071 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................................1073 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.................................................................................1073 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY....................................................................................1074 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY.............................................................................................1076 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY.........................................................................................1076 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY............................................................................................1077 WORK EQUIPMENT.....................................................................................................................................1079 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY.....................................................................................................1079 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY................................................................................................1079 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY..............................................................................................1081 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................................1083 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY..................................................................................1084 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.....................................................................................1087 CAB AND ITS ATTACHMENTS............................................................................................................................1092 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)..........................................................................................1092 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY (CAB SPEC).....................................................................................1092 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY (CAB SPEC)...................................................................................1098 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY (CANOPY SPEC).......................................................................................1103 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC)......................................................................................1103 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY (CANOPY SPEC).....................................................................................1108 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)..........................................................................................1113 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS).....................................................................................1114 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)...................................................................................1115 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY.......................................................................................................1123 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY..................................................................................................1123 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY................................................................................................1124 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...............................................................................................1126 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY..........................................................................................1126 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY........................................................................................1130 REMOVE AND INSTALL OPERATOR'S SEAT.............................................................................................................1135 METHOD FOR REMOVING OPERATOR'S SEAT........................................................................................................1135 METHOD FOR INSTALLING OPERATOR'S SEAT......................................................................................................1135 REMOVE AND INSTALL SEAT BELT...................................................................................................................1137 METHOD FOR REMOVING SEAT BELT..............................................................................................................1137 METHOD FOR INSTALLING SEAT BELT............................................................................................................1137 ELECTRICAL SYSTEM..................................................................................................................................1138 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY..................................................................................................1138 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY.............................................................................................1138 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...........................................................................................1139 REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY.................................................................................................1140 METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY............................................................................................1140 METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY..........................................................................................1141 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY....................................................................................................1143 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...............................................................................................1143 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY.............................................................................................1144 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...................................................................................................1146 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY..............................................................................................1146 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY............................................................................................1148 REMOVE AND INSTALL QUICK RELEASE BATTERY TERMINAL (-)..........................................................................................1150 METHOD FOR INSTALLING QUICK RELEASE BATTERY TERMINAL (-)...................................................................................1150 METHOD FOR REMOVING QUICK RELEASE BATTERY TERMINAL (-).....................................................................................1151 60 MAINTENANCE STANDARD................................................................................................................................1153 CONTENTS...........................................................................................................................................1154 ABBREVIATION LIST..................................................................................................................................1155 ENGINE AND COOLING SYSTEM..........................................................................................................................1161 MAINTENANCE STANDARD FOR PTO...................................................................................................................1161 MAINTENANCE STANDARD OF COOLING SYSTEM.........................................................................................................1162 POWER TRAIN........................................................................................................................................1163 MAINTENANCE STANDARD OF SWING CIRCLE...........................................................................................................1163 MAINTENANCE STANDARD OF SWING MACHINERY........................................................................................................1164 MAINTENANCE STANDARD OF SPROCKET...............................................................................................................1166 UNDERCARRIAGE AND FRAME............................................................................................................................1167 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION..........................................................................................1167 MAINTENANCE STANDARD OF IDLER..................................................................................................................1169 MAINTENANCE STANDARD OF TRACK ROLLER...........................................................................................................1171 MAINTENANCE STANDARD OF CARRIER ROLLER.........................................................................................................1172 MAINTENANCE STANDARD OF TRACK SHOE.............................................................................................................1173 MAINTENANCE STANDARD OF DOUBLE SHOE............................................................................................................1175 MAINTENANCE STANDARD OF ROAD LINER.............................................................................................................1176 MAINTENANCE STANDARD FOR RUBBER SHOE...........................................................................................................1177 HYDRAULIC SYSTEM...................................................................................................................................1178 MAINTENANCE STANDARD OF HYDRAULIC TANK.........................................................................................................1178 MAINTENANCE STANDARD OF MAIN PUMP..............................................................................................................1179 MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE..............................................................................................1180 MAINTENANCE STANDARD OF PC-EPC VALVE...........................................................................................................1181 MAINTENANCE STANDARD OF SWING MOTOR............................................................................................................1182 MAINTENANCE STANDARD OF TRAVEL MOTOR...........................................................................................................1184 MAINTENANCE STANDARD OF CONTROL VALVE..........................................................................................................1185 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE.....................................................................................1194 MAINTENANCE STANDARD OF BLADE PPC VALVE........................................................................................................1197 MAINTENANCE STANDARD OF BOOM SWING PPC VALVE...................................................................................................1199 MAINTENANCE STANDARD OF TRAVEL PPC VALVE.......................................................................................................1201 MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE...................................................................................................1204 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT....................................................................................................1206 WORK EQUIPMENT.....................................................................................................................................1207 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE.................................................................................................1207 DIMENSION OF ARM...........................................................................................................................1217 DIMENSIONS OF BUCKET.......................................................................................................................1219 MAINTENANCE STANDARD OF BOOM CYLINDER..........................................................................................................1221 MAINTENANCE STANDARD OF ARM CYLINDER...........................................................................................................1223 MAINTENANCE STANDARD OF BUCKET CYLINDER........................................................................................................1225 MAINTENANCE STANDARD OF BLADE CYLINDER.........................................................................................................1226 MAINTENANCE STANDARD OF BOOM SWING CYLINDER....................................................................................................1228 80 APPENDIX............................................................................................................................................1231 CONTENTS...........................................................................................................................................1232 ABBREVIATION LIST..................................................................................................................................1233 AIR CONDITIONER SYSTEM.............................................................................................................................1239 PRECAUTIONS FOR REFRIGERANT....................................................................................................................1239 AIR CONDITIONER COMPONENT......................................................................................................................1240 SPECIFICATIONS OF AIR CONDITIONER..............................................................................................................1241 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE..............................................................................................1242 OUTLINE OF REFRIGERATION CYCLE.................................................................................................................1243 COMPONENT PARTS OF AIR CONDITIONER SYSTEM..........................................................................................................1245 AIR CONDITIONER UNIT...........................................................................................................................1245 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT..............................................................................................1245 COMPRESSOR.....................................................................................................................................1247 STRUCTURE OF COMPRESSOR....................................................................................................................1247 SPECIFICATIONS OF COMPRESSOR...............................................................................................................1247 FUNCTION OF COMPRESSOR.....................................................................................................................1247 CONDENSER......................................................................................................................................1249 STRUCTURE OF CONDENSER.....................................................................................................................1249 SPECIFICATIONS OF CONDENSER................................................................................................................1249 FUNCTION OF CONDENSER......................................................................................................................1249 RECEIVER DRIER.................................................................................................................................1250 STRUCTURE OF RECEIVER DRIER................................................................................................................1250 SPECIFICATIONS OF RECEIVER DRIER...........................................................................................................1250 FUNCTION OF RECEIVER DRIER.................................................................................................................1250 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.....................................................................................................1251 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).....................................................................1253 A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL).............................................................1256 A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION...............................................................................................1260 A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM)..........................................................1263 A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS).........................................................1267 A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM...................................................................................................1268 A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS......................................................................................1269 A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS.................................................................................................1270 A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER................................................................................................1271 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS............................................................1272 HANDLE COMPRESSOR OIL..............................................................................................................................1274 90 CIRCUIT DIAGRAMS....................................................................................................................................1275 CONTENTS...........................................................................................................................................1276 ABBREVIATION LIST..................................................................................................................................1279 HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................1285 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM......................................................................................................1285 HYDRAULIC CIRCUIT DIAGRAM: PC30MR-5............................................................................................................1289 HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC30MR-5 (1/2).......................................................................1290 HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC30MR-5 (2/2).......................................................................1291 HYDRAULIC CIRCUIT DIAGRAM: PC35MR-5............................................................................................................1292 HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC35MR-5 (1/2).......................................................................1293 HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC35MR-5 (2/2).......................................................................1294 ELECTRICAL CIRCUIT DIAGRAM.........................................................................................................................1295 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................1295 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 - 52907)(1/5)...................................................................1299 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 - 52907)(2/5)...................................................................1300 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 - 52907)(3/5)...................................................................1301 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 - 52907)(4/5)...................................................................1302 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 - 52907)(5/5)...................................................................1303 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(1/5)....................................................................1304 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(2/5)....................................................................1305 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(3/5)....................................................................1306 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(4/5)....................................................................1307 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(5/5)....................................................................1308 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 - 31037)(1/5)...................................................................1309 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 - 31037)(2/5)...................................................................1310 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 - 31037)(3/5)...................................................................1311 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 - 31037)(4/5)...................................................................1312 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 - 31037)(5/5)...................................................................1313 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(1/5)....................................................................1314 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(2/5)....................................................................1315 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(3/5)....................................................................1316 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(4/5)....................................................................1317 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(5/5)....................................................................1318 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(1/5)....................................1319 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(2/5)....................................1320 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(3/5)....................................1321 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(4/5)....................................1322 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(5/5)....................................1323 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(1/5).....................................1324 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(2/5).....................................1325 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(3/5).....................................1326 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(4/5).....................................1327 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(5/5).....................................1328 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(1/5)....................................1329 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(2/5)....................................1330 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(3/5)....................................1331 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(4/5)....................................1332 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(5/5)....................................1333 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(1/5).....................................1334 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(2/5).....................................1335 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(3/5).....................................1336 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(4/5).....................................1337 ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(5/5).....................................1338 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 - 52848)(1/6)......................................................................1339 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 - 52848)(2/6)......................................................................1340 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 - 52848)(3/6)......................................................................1341 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 - 52848)(4/6)......................................................................1342 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 - 52848)(5/6)......................................................................1343 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 - 52848)(6/6)......................................................................1344 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(1/6).......................................................................1345 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(2/6).......................................................................1346 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(3/6).......................................................................1347 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(4/6).......................................................................1348 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(5/6).......................................................................1349 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(6/6).......................................................................1350 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 - 31023)(1/6)......................................................................1351 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 - 31023)(2/6)......................................................................1352 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 - 31023)(3/6)......................................................................1353 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 - 31023)(4/6)......................................................................1354 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 - 31023)(5/6)......................................................................1355 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 - 31023)(6/6)......................................................................1356 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(1/6).......................................................................1357 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(2/6).......................................................................1358 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(3/6).......................................................................1359 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(4/6).......................................................................1360 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(5/6).......................................................................1361 ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(6/6).......................................................................1362 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(1/6).......................................1363 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(2/6).......................................1364 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(3/6).......................................1365 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(4/6).......................................1366 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(5/6).......................................1367 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 - 52556)(6/6).......................................1368 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(1/6)........................................1369 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(2/6)........................................1370 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(3/6)........................................1371 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(4/6)........................................1372 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(5/6)........................................1373 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(6/6)........................................1374 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(1/6).......................................1375 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(2/6).......................................1376 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(3/6).......................................1377 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(4/6).......................................1378 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(5/6).......................................1379 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 - 30888)(6/6).......................................1380 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(1/6)........................................1381 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(2/6)........................................1382 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(3/6)........................................1383 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(4/6)........................................1384 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(5/6)........................................1385 ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(6/6)........................................1386 INDEX...................................................................................................................................................1387
DESCRIPTION:
KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams
S.S 21/12/24
