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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL SEN06591-11 – PDF DOWNLOAD
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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL SEN06591-11 – PDF DOWNLOAD
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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL SEN06591-11 – PDF DOWNLOAD
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KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL SEN06591-11 – PDF DOWNLOAD
Language : English
Pages : 1508
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File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL SEN06591-11 – 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 Procedures If Fire Occurs..................................................................................................................... 33 Precautions When You Discard Waste Materials.................................................................................................. 34 Precautions When You Handle Hydraulic Equipment............................................................................................... 35 Precautions When You Disconnect and Connect Pipings........................................................................................... 38 Precautions When You Handle Electrical Equipment.............................................................................................. 45 Precautions When You Handle Fuel System Equipment............................................................................................. 47 Precautions When You Handle Intake System Equipment........................................................................................... 48 Practical Use of KOMTRAX...................................................................................................................... 49 Disconnect and Connect Push-Pull Type Coupler................................................................................................. 50 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................... 50 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................... 51 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................... 52 Precautions for Disconnection and Connection of Connectors.................................................................................... 54 Disconnect and Connect Deutsch Connector...................................................................................................... 58 How to Disconnect and Connect Slide Lock Type Connector....................................................................................... 59 Disconnect and Connect Connector with Lock to Pull............................................................................................ 61 Disconnect and Connect Connector with Lock to Push............................................................................................ 62 Disconnect and Connect Connector with Housing to Rotate....................................................................................... 64 How to Read the Codes for Electric Cable...................................................................................................... 65 Explanation of Terms for Maintenance Standard................................................................................................. 69 Standard Tightening Torque Table.............................................................................................................. 72 Conversion Table.............................................................................................................................. 79 01 Specification...................................................................................................................................... 85 Table of Contents................................................................................................................................. 86 Abbreviation List................................................................................................................................. 87 Specifications.................................................................................................................................... 93 Specification Drawing......................................................................................................................... 93 Specification Drawing: PC30MR-5........................................................................................................... 93 Specification Drawing: PC35MR-5........................................................................................................... 95 Working Range Drawings........................................................................................................................ 97 Working Range: PC30MR-5................................................................................................................... 97 Working Range: PC35MR-5................................................................................................................... 98 Specifications................................................................................................................................ 99 Specifications: PC30MR-5.................................................................................................................. 99 Specifications: PC35MR-5.................................................................................................................. 103 Weight Table.................................................................................................................................. 108 Weight Table: PC30MR-5.................................................................................................................... 108 Weight Table: PC35MR-5.................................................................................................................... 110 Table of Fuel, Coolant, and Lubricants........................................................................................................ 112 10 Structure and Function............................................................................................................................. 113 Table of Contents................................................................................................................................. 114 Abbreviation List................................................................................................................................. 116 Boot-up System.................................................................................................................................... 122 Layout Drawing of Boot-up System.............................................................................................................. 122 System Operating Lamp System.................................................................................................................. 123 System Diagram of System Operating Lamp System............................................................................................ 123 Function of Operation Lamp System......................................................................................................... 123 Quick Release Battery Terminal (-)............................................................................................................ 125 Function of Quick Release Battery Terminal (-)............................................................................................ 125 Engine System..................................................................................................................................... 126 Layout Drawing of Engine System............................................................................................................... 126 Engine Control System......................................................................................................................... 127 System Diagram of Engine Control.......................................................................................................... 127 Function of Engine Control System......................................................................................................... 129 Auto-Deceleration System...................................................................................................................... 135 System Diagram of Auto-Deceleration System................................................................................................ 135 Function of Auto-Deceleration System...................................................................................................... 135 Operation of Auto-Deceleration System..................................................................................................... 136 Overheat Prevention System.................................................................................................................... 137 Overheat Prevention System Diagram........................................................................................................ 137 Function of Overheat Prevention System.................................................................................................... 138 Automatic Idle Stop System.................................................................................................................... 139 System Diagram of Automatic Idle Stop System.............................................................................................. 139 Function of Automatic Idle Stop System.................................................................................................... 139 Component Parts of Engine System.............................................................................................................. 141 PTO....................................................................................................................................... 141 Cooling System.................................................................................................................................... 142 Layout Drawing of Cooling System.............................................................................................................. 142 Specifications of Cooling System.......................................................................................................... 143 Control System.................................................................................................................................... 144 Layout Drawing of Control System.............................................................................................................. 144 Machine Monitor System........................................................................................................................ 145 System Diagram of Machine Monitor System.................................................................................................. 145 KOMTRAX System................................................................................................................................ 146 System Diagram of KOMTRAX System.......................................................................................................... 146 Function of KOMTRAX System................................................................................................................ 146 Component Parts of Control System............................................................................................................. 147 Machine Monitor........................................................................................................................... 147 KOMTRAX Terminal.......................................................................................................................... 155 Machine Controller........................................................................................................................ 157 Resistor for PC-EPC Valve................................................................................................................. 161 Fuel Control Dial......................................................................................................................... 162 Hydraulic System.................................................................................................................................. 164 Layout Drawing of Hydraulic System............................................................................................................ 164 CLSS.......................................................................................................................................... 167 Structure of CLSS......................................................................................................................... 167 Function of CLSS.......................................................................................................................... 168 Engine and Pump Combined Control System....................................................................................................... 170 Engine and Pump Combined Control System Diagram........................................................................................... 170 Function of Engine and Pump Combined Control System....................................................................................... 171 Component Parts of Hydraulic System........................................................................................................... 173 Hydraulic Tank............................................................................................................................ 173 Main Pump................................................................................................................................. 177 Control Valve............................................................................................................................. 188 Work Equipment System............................................................................................................................. 229 Layout Drawing of Work Equipment System....................................................................................................... 229 Structure of Valve Control.................................................................................................................... 232 PPC Lock System............................................................................................................................... 234 System Diagram of PPC Lock................................................................................................................ 234 Function of PPC Lock System............................................................................................................... 235 Work Equipment and Travel Automatic Lock System............................................................................................... 236 Function of Work Equipment and Travel Automatic Lock System............................................................................... 236 Operation of Lock Lever Automatic Lock System............................................................................................. 236 Attachment Oil Flow Adjuster System........................................................................................................... 237 Attachment Oil Flow Adjuster System Diagram............................................................................................... 237 Function of Attachment Oil Flow Adjuster System........................................................................................... 238 Component Parts of Work Equipment System...................................................................................................... 239 Work Equipment and Swing PPC Valve........................................................................................................ 239 Attachment PPC Valve...................................................................................................................... 244 Blade PPC Valve........................................................................................................................... 246 Boom Swing PPC Valve...................................................................................................................... 248 Bipartite Solenoid Valve.................................................................................................................. 250 Multi-Control Valve....................................................................................................................... 253 Pilot Circuit Accumulator................................................................................................................. 254 Swing System...................................................................................................................................... 255 Layout Drawing of Swing System................................................................................................................ 255 Component Parts of Swing System............................................................................................................... 256 Swing Motor............................................................................................................................... 256 Swing Machinery........................................................................................................................... 261 Swing Circle.............................................................................................................................. 263 Travel System..................................................................................................................................... 264 Layout Drawing of Travel System............................................................................................................... 264 System Diagram of Travel Control System....................................................................................................... 266 Function of Travel Control System......................................................................................................... 266 Component Parts of Travel System.............................................................................................................. 268 Travel Motor.............................................................................................................................. 268 Travel PPC Valve.......................................................................................................................... 276 Center Swivel Joint....................................................................................................................... 278 Undercarriage and Frame........................................................................................................................... 279 Layout Drawing of Undercarriage............................................................................................................... 279 Specifications of Undercarriage........................................................................................................... 279 Idler Cushion................................................................................................................................. 280 Structure of Idler Cushion................................................................................................................ 280 Specifications of Idler Cushion........................................................................................................... 280 Work Equipment.................................................................................................................................... 281 Structure of Work Equipment................................................................................................................... 281 Function of Work Equipment.................................................................................................................... 282 Work Equipment Clearance Adjustment Shim...................................................................................................... 283 Function of Work Equipment Clearance Adjustment Shim...................................................................................... 283 CAB Related Parts................................................................................................................................. 284 ROPS CAB...................................................................................................................................... 284 Structure of ROPS CAB..................................................................................................................... 284 Function of ROPS CAB...................................................................................................................... 285 Tilt Type Floor............................................................................................................................... 286 Structure of Tilt Type Floor.............................................................................................................. 286 Function of Tilt Type Floor............................................................................................................... 286 20 Standard Value Table............................................................................................................................... 287 Table of Contents................................................................................................................................. 288 Abbreviation List................................................................................................................................. 289 Standard Value Table for Engine................................................................................................................... 295 Standard Value Table for Engine: PC30MR-5..................................................................................................... 295 Standard Value Table for Engine: PC35MR-5..................................................................................................... 297 Standard Value Table for Machine.................................................................................................................. 299 Standard Value Table for Machine: PC30MR-5.................................................................................................... 299 Standard Value Table for Machine: PC35MR-5.................................................................................................... 314 Machine Posture and Procedures to Measure Performance......................................................................................... 329 30 Testing and Adjusting.............................................................................................................................. 333 Table of Contents................................................................................................................................. 334 Abbreviation List................................................................................................................................. 337 Related Information on Testing and Adjusting...................................................................................................... 343 Tools for Testing and Adjusting............................................................................................................... 343 Sketch of Tools for Testing and Adjusting..................................................................................................... 347 Engine and Cooling System......................................................................................................................... 349 Examine Engine Speed.......................................................................................................................... 349 How to Examine Engine Speed............................................................................................................... 349 Examine Exhaust Gas Color..................................................................................................................... 352 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................. 352 How to Examine Exhaust Gas Color with Smoke Meter......................................................................................... 353 Examine and Adjust Valve Clearance............................................................................................................ 354 Check Valve Clearance..................................................................................................................... 354 Adjust Valve Clearance.................................................................................................................... 355 Examine Compression Pressure.................................................................................................................. 357 How to Examine Compression Pressure....................................................................................................... 357 Examine Engine Oil Pressure................................................................................................................... 360 How to Examine Engine Oil Pressure........................................................................................................ 360 Examine and Adjust Fuel Injection Timing...................................................................................................... 362 How to Examine Fuel Injection Timing...................................................................................................... 362 Adjust Fuel Injection Timing.............................................................................................................. 364 Bleed Air from Fuel System.................................................................................................................... 367 How to Bleed Air from Fuel System......................................................................................................... 367 Examine Fuel Circuit for Leakage.............................................................................................................. 368 How to Examine Fuel System for Leakage.................................................................................................... 368 Examine and Adjust Alternator Belt Tension.................................................................................................... 369 How to Examine Alternator Belt Tension.................................................................................................... 369 Adjust Alternator Belt Tension............................................................................................................ 369 Examine and Adjust Air Conditioner Compressor Belt Tension.................................................................................... 370 How to Examine Air Conditioner Compressor Belt Tension.................................................................................... 370 How to Adjust Air Conditioner Compressor Belt Tension..................................................................................... 370 Power Train....................................................................................................................................... 371 Examine Swing Circle Bearing Clearance........................................................................................................ 371 How to Examine Swing Circle Bearing Clearance............................................................................................. 371 Undercarriage and Frame........................................................................................................................... 372 Examine and Adjust Track Tension.............................................................................................................. 372 How to Examine Track Tension.............................................................................................................. 372 How to Adjust Track Tension............................................................................................................... 372 Hydraulic System.................................................................................................................................. 373 Release Remained Pressure in Hydraulic Circuit................................................................................................ 373 How to Release Remained Pressure from Hydraulic Tank...................................................................................... 373 How to Release Remained Pressure in PPC Accumulator Circuit............................................................................... 373 How to Release Remained Pressure in Hydraulic Cylinder Circuit............................................................................ 373 How to Release Remained Pressure from Swing Motor Circuit................................................................................. 378 How to Release Remained Pressure from Travel Motor Circuit................................................................................ 378 Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits............................................................ 379 How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits............................................................ 379 Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits.................................................................... 389 Examine and Adjust Swing and Blade Circuit Oil Pressure....................................................................................... 391 How to Examine Oil Pressure in Swing and Blade Circuits................................................................................... 391 Adjust Oil Pressure in Swing and Blade Circuits........................................................................................... 396 Examine and Adjust Oil Pressure in Control Circuit............................................................................................ 398 Examine Oil Pressure in Control Circuit................................................................................................... 398 Adjust Oil Pressure in Control Circuit.................................................................................................... 400 Adjust Oil Pressure in Pump PC Control Circuit................................................................................................ 402 How to Adjust Oil Pressure in Pump PC Control Circuit..................................................................................... 402 Examine and Adjust Oil Pressure in Pump LS Control Circuit.................................................................................... 404 Examine LS Differential Pressure with Machine Monitor..................................................................................... 404 Examine LS Differential Pressure by Testing Tool.......................................................................................... 406 Adjust LS Valve........................................................................................................................... 407 Examine Outlet Pressure of Solenoid Valve..................................................................................................... 409 How to Examine Outlet Pressure of Solenoid Valve by Machine Monitor....................................................................... 409 How to Examine Outlet Pressure of Solenoid Valve by Testing Tool.......................................................................... 410 Operating Condition of Solenoid Valve..................................................................................................... 411 Examine PPC Valve Outlet Pressure............................................................................................................. 412 How to Examine Outlet Pressure of PPC Valve with Machine Monitor.......................................................................... 412 How to Examine Outlet Pressure of PPC Valve by Testing Tool............................................................................... 415 Adjust Play of Work Equipment and Swing PPC Valves............................................................................................ 417 How to Adjust Play of Work Equipment and Swing PPC Valves................................................................................. 417 Examine Swing Parking Brake Release Pressure.................................................................................................. 418 How to Examine Swing Parking Brake Release Pressure....................................................................................... 418 Examine and Adjust Travel Deviation........................................................................................................... 419 How to Examine Travel Deviation........................................................................................................... 419 How to Adjust Travel Deviation............................................................................................................ 419 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................................... 422 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder..................................................... 422 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder...................................................................... 422 How to Examine Parts that Cause Hydraulic Drift of PPC Valve.............................................................................. 423 Examine Oil Leakage........................................................................................................................... 424 How to Examine Oil Leakage from Boom Cylinder............................................................................................. 424 How to Examine Oil Leakage from Arm Cylinder.............................................................................................. 425 How to Examine Oil Leakage from Bucket Cylinder........................................................................................... 426 How to Examine Oil Leakage from Blade Cylinder............................................................................................ 426 Bleed Air from Hydraulic System............................................................................................................... 428 How to Bleed Air from Hydraulic System.................................................................................................... 429 Pressurize Hydraulic Tank..................................................................................................................... 431 How to Pressurize Hydraulic Tank.......................................................................................................... 431 CAB Related Parts................................................................................................................................. 432 Open and Close Floor Unit..................................................................................................................... 432 Procedure to Open Floor Unit.............................................................................................................. 433 Procedure to Close Floor Unit............................................................................................................. 438 Electrical System................................................................................................................................. 442 Set and Operate Machine Monitor............................................................................................................... 442 Operator Mode............................................................................................................................. 445 Examine Function by LCD (Liquid Crystal Display).......................................................................................... 445 Examine Function of Service Meter......................................................................................................... 445 Usage Limitation and Maintenance Password Change Function................................................................................. 445 Service Mode.............................................................................................................................. 448 How to Operate Service Mode............................................................................................................... 448 How to See Pre-defined Monitoring Information............................................................................................. 449 How to Examine Self-Define Monitor Information............................................................................................ 451 Abnormality Record Menu................................................................................................................... 457 How to See Maintenance Record............................................................................................................. 460 Maintenance Mode Setting.................................................................................................................. 461 Set Phone Number Entry.................................................................................................................... 465 Default Menu.............................................................................................................................. 467 Adjustment Menu........................................................................................................................... 472 How to Operate Battery Disconnect Switch Setting.......................................................................................... 476 KOMTRAX Settings Menu..................................................................................................................... 478 Show Service Message...................................................................................................................... 480 How to Start Up KOMTRAX Terminal.............................................................................................................. 482 Handle Voltage Circuit of Engine Controller................................................................................................... 487 Handle Quick Release Battery Terminal (-)..................................................................................................... 488 Examine Diodes................................................................................................................................ 489 Examine Diodes by Digital Tester.......................................................................................................... 489 How to Examine Diodes by Analog Tester.................................................................................................... 489 Pm Clinic......................................................................................................................................... 490 Pm Clinic Service............................................................................................................................. 490 Pm Clinic Check Sheet: PC30MR-5........................................................................................................... 491 Pm Clinic Check Sheet: PC35MR-5........................................................................................................... 499 40 Troubleshooting.................................................................................................................................... 507 Table of Contents................................................................................................................................. 508 Abbreviation List................................................................................................................................. 512 Related Information to Troubleshooting............................................................................................................ 518 General Troubleshooting Points................................................................................................................ 518 Sequence of Events in Troubleshooting......................................................................................................... 519 Checks Before Troubleshooting................................................................................................................. 521 Inspection Procedure Before Troubleshooting................................................................................................... 523 Walk-Around Check......................................................................................................................... 523 Test in Accordance with Testing Procedure..................................................................................................... 524 Examine Fuel Level and Type............................................................................................................... 524 Examine Water Separator, Drain Water and Sediment......................................................................................... 525 Examine Fuel Main Filter Cartridge........................................................................................................ 525 Examine Engine Oil Level (Oil Quantity in Oil Pan)........................................................................................ 528 Examine Coolant Level (Reservoir Tank).................................................................................................... 528 Examine Air Cleaner Clogging.............................................................................................................. 529 Clean Outer Element (Single Element)...................................................................................................... 530 Replace Single Element.................................................................................................................... 532 Examine Hydraulic Oil Level............................................................................................................... 533 Examine Hydraulic Oil Strainer............................................................................................................ 537 Examine Hydraulic Oil Filter.............................................................................................................. 539 Examine Oil Level in Final Drive Case..................................................................................................... 540 Bleed Air from Fuel System................................................................................................................ 540 Bleed Air from Hydraulic System........................................................................................................... 540 How to Examine Electric Equipment......................................................................................................... 541 Preparation for Troubleshooting of Electrical System.......................................................................................... 548 Procedure for Troubleshooting................................................................................................................. 552 Symptom and Troubleshooting Numbers........................................................................................................... 555 Information Shown in Troubleshooting Table.................................................................................................... 559 Connector List and Layout..................................................................................................................... 561 Connector Contact Connection Table............................................................................................................ 572 Connector Contact Identification (For 3D88E-7 Engine)......................................................................................... 612 T-Branch Box and T-Branch Adapter Table....................................................................................................... 614 Fuse Location Table........................................................................................................................... 620 Failure Code Table............................................................................................................................ 626 Troubleshooting by Failure Code (Display of Code)................................................................................................. 632 Failure Code [989L00]......................................................................................................................... 632 Failure Code [989M00]......................................................................................................................... 633 Failure Code [989N00]......................................................................................................................... 634 Failure Code [B@BCNS]......................................................................................................................... 635 Failure Code [D19JKZ]......................................................................................................................... 636 Failure Code [D19JKZ]......................................................................................................................... 639 Failure Code [D811MC]......................................................................................................................... 642 Failure Code [D862KA]......................................................................................................................... 643 Failure Code [D8ALKA]......................................................................................................................... 644 Failure Code [D8ALKB]......................................................................................................................... 646 Failure Code [D8AQKR]......................................................................................................................... 648 Failure Code [DAF0KT]......................................................................................................................... 653 Failure Code [DAF0MB]......................................................................................................................... 654 Failure Code [DAF0MC]......................................................................................................................... 655 Failure Code [DAF3KK]......................................................................................................................... 656 Failure Code [DAF9KQ]......................................................................................................................... 661 Failure Code [DAFGMC]......................................................................................................................... 662 Failure Code [DAFLKA]......................................................................................................................... 663 Failure Code [DAFLKB]......................................................................................................................... 665 Failure Code [DAFQKR]......................................................................................................................... 667 Failure Code [DB2QKR]......................................................................................................................... 668 Failure Code [DBH0MC]......................................................................................................................... 673 Failure Code [DBH2KK]......................................................................................................................... 674 Failure Code [DBH2KK]......................................................................................................................... 677 Failure Code [DBH5KP]......................................................................................................................... 680 Failure Code [DBH5KP]......................................................................................................................... 682 Failure Code [DBH9KQ]......................................................................................................................... 684 Failure Code [DBHLKA]......................................................................................................................... 687 Failure Code [DBHLKB]......................................................................................................................... 689 Failure Code [DBHQKR]......................................................................................................................... 691 Failure Code [DBHQKR]......................................................................................................................... 696 Failure Code [DDNRKA]......................................................................................................................... 701 Failure Code [DDNRKY]......................................................................................................................... 704 Failure Code [DDNS00]......................................................................................................................... 707 Failure Code [DDWLKA]......................................................................................................................... 710 Failure Code [DDWLKB]......................................................................................................................... 712 Failure Code [DFB1KZ]......................................................................................................................... 714 Failure Code [DFB3L8]......................................................................................................................... 716 Failure Code [DFB5KZ]......................................................................................................................... 718 Failure Code [DHS1MA]......................................................................................................................... 720 Failure Code [DHS5MA]......................................................................................................................... 722 Failure Code [DKULKA]......................................................................................................................... 724 Failure Code [DKULKB]......................................................................................................................... 727 Failure Code [DKULKY]......................................................................................................................... 730 Failure Code [DV00KB]......................................................................................................................... 733 Failure Code [DV20KB]......................................................................................................................... 734 Failure Code [DW43KA]......................................................................................................................... 736 Failure Code [DW43KB]......................................................................................................................... 738 Failure Code [DW43KY]......................................................................................................................... 740 Failure Code [DW4CKY]......................................................................................................................... 741 Failure Code [DXA8KA]......................................................................................................................... 744 Failure Code [DXA8KB]......................................................................................................................... 748 Failure Code [DXE7KA]......................................................................................................................... 752 Failure Code [DXE7KB]......................................................................................................................... 754 Failure Code [DXE7KY]......................................................................................................................... 756 Failure Code [DXEAKA]......................................................................................................................... 757 Failure Code [DXEAKB]......................................................................................................................... 759 Failure Code [DXEAKY]......................................................................................................................... 761 Troubleshooting of Electrical System (E-Mode)..................................................................................................... 762 E-1 Engine Does Not Start (Engine Does Not Crank)............................................................................................. 762 E-2 Engine Does Not Start (Engine Does Not Crank)............................................................................................. 769 E-3 Engine Does Not Start (Fuel Feed Pump System)............................................................................................. 776 E-4 Engine Does Not Start (Fuel Feed Pump System)............................................................................................. 778 E-5 Automatic Preheating System Does Not Work................................................................................................. 780 E-6 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing.............................................................. 784 E-7 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing.............................................................. 787 E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation.................................................................. 790 E-9 Charge Level Monitor Comes On in Red While Engine is in Operation......................................................................... 791 E-10 Fuel Level Monitor Comes On in Red While Engine Runs..................................................................................... 792 E-11 Engine Coolant Temperature Monitor Comes on in Red While Engine is in Operation.......................................................... 793 E-12 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation................................................................. 794 E-13 Fuel Gauge Display Does Not Move from Minimum or Maximum................................................................................. 795 E-14 Display of Fuel Gauge is Different from Actual Fuel Level................................................................................ 797 E-15 Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum........................................................... 798 E-16 Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature................................................. 799 E-17 Some Areas of Machine Monitor Screen are Not Shown....................................................................................... 800 E-18 Function Switch Does Not Operate......................................................................................................... 801 E-19 Auto-Decelerator is Not Operated or Canceled with Lever.................................................................................. 802 E-20 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed........................................................ 803 E-21 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change.............................................................. 804 E-22 Alarm Buzzer Does Not Sound.............................................................................................................. 807 E-23 Alarm Buzzer Cannot be Canceled.......................................................................................................... 809 E-24 Service Meter is Not Shown, While Starting Switch is in OFF Position..................................................................... 811 E-25 Service Mode Cannot be Selected.......................................................................................................... 812 E-26 All of Work Equipment, Swing, and Travel Mechanism Do Not Move........................................................................... 813 E-27 All Work Equipment, Swing and Travel Do Not Lock......................................................................................... 817 E-28 Alarm Does Not Sound During Travel....................................................................................................... 820 E-29 Travel Alarm Does Not Stop When Machine Stops............................................................................................ 822 E-30 Horn Does Not Sound...................................................................................................................... 823 E-31 Horn Does Not Sound (For Proportional Lever Spec)........................................................................................ 827 E-32 Horn Does Not Stop....................................................................................................................... 831 E-33 Horn Does Not Stop (For Proportional Lever Spec)......................................................................................... 834 E-34 Working Lamp and Headlamp Do Not Come On (Canopy Spec)................................................................................... 837 E-35 Working Lamp, Headlamp, and Additional Lamp Do Not Come On (CAB Spec).................................................................... 842 E-36 When Wiper Switch is Operated, Windshield Wiper Does Not Operate......................................................................... 847 E-37 Window Washer Does Not Operate When Window Washer Switch is Operated..................................................................... 850 E-38 "Travel" is Not Shown Correctly with Monitoring Function................................................................................. 853 E-39 Swing or Arm IN is Not Shown Normally in Monitoring Function............................................................................. 854 E-40 Work Equipment is Not Shown Normally in Monitoring Function.............................................................................. 855 E-41 KOMTRAX System Does Not Operate Correctly................................................................................................ 857 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)..................................................................................... 858 Information Shown in Troubleshooting Table (H-Mode)........................................................................................... 858 H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate................................................................................. 859 H-2 All Work Equipment or Travel Does Not Operate............................................................................................. 860 H-3 Travel or Blade Does Not Operate.......................................................................................................... 861 H-4 Swing or Blade Does Not Operate........................................................................................................... 862 H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low......................................................................... 863 H-6 All Work Equipment and Travel Speed or Power is Low....................................................................................... 864 H-7 Travel and Blade Speed or Power is Low.................................................................................................... 865 H-8 Swing and Blade Speed or Power is Low..................................................................................................... 866 H-9 Fine Control Performance or Response is Unsatisfactory.................................................................................... 867 H-10 Unusual Noise is Heard from Around Main Pump............................................................................................. 868 H-11 Engine Speed Drops Largely or Engine Stops............................................................................................... 869 H-12 All Work Equipment Speed or Power is Low................................................................................................. 871 H-13 All Work Equipment and Blade Speed or Power is Low....................................................................................... 872 H-14 Blade Does Not Operate................................................................................................................... 873 H-15 All Work Equipment Do Not Operate........................................................................................................ 874 H-16 All Work Equipment or Blade Do Not Operate............................................................................................... 875 H-17 Speed or Power of Boom is Low............................................................................................................ 876 H-18 Speed or Power of Boom is Low (Piping Specification)..................................................................................... 878 H-19 Arm Speed or Power is Low................................................................................................................ 880 H-20 Bucket Speed or Power is Low............................................................................................................. 881 H-21 Blade Speed or Power is Low.............................................................................................................. 882 H-22 Boom Swing Speed or Power is Low......................................................................................................... 884 H-23 Work Equipment Does Not Move in Single Operation......................................................................................... 885 H-24 Hydraulic Drift of Boom is Large......................................................................................................... 886 H-25 Hydraulic Drift of Arm is Large.......................................................................................................... 887 H-26 Hydraulic Drift of Bucket is Large....................................................................................................... 888 H-27 Hydraulic Drift of Blade is Large........................................................................................................ 889 H-28 Time Lag of Work Equipment is Large...................................................................................................... 891 H-29 In Mixed Operation of Work Equipment, Equipment Having Heavier Load Moves Slower......................................................... 892 H-30 Machine Does Not Travel Straight......................................................................................................... 893 H-31 Machine Does Not Move Off Straight....................................................................................................... 895 H-32 Machine is Not Steered Correctly or Steering Power is Low................................................................................ 896 H-33 Travel Speed is Low...................................................................................................................... 898 H-34 Two Sides of Crawlers Do Not Move........................................................................................................ 900 H-35 One of Tracks Does Not Run............................................................................................................... 901 H-36 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast........................................................................ 903 H-37 Upper Structure Does Not Swing to Right and Left......................................................................................... 904 H-38 Upper Structure Does Not Swing to the Right and Left (Air Conditioner Installed Model)................................................... 906 H-39 Upper Structure Swings Only to Right or Left............................................................................................. 908 H-40 Swings Only in One Direction (Air Conditioner Installed Model)........................................................................... 910 H-41 Swing Acceleration or Swing Speed is Low in Right and Left Directions.................................................................... 912 H-42 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left) (Air Conditioner Installed Model)........................ 914 H-43 Swing Acceleration or Swing Speed is Low in Only One Direction........................................................................... 916 H-44 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction, Right or Left) (Air Conditioner Installed Model).... 917 H-45 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)......................................................... 918 H-46 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) (Air Conditioner Installed Model)....................... 919 H-47 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)..................................................... 920 H-48 Shock is Large When Upper Structure Stops Swing Operation................................................................................ 921 H-49 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation.................................................................. 922 H-50 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)................................................................... 923 H-51 Swing Drift on a Slope is Large (While Swing Parking Brake is Released).................................................................. 924 H-52 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) (Air Conditioner Installed Model)................................ 925 Troubleshooting of Engine (S-Mode)................................................................................................................ 926 Information Shown in Troubleshooting Table (S-Mode)........................................................................................... 926 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position.................................................................... 927 S-2 Engine Cranks but No Exhaust Smoke Comes Out.............................................................................................. 928 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).................................................. 929 S-4 Engine Startability is Unsatisfactory..................................................................................................... 930 S-5 Engine Does Not Pick Up Smoothly.......................................................................................................... 932 S-6 Engine Stops During Operation............................................................................................................. 933 S-7 Engine Runs Rough or is Not Stable........................................................................................................ 934 S-8 Engine Lacks Power........................................................................................................................ 935 S-9 Engine Oil Consumption is Excessive....................................................................................................... 937 S-10 Oil Becomes Dirty Quickly................................................................................................................ 938 S-11 Fuel Consumption is Excessive............................................................................................................ 939 S-12 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).................................................................... 940 S-13 Oil Pressure Drops....................................................................................................................... 941 S-14 Fuel Mixes Into Engine Oil............................................................................................................... 943 S-15 Water Mixes Into Engine Oil (Milky)...................................................................................................... 944 S-16 Coolant Temperature Increases Too High (Overheat)........................................................................................ 945 S-17 There is an Unusual Noise................................................................................................................ 946 S-18 Vibration is Excessive................................................................................................................... 947 S-19 Air Cannot be Bled from Fuel Circuit..................................................................................................... 948 50 Disassembly and Assembly........................................................................................................................... 949 Table of Contents................................................................................................................................. 950 Abbreviation List................................................................................................................................. 953 Related Information on Disassembly and Assembly................................................................................................... 959 How to Read This Manual....................................................................................................................... 959 Coating Materials List........................................................................................................................ 960 Special Tool List............................................................................................................................. 965 Sketches of Special Tools..................................................................................................................... 971 Engine and Cooling System......................................................................................................................... 972 Remove and Install Radiator and Hydraulic Oil Cooler Assembly................................................................................. 972 How to Remove Radiator and Hydraulic Oil Cooler Assembly.................................................................................. 972 How to Install Radiator and Hydraulic Oil Cooler Assembly................................................................................. 979 Remove and Install Engine and Main Pump Assembly.............................................................................................. 985 Remove Engine and Main Pump Assembly...................................................................................................... 985 Install Engine and Main Pump Assembly..................................................................................................... 993 Remove and Install Fuel Cooler Assembly.......................................................................................................1001 Remove Fuel Cooler Assembly...............................................................................................................1001 Install Fuel Cooler Assembly..............................................................................................................1003 Remove and Install Fuel Tank Assembly.........................................................................................................1005 Remove Fuel Tank Assembly.................................................................................................................1005 Install Fuel Tank Assembly................................................................................................................1007 Remove and Install Air Conditioner Condenser Assembly.........................................................................................1010 How to Remove Air Conditioner Condenser Assembly..........................................................................................1010 How to Install Air Conditioner Condenser Assembly.........................................................................................1011 Power Train.......................................................................................................................................1013 Remove and Install Travel Motor and Final Drive Assembly......................................................................................1013 Remove Travel Motor and Final Drive Assembly..............................................................................................1013 Install Travel Motor and Final Drive Assembly.............................................................................................1015 Disassemble and Assemble Final Drive Assembly.................................................................................................1017 How to Disassemble Final Drive Assembly...................................................................................................1017 How to Assemble Final Drive Assembly......................................................................................................1021 Remove and Install Swing Motor and Swing Machinery Assembly...................................................................................1027 Remove Swing Motor and Swing Machinery Assembly...........................................................................................1027 Install Swing Motor and Swing Machinery Assembly..........................................................................................1028 Disassemble and Assemble Swing Machinery Assembly.............................................................................................1030 Disassemble Swing Machinery Assembly......................................................................................................1030 Assemble Swing Machinery Assembly.........................................................................................................1033 Remove and Install Swing Circle Assembly......................................................................................................1037 Remove Swing Circle Assembly..............................................................................................................1037 Install Swing Circle Assembly.............................................................................................................1037 Undercarriage and Frame...........................................................................................................................1039 Disassemble and Assemble Recoil Spring Assembly...............................................................................................1039 Disassemble Recoil Spring Assembly........................................................................................................1039 Assemble Recoil Spring Assembly...........................................................................................................1040 Separate and Connect Track Assembly...........................................................................................................1042 Separate Track Assembly...................................................................................................................1042 Install Track Assembly....................................................................................................................1042 Disassemble and Assemble Idler Assembly.......................................................................................................1044 Disassemble Idler Assembly................................................................................................................1044 Assemble Idler Assembly...................................................................................................................1045 Disassemble and Assemble Track Roller Assembly................................................................................................1048 Disassemble Track Roller Assembly.........................................................................................................1048 Assemble Track Roller Assembly............................................................................................................1049 Disassemble and Assemble Carrier Roller Assembly..............................................................................................1051 Disassemble Carrier Roller Assembly.......................................................................................................1051 Assemble Carrier Roller Assembly..........................................................................................................1052 Remove and Install Revolving Frame Assembly...................................................................................................1054 Remove Revolving Frame Assembly...........................................................................................................1054 Install Revolving Frame Assembly..........................................................................................................1055 Remove and Install Counterweight Assembly.....................................................................................................1057 Remove Counterweight Assembly.............................................................................................................1057 Install Counterweight Assembly............................................................................................................1061 Hydraulic System..................................................................................................................................1064 Remove and Install Center Swivel Joint Assembly...............................................................................................1064 Remove Center Swivel Joint Assembly.......................................................................................................1064 Install Center Swivel Joint Assembly......................................................................................................1066 Disassemble and Assemble Center Swivel Joint Assembly.........................................................................................1068 Disassemble Center Swivel Joint Assembly..................................................................................................1069 Assemble Center Swivel Joint Assembly.....................................................................................................1070 Remove and Install Hydraulic Tank Assembly....................................................................................................1071 Remove Hydraulic Tank Assembly............................................................................................................1071 How to Install Hydraulic Tank Assembly....................................................................................................1074 Remove and Install Main Pump Assembly.........................................................................................................1077 Remove Main Pump Assembly.................................................................................................................1077 Install Main Pump Assembly................................................................................................................1080 Remove and Install Accumulator Assembly.......................................................................................................1083 How to Remove Accumulator Assembly........................................................................................................1083 How to Install Accumulator Assembly.......................................................................................................1083 Disassemble and Assemble Work Equipment PPC Valve Assembly....................................................................................1085 Disassemble Work Equipment PPC Valve Assembly.............................................................................................1085 How to Assemble Work Equipment PPC Valve Assembly.........................................................................................1086 Disassemble and Assemble Travel PPC Valve Assembly............................................................................................1088 Disassemble Travel PPC Valve Assembly.....................................................................................................1088 How to Assemble Travel PPC Valve Assembly.................................................................................................1089 Work Equipment....................................................................................................................................1091 Remove and Install Blade Assembly.............................................................................................................1091 Remove Blade Assembly.....................................................................................................................1091 Install Blade Assembly....................................................................................................................1092 Remove and Install Work Equipment Assembly....................................................................................................1093 Remove Work Equipment Assembly............................................................................................................1093 Install Work Equipment Assembly...........................................................................................................1095 Disassemble and Assemble Work Equipment Cylinder Assembly.....................................................................................1097 How to Disassemble Work Equipment Cylinder Assembly.......................................................................................1098 How to Assemble Work Equipment Cylinder Assembly..........................................................................................1101 CAB Related Parts.................................................................................................................................1107 Remove and Install Operator CAB Assembly (CAB Specification)..................................................................................1107 Remove Operator CAB Assembly (CAB Specification)..........................................................................................1107 Install Operator CAB Assembly (CAB Specification).........................................................................................1113 Remove and Install Floor Frame Assembly (Canopy Specification)................................................................................1118 Remove Floor Frame Assembly (Canopy Specification)........................................................................................1118 Install Floor Frame Assembly (Canopy Specification).......................................................................................1123 Remove and Install Operator Cab Glass (Adhered Glass).........................................................................................1128 Remove Operator CAB Glass (Adhered Glass).................................................................................................1129 Install Operator CAB Glass (Adhered Glass)................................................................................................1130 Remove and Install Front Window Assembly......................................................................................................1138 Remove Front Window Assembly..............................................................................................................1138 Install Front Window Assembly.............................................................................................................1139 Remove and Install Air Conditioner Unit Assembly..............................................................................................1141 Remove Air Conditioner Unit Assembly......................................................................................................1141 Install Air Conditioner Unit Assembly.....................................................................................................1145 Remove and Install Operator Seat..............................................................................................................1150 Remove Operator's Seat....................................................................................................................1150 Install Operator's Seat...................................................................................................................1150 How to Remove and Install Seat Belt...........................................................................................................1152 How to Remove Seat Belt...................................................................................................................1152 How to Install Seatbelt...................................................................................................................1152 Electrical System.................................................................................................................................1153 Remove and Install Engine Controller Assembly.................................................................................................1153 Remove Engine Controller Assembly.........................................................................................................1153 Install Engine Controller Assembly........................................................................................................1154 Remove and Install Machine Controller Assembly................................................................................................1155 Remove Machine Controller Assembly........................................................................................................1155 Install Machine Controller Assembly.......................................................................................................1156 Remove and Install Machine Monitor Assembly...................................................................................................1158 Remove Machine Monitor Assembly...........................................................................................................1158 Install Machine Monitor Assembly..........................................................................................................1159 Remove and Install KOMTRAX Terminal Assembly..................................................................................................1161 Remove KOMTRAX Terminal Assembly..........................................................................................................1161 Install KOMTRAX Terminal Assembly.........................................................................................................1163 Remove and Install Quick Release Battery Terminal (-).........................................................................................1165 How to Install Quick Release Battery Terminal (-).........................................................................................1165 How to Remove Quick Release Battery Terminal (-)..........................................................................................1166 60 Maintenance Standard...............................................................................................................................1167 Table of Contents.................................................................................................................................1168 Abbreviation List.................................................................................................................................1169 Engine and Cooling System.........................................................................................................................1175 Maintenance Standard for PTO..................................................................................................................1175 Maintenance Standard for Cooling System.......................................................................................................1176 Power Train.......................................................................................................................................1177 Maintenance Standard for Swing Circle.........................................................................................................1177 Maintenance Standard for Swing Machinery......................................................................................................1178 Maintenance Standard for Sprocket.............................................................................................................1180 Undercarriage and Frame...........................................................................................................................1181 Maintenance Standard for Track Frame and Idler Cushion........................................................................................1181 Maintenance Standard for Idler................................................................................................................1183 Maintenance Standard for Track Roller.........................................................................................................1185 Maintenance Standard for Carrier Roller.......................................................................................................1186 Maintenance Standard for Track Shoes..........................................................................................................1187 Maintenance Standard for Double Shoes.........................................................................................................1189 Maintenance Standard for Road Liner...........................................................................................................1190 Maintenance Standard for Rubber Shoes.........................................................................................................1191 Hydraulic System..................................................................................................................................1192 Maintenance Standard for Hydraulic Tank.......................................................................................................1192 Maintenance Standard for Main Pump............................................................................................................1193 Maintenance Standard for Main Pump Servo Valve............................................................................................1194 Maintenance Standard for PC-EPC Valve.........................................................................................................1195 Maintenance Standard for Swing Motor..........................................................................................................1196 Maintenance Standard for Travel Motor.........................................................................................................1198 Maintenance Standard for Control Valve........................................................................................................1199 Maintenance Standard for Work Equipment and Swing PPC Valve...................................................................................1208 Maintenance Standard for Blade PPC Valve......................................................................................................1211 Maintenance Standard for Boom Swing PPC Valve.................................................................................................1213 Maintenance Standard for Travel PPC Valve.....................................................................................................1215 Maintenance Standard for Attachment PPC Valve.................................................................................................1218 Maintenance Standard for Center Swivel Joint..................................................................................................1220 Work Equipment....................................................................................................................................1221 Maintenance Standard for Work Equipment Linkage...............................................................................................1221 Dimensions of Arm.........................................................................................................................1231 Dimensions of Bucket......................................................................................................................1233 Maintenance Standard for Boom Cylinder........................................................................................................1235 Maintenance Standard for Arm Cylinder.........................................................................................................1237 Maintenance Standard for Bucket Cylinder......................................................................................................1239 Maintenance Standard for Blade Cylinder.......................................................................................................1240 Maintenance Standard for Boom Swing Cylinder..................................................................................................1242 80 Appendix...........................................................................................................................................1245 Table of Contents.................................................................................................................................1246 Abbreviation List.................................................................................................................................1247 Air Conditioner System............................................................................................................................1253 Precautions for Refrigerant...................................................................................................................1253 Air Conditioner Component.....................................................................................................................1254 Specifications of Air Conditioner.............................................................................................................1255 Structure and Function of Refrigeration Cycle.................................................................................................1256 Outline of Refrigeration Cycle................................................................................................................1257 Component Parts of Air Conditioner System.........................................................................................................1259 Air Conditioner Unit..........................................................................................................................1259 Configuration Diagram of Air Conditioner Unit.............................................................................................1259 Compressor....................................................................................................................................1261 Structure of Compressor...................................................................................................................1261 Specifications of Compressor..............................................................................................................1261 Function of Compressor....................................................................................................................1261 Condenser.....................................................................................................................................1263 Structure of Condenser....................................................................................................................1263 Specifications of Condenser...............................................................................................................1263 Function of Condenser.....................................................................................................................1263 Receiver Drier................................................................................................................................1265 Structure of Receiver Dryer...............................................................................................................1265 Specifications of Receiver Dryer..........................................................................................................1265 Function of Receiver Dryer................................................................................................................1265 Information Shown in Troubleshooting Table........................................................................................................1266 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)....................................................................1267 A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)............................................................1270 A-3 Troubleshooting for Temperature Control Function..............................................................................................1274 A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System).........................................................1277 A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems)........................................................1281 A-6 Troubleshooting for Hot Water Circuit System..................................................................................................1282 A-7 Unusual Noise is Heard from Air Conditioner Related Parts.....................................................................................1283 A-8 Water Leaks from Air Conditioner Related Parts................................................................................................1284 A-9 Troubleshooting for Fresh/Recirc Air Changeover...............................................................................................1285 Precautions for Disconnection and Connection of Air Conditioner Piping............................................................................1286 Handle Compressor Oil.............................................................................................................................1288 90 Circuit Diagrams...................................................................................................................................1289 Table of Contents.................................................................................................................................1290 Abbreviation List.................................................................................................................................1293 Hydraulic Circuit Diagram.........................................................................................................................1299 Symbols Used in Hydraulic Circuit Diagram.....................................................................................................1299 Hydraulic Circuit Diagram: PC30MR-5...........................................................................................................1303 Hydraulic Circuit Diagram (Quick Coupler Specifications): PC30MR-5 (1/2)......................................................................1305 Hydraulic Circuit Diagram (Quick Coupler Specifications): PC30MR-5 (2/2)......................................................................1307 Hydraulic Circuit Diagram: PC35MR-5...........................................................................................................1309 Hydraulic Circuit Diagram (Quick Coupler Specifications): PC35MR-5 (1/2)......................................................................1311 Hydraulic Circuit Diagram (Quick Coupler Specifications): PC35MR-5 (2/2)......................................................................1313 Electrical Circuit Diagram........................................................................................................................1315 Symbols Used in Electric Circuit Diagram......................................................................................................1315 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 50001 - 52907)(1/5)..................................................................1319 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 50001 - 52907)(2/5)..................................................................1321 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 50001 - 52907)(3/5)..................................................................1323 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 50001 - 52907)(4/5)..................................................................1325 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 50001 - 52907)(5/5)..................................................................1327 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 52908 and Up)(1/5)...................................................................1329 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 52908 and Up)(2/5)...................................................................1331 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 52908 and Up)(3/5)...................................................................1333 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 52908 and Up)(4/5)...................................................................1335 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 52908 and Up)(5/5)...................................................................1337 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 30001 - 31037)(1/5)..................................................................1339 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 30001 - 31037)(2/5)..................................................................1341 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 30001 - 31037)(3/5)..................................................................1343 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 30001 - 31037)(4/5)..................................................................1345 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 30001 - 31037)(5/5)..................................................................1347 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 31038 and Up)(1/5)...................................................................1349 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 31038 and Up)(2/5)...................................................................1351 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 31038 and Up)(3/5)...................................................................1353 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 31038 and Up)(4/5)...................................................................1355 Electrical Circuit Diagram (Canopy Spec) (Serial Number: 31038 and Up)(5/5)...................................................................1357 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(1/5)...................................1359 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(2/5)...................................1361 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(3/5)...................................1363 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(4/5)...................................1365 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(5/5)...................................1367 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(1/5)....................................1369 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(2/5)....................................1371 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(3/5)....................................1373 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(4/5)....................................1375 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(5/5)....................................1377 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(1/5)...................................1379 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(2/5)...................................1381 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(3/5)...................................1383 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(4/5)...................................1385 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(5/5)...................................1387 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(1/5)....................................1389 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(2/5)....................................1391 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(3/5)....................................1393 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(4/5)....................................1395 Electrical Circuit Diagram (For Canopy Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(5/5)....................................1397 Electrical Circuit Diagram (Cab Spec) (Serial Number: 50001 - 52848)(1/6).....................................................................1399 Electrical Circuit Diagram (Cab Spec) (Serial Number: 50001 - 52848)(2/6).....................................................................1401 Electrical Circuit Diagram (Cab Spec) (Serial Number: 50001 - 52848)(3/6).....................................................................1403 Electrical Circuit Diagram (Cab Spec) (Serial Number: 50001 - 52848)(4/6).....................................................................1405 Electrical Circuit Diagram (Cab Spec) (Serial Number: 50001 - 52848)(5/6).....................................................................1407 Electrical Circuit Diagram (Cab Spec) (Serial Number: 50001 - 52848)(6/6).....................................................................1409 Electrical Circuit Diagram (Cab Spec) (Serial Number: 52849 and Up)(1/6)......................................................................1411 Electrical Circuit Diagram (Cab Spec) (Serial Number: 52849 and Up)(2/6)......................................................................1413 Electrical Circuit Diagram (Cab Spec) (Serial Number: 52849 and Up)(3/6)......................................................................1415 Electrical Circuit Diagram (Cab Spec) (Serial Number: 52849 and Up)(4/6)......................................................................1417 Electrical Circuit Diagram (Cab Spec) (Serial Number: 52849 and Up)(5/6)......................................................................1419 Electrical Circuit Diagram (Cab Spec) (Serial Number: 52849 and Up)(6/6)......................................................................1421 Electrical Circuit Diagram (Cab Spec) (Serial Number: 30001 - 31023)(1/6).....................................................................1423 Electrical Circuit Diagram (Cab Spec) (Serial Number: 30001 - 31023)(2/6).....................................................................1425 Electrical Circuit Diagram (Cab Spec) (Serial Number: 30001 - 31023)(3/6).....................................................................1427 Electrical Circuit Diagram (Cab Spec) (Serial Number: 30001 - 31023)(4/6).....................................................................1429 Electrical Circuit Diagram (Cab Spec) (Serial Number: 30001 - 31023)(5/6).....................................................................1431 Electrical Circuit Diagram (Cab Spec) (Serial Number: 30001 - 31023)(6/6).....................................................................1433 Electrical Circuit Diagram (Cab Spec) (Serial Number: 31024 and Up)(1/6)......................................................................1435 Electrical Circuit Diagram (Cab Spec) (Serial Number: 31024 and Up)(2/6)......................................................................1437 Electrical Circuit Diagram (Cab Spec) (Serial Number: 31024 and Up)(3/6)......................................................................1439 Electrical Circuit Diagram (Cab Spec) (Serial Number: 31024 and Up)(4/6)......................................................................1441 Electrical Circuit Diagram (Cab Spec) (Serial Number: 31024 and Up)(5/6)......................................................................1443 Electrical Circuit Diagram (Cab Spec) (Serial Number: 31024 and Up)(6/6)......................................................................1445 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(1/6)......................................1447 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(2/6)......................................1449 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(3/6)......................................1451 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(4/6)......................................1453 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(5/6)......................................1455 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 50001 - 52556)(6/6)......................................1457 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(1/6).......................................1459 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(2/6).......................................1461 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(3/6).......................................1463 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(4/6).......................................1465 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(5/6).......................................1467 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 52557 and Up)(6/6).......................................1469 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(1/6)......................................1471 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(2/6)......................................1473 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(3/6)......................................1475 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(4/6)......................................1477 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(5/6)......................................1479 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30001 - 30888)(6/6)......................................1481 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(1/6).......................................1483 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(2/6).......................................1485 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(3/6).......................................1487 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(4/6).......................................1489 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(5/6).......................................1491 Electrical Circuit Diagram (For Cab Spec Machine with Quick Coupler) (Serial Number: 30889 and Up)(6/6).......................................1493 Index..................................................................................................................................................1495
DESCRIPTION:
KOMATSU PC30MR-5 PC35MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL SEN06591-11 – 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 Specification
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 Others
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 22/12/24
