Komatsu PC30R-8 PC35R-8 PC40R-8 PC45R-8 Excavator Shop Manual PDF
$30.95
Komatsu PC30R-8 PC35R-8 PC40R-8 PC45R-8 Excavator Shop Manual SEBM012604 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PC30R-8 10001 and up
PC35R-8 35001 and up
PC40R-8 30001 and up
PC45R-8 5001 and up
Description
Komatsu PC30R-8 PC35R-8 PC40R-8 PC45R-8 Excavator Shop Manual SEBM012604 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC30R-8 PC35R-8 PC40R-8 PC45R-8 Excavator Shop Manual SEBM012604 – PDF DOWNLOAD
Language : English
Pages : 588
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Komatsu PC30R-8 PC35R-8 PC40R-8 PC45R-8 Excavator Shop Manual SEBM012604 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PC30R-8 10001 and up
PC35R-8 35001 and up
PC40R-8 30001 and up
PC45R-8 5001 and up
MAIN MENU 0
COVER 1
CONTENTS 2
00 FOREWARD 6
SAFETY 6
FOREWARD 8
HOW TO READ THE SHOP MANUAL 9
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
GENERAL ASSEMBLY DRAWING 27
SPECIFICATIONS 35
WEIGHT TABLE 43
LIST OF LUBRICANT AND WATER 47
10 STRUCTURE AND FUNCTION 49
PTO (COUPLING) 50
RADIATOR, OIL COOLER 51
ENGINE CONTROL 52
POWER TRAIN 53
SWING CIRCLE 54
SWING MACHINERY 55
TRACK FRAME, RECOIL SPRING 56
HYDRAULIC PIPING 57
HYDRAULIC CIRCUIT DIAGRAM 58
HYDRAULIC PUMP 66
CENTER SWIVEL JOINT 73
SWING MOTOR 74
TRAVEL MOTOR 79
9-SPOOL CONTROL VALVE 90
CLSS 98
MULTI-CONTROL VALVE 122
ELECTRICAL WIRING DIAGRAM 123
VALVE CONTROL 125
WORK EQUIPMENT, SWING PPC VALVE 126
SOLENOID VALVE 130
WORK EQUIPMENT 132
MACHINE MONITOR SYSTEM 133
ELECTRICAL CIRCUIT DIAGRAM 137
HYDRAULIC CYLINDER 138
20 TESTING AND ADJUSTING 139
STANDARD VALUE TABLE 140
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 140
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 142
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 158
TESTING AND ADJUSTING 161
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 162
MEASURING ENGINE SPEED 163
MEASURING EXHAUST COLOR 164
ADJUSTING VALVE CLEARANCE 165
MEASURING COMPRESSION PRESSURE 166
TESTING AND ADJUSTING FUEL INJECTION TIMING 167
MEASURING ENGINE OIL PRESSURE 168
TESTING AND ADJUSTING FAN BELT TENSION 169
ADJUSTING CONTROL LEVERS AND PEDALS 170
MEASURING SPROCKET WEAR 173
TESTING AND ADJUSTING TRACK SHOE TENSION 174
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 175
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE 178
ADJUSTING PC VALVE 180
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE 181
TESTING OUTPUT PRESSURE OF SOLENOID VALVE 184
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE (PC20R) 185
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 187
TESTING AND ADJUSTING TRAVEL DEVIATION 188
TESTING OIL LEAKAGE 189
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 190
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 190
PRESSURIZING HYDRAULIC TANK 190
BLEEDING AIR 191
TROUBLESHOOTING 193
POINTS TO REMEMBER WHEN TROUBLESHOOTING 194
SEQUENCE OF EVENTS IN TROUBLESHOOTING 195
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 196
CHECKS BEFORE TROUBLESHOOTING 204
CONNECTOR TYPES AND MOUNTING LOCATIONS 205
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 208
METHOD OF USING TROUBLESHOOTING CHARTS 218
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 221
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 222
E-1 ENGINE DOES NOT START 224
A) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM) 224
B) WHEN STARTING MOTOR TURNS (ENGINE STOPE SOLENOID SYSTEM) 227
E-2 ENGINE DOES NOT STOP 229
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED 230
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED 231
E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED 232
E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED 233
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 235
TABLE OF FAILURE MODES AND CAUSES 236
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING TRAVEL ARE SLOW OR LACK POWER 238
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 239
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 240
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 240
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 241
H-6 BOOM IS SLOW OR LACKS POWER 242
H-7 ARM IS SLOW OR LACKS POWER 242
H-8 BUCKET IS SLOW OR LACKS POWER 243
H-9 BOOM SWING IS SLOW OR LACKS POWER 243
H-10 BLADE IS SLOW OR LACKS POWER 244
H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL) 244
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE) 245
A) BOOM 245
B) ARM, BUCKET, BOOM SWING 245
C) BLADE 245
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 246
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 246
H-15 TRAVEL DEVIATION 247
A) DEVIATION IN NORMAL TRAVEL 247
B) DEVEIATION WHEN STARTING 247
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER 248
H-17 STEERING DOES NOT TURN EASILY 248
H-18 TRAVEL SPEED DOES NOT SWITCH 249
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 249
H-20 SWING SPEED IS SLOW OR LACKS POWER 250
A) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS 250
B) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY (LEFT OR RIGHT) 250
H-21 DOES NOT SWING 251
A) DOES NOT SWING IN EITHER DIRECTION 251
B) DOES NOT SWING N ONE DIRECTION (LEFT OR RIGHT) 251
H-22 SWING ACCELERATION IS POOR 252
A) ACCELERATION IS POOR IN BOTH DIRECTIONS 252
B) ACCELERATION IS POOR IN ONE DIRECTION ONLY (LEFT OR RIGHT) 252
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING 253
A) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS 253
B) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY (LEFT OR RIGHT) 253
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY) 254
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 254
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING 254
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 255
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS 256
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN 257
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 ECONDS), LAMPS DO NOT GO 257
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS 258
A) NO GAUGE LAMPS LIGHT UP (FUEL, COOLANT TEMPERATURE) 258
B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE), PILOT LAMP (PREHEATING) DO NOT LIGHT UP 258
M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS), EVEN IF STARTING SWITCH IS TURNED TO START, SELF CHECK IS NOT COMP 258
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES OT LIGHT UP 259
M-6 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 259
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP 260
M-8 WHEN ENGINE IS RUNNING , ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP 260
M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP 261
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 262
A) LEVEL DOES NOT RISE FROM SEGMENT C 262
B) LEVEL DOES NOT GO DOWN FROM SEGMENT H, OR ALL SEGMENTS GO OUT 262
C) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY 263
M-11 ABNORMALITY IN FUEL GAUGE 264
A) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT 264
B) LEVEL DOES NOT GO DOWN FROM SEGMENT F 264
C) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY 265
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 266
A) BUZZER DOES NOT SOUND 266
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 266
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE 267
A) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP 267
B) WHEN CHARGE CAUTION LAMP LIGHTS UP 267
C) PILOT LAMP DOES NOT FLASH (SERVICE METER IS ACTUATED) 267
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 268
A) GAUGE LIGHTING DOES NOT LIGHT UP 268
B) SERVICE METER LIGHTING DOES NOT LIGHT UP 268
30 DISASSEMBLY AND ASSEMBLY 269
METHOD OF USING MANUAL 271
PRECAUTIONS WHEN CARRYING OUT OPERATION 272
SPECIAL TOOL LIST 274
SKETCHES OF SPECIAL TOOLS 279
STARTING MOTOR (REMOVAL, INSTALLATION) 285
ALTERNATOR (REMOVAL, INSTALLATION) 286
FUEL INJECTION PUMP (REMOVAL) 287
FUEL INJECTION PUMP (INSTALLATION) 288
NOZZEL HOLDER (REMOVAL, INSTALLATION) 291
WATER PUMP (REMOVAL) 292
WATER PUMP (INSTALLATION) 293
THERMOSTAT (REMOVAL, INSTALLATION) 294
ENGINE FRONT SEAL (REMOVAL, INSTALLATION) 295
ENGINE REAR SEAL (REMOVAL) 296
ENGINE REAR SEAL (INSTALLATION) 297
CYLINDER HEAD (REMOVAL) 298
CYLINDER HEAD (INSTALLATION) 300
RADIATOR, HYDRAULIC COOLER (REMOVAL 304
RADIATOR, HYDRAULIC COOLER (INSTALLATION) 305
ENGINE, HYDRAULIC PUMP (REMOVAL) 306
ENGINE, HYDRAULIC PUMP (INSTALLATION) 310
FUEL TANK (REMOVAL, INSTALLATION) 311
DAMPER (REMOVAL, INSTALLATION) 312
CENTER SWIVEL JOINT (REMOVAL, INSTALLATION) 313
CENTER SWIVEL JOINT (DISASSEMBLY, ASSEMBLY) 314
TRAVEL MOTOR (REMOVAL, INSTALLATION) 315
PHV-300 (FOR PC30R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR 316
PHV-350 (FOR PC35R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR 331
PHV-500 (FOR PC40R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR 346
GM06VL (FOR PC45R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR 361
SAFETY 362
SECTIONAL DRAWING OF ASSEMBLY 363
PARTS LIST 365
TOOLS 366
TIGHTENING TORQUE 373
DISASSEMBLY 374
MAINTENANCE STANDARDS TABLE 396
ASSEMBLY 398
DIMENSIONS TABLE OF CLEARANCE ADJUSTMENT PARTS 424
PERFORMANCE CONFIRMATION TEST 425
SPROCKET (REMOVAL, INSTALLATION) 426
SWING MOTOR, SWING MACHINERY (REMOVAL) 427
SWING MOTOR, SWING MACHINERY (INSTALLATION) 428
SWING MOTOR, SWING MACHINERY (DISASSEMBLY) 429
SWING MOTOR, SWING MACHINERY (ASSEMBLY) 432
DISASSEMBLY SWING MOTOR ASSEMBLY LMF 16AB 435
ASSEMBLY SWING MOTOR ASSEMBLY LMF 16AB 440
REVOLVING FRAME (REMOVAL) 448
REVOLVING FRAME (INSTALLATION) 450
SWING CIRCLE (REMOVAL, INSTALLATION) 451
IDLER (REMOVAL, INSTALLATION) 452
IDLER (DISASSEMBLY) 453
IDLER (ASSEMBLY) 454
RECOIL SPRING (REMOVAL, INSTALLATION) 455
RECOIL SPRING (DISASSEMBLY) 456
RECOIL SPRING (ASSEMBLY) 458
TRACK ROLLER (REMOVAL, INSTALLATION) 460
TRACK ROLLER (DISASSEMBLY) 461
TRACK ROLLER (ASSEMBLY) 462
CARRIER ROLLER (REMOVAL, INSTALLATON) 463
CARRIER ROLLER (DISASSEMBLY, ASSEMBLY) 464
RUBBER SHOE (REMOVAL, INSTALLATION) 465
STEEL SHOE (REMOVAL, INSTALLATION) 466
HYDRAULIC TANK (REMOVAL, INSTALLATION) 468
HYDRAULIC COOLER (REMOVAL, INSTALLATION) 469
HYDRAULIC PUMP (REMOVAL, INSTALLATION) 470
DISASSEMBLY OF MAIN PUMP ASSEMBLY (LPV 45) 471
ASSEMBLY OF MAIN PUMP ASSEMBLY (LPV 45) 479
CONTROL VALVE (REMOVAL) 490
CONTROL VALVE (INSTALLATION) 491
CONTROL VALVE (DISASSEMBLY) 492
CONTROL VALVE (ASSEMBLY) 500
2-SPOOL SOLENOID VALVE (REMOVAL, INSTALLATION) 507
LEFT PPC VALVE (REMOVAL, INSTALLATION) 508
RIGHT PPC VALVE (REMOVAL, INSTALLATION) 509
PPC VALVE (DISASSEMBLY) 510
PPC VALVE (ASSEMBLY) 511
BOOM CYLINDER (REMOVAL) 512
BOOM CYLINDER (INSTALLATION) 513
ARM CYLINDER (REMOVAL) 514
ARM CYLINDER (INSTALLATION) 515
BUCKET CYLINDER (REMOVAL) 516
BUCKET CYLINDER (INSTALLATION) 517
BOOM SWING CYLINDER (REMOVAL) 518
BOOM SWING CYLINDER (INSTALLATION) 519
BLADE CYLINDER (REMOVAL) 520
BLADE CYLINDER (INSTALLATION) 521
HYDRAULIC CYLINDER (DISASSEMBLY) 522
HYDRAULIC CYLINDER (ASSEMBLY) 525
WORK EQUIPMENT (REMOVAL) 528
WORK EQUIPMENT (INSTALLATION) 529
BUCKET (REMOVAL, INSTALLATION) 530
ARM (REMOVAL) 531
ARM (INSTALLATION) 532
BUCKET, ARM (REMOVAL) 533
BUCKET, ARM (INSTALLATION) 534
BOOM (REMOVAL) 535
BOOM (INSTALLATION) 536
BOOM SWING BRACKET (REMOVAL) 537
BOOM SWING BRACKET (INSTALLATION) 538
BLADE (REMOVAL) 539
BLADE (INSTALLATION) 540
OPERATOR’S CAB (REMOVAL, INSTALLATION) 541
CANOPY (REMOVAL, INSTALLATION) 541
FLOOR FRAME (REMOVAL, INSTALLATION) 542
40 MAINTENANCE STANDARD 545
SWING CIRCLE 546
SWING MACHINERY 548
SPROCKET 550
TRACK FRAME, RECOIL SPRING 552
IDLER 554
TRACK ROLLER 555
CARRIER ROLLER 556
TRACK SHOE 557
CENTER SWIVEL JOINT 562
HYDRAULIC PUMP 563
WORK EQUIPMENT, SWING PPC VALVE 564
SWING MOTOR 565
9-SPOOL CONTROL VALVE 566
HYDRAULIC CYLINDER 572
WORK EQUIPMENT 576
90 OTHER 580
HYDRAULIC CIRCUIT DIAGRAM PC30R-8 581
HYDRAULIC CIRCUIT DIAGRAM PC35R-8 583
HYDRAULIC CIRCUIT DIAGRAM PC40R-8 584
HYDRAULIC CIRCUIT DIAGRAM PC45R-8 585
ELECTRICAL CIRCUIT DIAGRAM 586
HYDRAULIC PIPING DRAWING 587
SYSTEM DIAGRAM DRAWING 588
DESCRIPTION:
Komatsu PC30R-8 PC35R-8 PC40R-8 PC45R-8 Excavator Shop Manual SEBM012604 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PC30R-8 10001 and up
PC35R-8 35001 and up
PC40R-8 30001 and up
PC45R-8 5001 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
IMAGES PREVIEW OF THE MANUAL:
S.V 22/12/24
