Komatsu PC33E-6 Electric Mini Excavator Shop Manual SEN06975-02 PDF

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Komatsu PC33E-6 Electric Mini Excavator Shop Manual SEN06975-02 – PDF DOWNLOAD

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Komatsu PC33E-6 Electric Mini Excavator Shop Manual SEN06975-02 – PDF DOWNLOAD 

Language : English
Pages : 1468
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC33E-6 Electric Mini Excavator Shop Manual SEN06975-02 – PDF DOWNLOAD 

SERIAL NUMBERS 2001 and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 14
How to Read the Shop Manual 14
Safety Notice for Operation 16
Precautions for Battery Type Mini Excavator 24
Notation of Battery Voltage 24
Components of Battery Type Mini Excavator 24
Precautions When You Handle Battery Type Mini Excavator 25
Precautions for Inspection and Maintenance of High Voltage Parts 25
Precautions to Prevent Fire 27
Procedures If Fire Occurs 28
Precautions When You Dispose of Waste Materials 29
Precautions When You Handle Hydraulic Equipment 30
Precautions When You Disconnect and Connect Pipings 33
Precautions When You Handle Electrical Equipment 39
Precautions Against High Voltage and High Temperature 41
Procedure for Inspection and Maintenance of High Voltage Parts 42
Procedure to Restore High Voltage Parts 47
Precautions When Machine Falls over and Power Electronics Components Have Damage 49
Precautions for Machine Not to be Put in Water 50
In Cold Weather 51
Practical Use of KOMTRAX 52
Disconnect and Connect Push-Pull Type Coupler 53
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 53
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 55
Precautions for Disconnection and Connection of Connectors 57
How to Disconnect and Connect Deutsch Connector 61
How to Disconnect and Connect Slide Lock Type Connector 62
How to Disconnect and Connect Connector with Lock to Pull 64
How to Disconnect and Connect Connector with Lock to Push 65
How to Disconnect and Connect Connector with Housing to Rotate 68
Standard Tightening Torque Table 69
Conversion Table 76
Abbreviation List 81
01 Specifications 85
Table of Contents 86
Specifications 87
Specification Drawing 87
Specification Drawing: PC33E-6 87
Working Range Drawings 88
Working Range Drawings: PC33E-6 88
Specifications 89
Specifications: PC33E-6 89
Weight Table 93
Weight Table: PC33E-6 93
Lubricant 95
How to Use Lubricants by Ambient Temperature 95
10 Structure and Function 97
Table of Contents 98
Boot-up System 101
Layout Drawing of Boot-up System 101
System Operating Lamp System 102
System Diagram of System Operating Lamp System 102
Function of Operation Lamp System 102
Operation of System Operating Lamp System 102
Special Power Supply for Battery 104
Function of Special Power Supply for Battery 104
Operation of Special Power Supply for Battery 104
Electric Motor Shutdown Secondary Switch 105
Function of Electric Motor Shutdown Secondary Switch 105
Operation of Electric Motor Shutdown Secondary Switch 105
ID Key System 106
System Diagram of ID Key System 106
Function of ID Key System 106
Operation of ID Key System 107
Component Parts of Boot-Up System 108
ID Key Controller 108
ID Key Antenna 110
Electric Drive System 111
Layout Drawing of Electric Drive System 111
Worker Protection System When You Disassemble Power Electronics Components 112
Function of Worker Protection System When You Disassemble Power Electronics Components 112
High Voltage Wiring (Power Cable) 113
Layout Drawing of High Voltage Wiring (Power Cable) 113
Structure of High Voltage Wiring (Power Cable) 113
Function of High Voltage Wiring (Power Cable) 113
Component Parts of Electric Drive System 114
Battery Assembly 114
BMS 118
Inverter 119
Power Supply Controller 122
MC2 Contactor 126
Electric Motor 127
Electric Motor System 128
Layout Drawing of Electric Motor System 128
Electric Motor Control System 129
System Diagram of Electric Motor Control System 129
Operation of Electric Motor Control System 129
Auto-Deceleration System 131
System Diagram of Auto-Deceleration System 131
Function of Auto-Deceleration System 131
Operation of Auto-Deceleration System 132
Overheat Prevention System 133
Overheat Prevention System Diagram 133
Function of Overheat Prevention System 134
Automatic Idle Stop System 135
System Diagram of Automatic Idle Stop System 135
Function of Automatic Idle Stop System 135
Operation of Automatic Idle Stop System 135
Cooling System 137
Layout Drawing of Cooling System 137
Specifications of Cooling System 137
Control System 138
Layout Drawing of Control System 138
Machine Monitor System 139
System Diagram of Machine Monitor System 139
Function of Machine Monitor System 139
KOMTRAX System 141
System Diagram of KOMTRAX System 141
Function of KOMTRAX System 141
Component Parts of Control System 142
Machine Monitor 142
KOMTRAX Terminal 152
Machine Controller 154
Resistor for PC-EPC Valve 158
Motor Speed Adjustment Dial 159
Hydraulic System 161
Layout Drawing of Hydraulic System 161
CLSS 163
System Diagram of CLSS 163
Function of CLSS 164
Electric Motor and Pump Combined Control System 166
System Diagram of Electric Motor and Pump Combined Control System 166
Function of Electric Motor and Pump Combined Control System 167
Component Parts of Hydraulic System 169
Hydraulic Tank 169
Main Pump 174
Control Valve 186
Work Equipment System 232
Layout Drawing of Work Equipment System 232
Structure of Valve Control 235
PPC Lock System 237
System Diagram of PPC Lock 237
Function of PPC Lock System 239
Work Equipment and Travel Automatic Lock System 240
Function of Work Equipment and Travel Automatic Lock System 240
Operation of Lock Lever Automatic Lock System 240
Component Parts of Work Equipment System 241
Work Equipment and Swing PPC Valve 241
Attachment EPC Valve 246
Blade PPC Valve 247
Boom Swing PPC Valve 249
Bipartite Solenoid Valve 251
Boom Anti-drop Valve 255
Arm Anti-Drop Valve 260
Pilot Circuit Accumulator 265
Swing System 266
Layout Drawing of Swing System 266
Component Parts of Swing System 267
Swing Motor 267
Swing Machinery 274
Swing Circle 276
Travel System 277
Layout Drawing of Travel System 277
System Diagram of Travel Control System 279
Function of Travel Control System 279
Component Parts of Travel System 281
Travel Motor 281
Travel PPC Valve 290
Center Swivel Joint 293
Undercarriage and Frame 294
Layout Drawing of Undercarriage 294
Specifications of Undercarriage 295
Idler Cushion 296
Structure of Idler Cushion 296
Specifications of Idler Cushion 296
Work Equipment 297
Structure of Work Equipment 297
Function of Work Equipment 298
Work Equipment Clearance Adjustment Shim 299
Function of Work Equipment Clearance Adjustment Shim 299
CAB Related Parts 300
Tilt Type Floor 300
Structure of Tilt Type Floor 300
Function of Tilt Type Floor 300
20 Standard Value Table 301
Table of Contents 302
Standard Value Table for Electric Motor 303
Standard Value Table for Electric Motor: PC33E-6 303
Standard Value Table for Machine 304
Standard Value Table for Machine: PC33E-6 304
Machine Posture and Procedures to Measure Performance 315
30 Testing and Adjusting 319
Table of Contents 320
Precautions Before Work 322
Related Information on Testing and Adjusting 323
Tools for Examination and Adjustment 323
Sketch of Tools for Testing and Adjusting 326
Motor and Cooling System 327
Examine Electric Motor Speed 327
How to Examine Electric Motor Speed 327
Electric Drive System 331
Precautions for Electric Drive System 331
Power Train 332
Examine Swing Circle Bearing Clearance 332
How to Examine Swing Circle Bearing Clearance 332
Undercarriage and Frame 334
Examine and Adjust Track Tension 334
How to Examine Track Tension 334
How to Adjust Track Tension 334
Hydraulic System 336
Release Remained Pressure from Hydraulic Circuit 336
How to Release Remained Pressure from Hydraulic Tank 336
How to Release Remained Pressure in Hydraulic Cylinder Circuit 336
How to Release Remained Pressure from Swing Motor Circuit 340
How to Release Remained Pressure from Travel Motor Circuit 341
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 342
How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 342
How to Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 354
Examine and Adjust Swing and Blade Circuit Oil Pressure 355
How to Examine Oil Pressure in Swing and Blade Circuits 355
How to Adjust Oil Pressure in Swing and Blade Circuits 361
Examine and Adjust Oil Pressure in Control Circuit 363
How to Examine Oil Pressure in Control Circuit 363
How to Adjust Oil Pressure in Control Circuit 366
Examine and Adjust LS Differential Pressure 367
How to Examine LS Differential Pressure 367
How to Adjust LS Differential Pressure 371
Adjust Oil Pressure in Pump PC Control Circuit 372
How to Adjust Oil Pressure in Pump PC Control Circuit 372
Examine Outlet Pressure of Solenoid Valve 374
How to Examine Outlet Pressure of Solenoid Valve by Machine Monitor 374
How to Examine Outlet Pressure of Solenoid Valve by Testing Tool 376
Operating Condition of Solenoid Valve 377
Examine PPC Valve Outlet Pressure 378
How to Examine Outlet Pressure of PPC Valve with Machine Monitor 379
How to Examine Outlet Pressure of PPC Valve by Testing Tool 381
Adjust Play of Work Equipment and Swing PPC Valves 383
How to Adjust Play of Work Equipment and Swing PPC Valves 383
Examine Swing Parking Brake Release Pressure 384
How to Examine Swing Parking Brake Release Pressure 384
Examine and Adjust Travel Deviation 385
How to Examine Travel Deviation 385
How to Adjust Travel Deviation 386
Examine Parts Which Cause Hydraulic Drift of Work Equipment 388
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 388
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 389
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 389
Examine Oil Leakage 390
How to Examine Oil Leakage from Boom Cylinder 390
How to Examine Oil Leakage from Arm Cylinder 391
How to Examine Oil Leakage from Bucket Cylinder 392
How to Examine Oil Leakage from Boom Swing Cylinder 393
How to Examine Oil Leakage from Blade Cylinder 394
Bleed Air from Hydraulic Circuit 396
How to Bleed Air from Hydraulic Circuit 397
Pressurize Hydraulic Tank 399
How to Pressurize Hydraulic Tank 399
Replace Pressure Reducing Valve Assembly 400
How to Replace Pressure Reducing Valve Assembly 401
CAB Related Parts 403
How to Open and Close Floor 403
Procedure to Open Floor 404
Procedure to Close Floor 407
Electrical System 410
Set and Operate Machine Monitor 410
Operator Mode 412
Function to Show Technician Identification Status Screen 412
Examine Function by LCD (Liquid Crystal Display) 413
Examine Function of Service Meter 413
Usage Limitation and Maintenance Password Change Function 413
Service Mode 416
How to Operate Service Mode 416
How to See Pre-defined Monitoring Information 418
How to See Battery Information 421
How to Examine Monitoring Information 423
Abnormality Record Menu 431
How to See Maintenance Record 435
Maintenance Mode Setting 436
How to Set Phone Number Entry 441
Default Setting Menu 442
Testing Menu 447
Adjustment Menu 448
How to Operate Battery Disconnect Switch Setting 450
KOMTRAX Settings Menu 450
How to Show Service Message 453
How to Start Up KOMTRAX Terminal 455
When KOMTRAX Terminal is Replaced 455
Communication Inspection on Machine Side 455
How to Stop Use of KOMTRAX Terminal 458
Handle Voltage Circuit of Motor Controller 460
Handle Special Power Supply for Battery 461
Examine Fuse 462
How to Examine Tube Fuse 462
How to Examine Slow-Blow Fuse 462
Measure Battery Voltage 464
How to Measure Battery Voltage 464
Examine Diodes 466
How to Examine Diodes by Digital Tester 466
How to Examine Diodes by Analog Tester 466
Pm Clinic 467
Pm Clinic Service 467
Pm Clinic Check Sheet: PC33E-6 468
40 Troubleshooting 475
Table of Contents 476
Precautions Before Work 482
Precautions Before Work for Battery Type Mini Excavator 482
Related Information for Troubleshooting 483
General Troubleshooting Points 483
Sequence of Events in Troubleshooting 484
Inspection Before Troubleshooting 486
Inspection Procedure Before Troubleshooting 487
Walk-around Check 487
Test in Accordance with Testing Procedure 488
Examine Hydraulic Oil Level 488
Examine Hydraulic Oil Strainer 490
Examine Hydraulic Oil Filter 492
Examine Oil Level in Final Drive Case 493
Bleed Air from Hydraulic System 493
How to Examine Electric Equipment 493
Preparation for Troubleshooting of Electrical System 497
Preparation for Troubleshooting from Service Connector 497
How to Connect Adapter for Troubleshooting Machine Monitor 497
Connect Adapter for Troubleshooting of Machine Controller 499
How to Connect Adapter to Troubleshoot KOMTRAX Terminal 499
Preparation for Troubleshooting of Inverter 500
Preparation for Troubleshooting of Power Supply Controller 500
Procedure for Troubleshooting 501
Symptom and Troubleshooting Numbers 505
Information Shown in Troubleshooting Table 508
Connector List and Layout (Canopy Specification) 510
Connector Layout (1) (Canopy Specification) 515
Connector Layout (2) (Canopy Specification) 517
Connector Contact Connection Table 519
T-Branch Box and T-Branch Adapter Table 566
Fuse Location Table 572
Failure Code Table 575
Troubleshooting by Failure Code (Display of Code) 585
Failure Code [989L00] 585
Failure Code [989M00] 586
Failure Code [989N00] 587
Failure Code [B@HANS] 588
Failure Code [D105KA] 590
Failure Code [D105KB] 592
Failure Code [D105KY] 594
Failure Code [D19JKZ] 596
Failure Code [D19ZKA] 600
Failure Code [D19ZKB] 602
Failure Code [D19ZKZ] 604
Failure Code [D1HBKA] 606
Failure Code [D1HBKB] 609
Failure Code [D1HBKY] 611
Failure Code [D610KF] 613
Failure Code [D6L1KA] 615
Failure Code [D6L1KB] 616
Failure Code [D6L2KA] 617
Failure Code [D6L2KB] 618
Failure Code [D6L3KB] 619
Failure Code [D6L4KT] 620
Failure Code [D6L5KE] 621
Failure Code [D6L5KF] 622
Failure Code [D6L5KR] 623
Failure Code [D6L6MA] 624
Failure Code [D6L7MA] 625
Failure Code [D6L8KR] 626
Failure Code [D6L9KR] 627
Failure Code [D6LBNS] 628
Failure Code [D6LCNS] 629
Failure Code [D6LDNS] 630
Failure Code [D6LENS] 631
Failure Code [D6LFKA] 632
Failure Code [D6LGKA] 633
Failure Code [D6LHNS] 634
Failure Code [D6LJNS] 635
Failure Code [D6LKKA] 636
Failure Code [D6LLKA] 637
Failure Code [D6LMKA] 638
Failure Code [D6LNKA] 639
Failure Code [D6LPNS] 640
Failure Code [D811MC] 641
Failure Code [D862KA] 642
Failure Code [D8ALKA] 643
Failure Code [D8ALKB] 645
Failure Code [D8AQKR] 647
Failure Code [DAF0KT] 653
Failure Code [DAF0MB] 654
Failure Code [DAF0MC] 655
Failure Code [DAF3KK] 656
Failure Code [DAF9KQ] 658
Failure Code [DAFGMC] 659
Failure Code [DAFLKA] 660
Failure Code [DAFLKB] 662
Failure Code [DAFQKR] 664
Failure Code [DBH0MC] 670
Failure Code [DBH2KK] 671
Failure Code [DBH2KT] 674
Failure Code [DBH3KK] 676
Failure Code [DBH5KP] 678
Failure Code [DBH6KP] 681
Failure Code [DBH9KQ] 684
Failure Code [DBHJKT] 686
Failure Code [DBHJKY] 687
Failure Code [DBHKKA] 688
Failure Code [DBHKKB] 689
Failure Code [DBHKKY] 690
Failure Code [DBHLKA] 691
Failure Code [DBHLKB] 693
Failure Code [DBHPKR] 695
Failure Code [DBHQKR] 699
Failure Code [DBHRKR] 705
Failure Code [DBHTKA] 710
Failure Code [DBHTKB] 712
Failure Code [DBHTKY] 714
Failure Code [DDNRKA] 716
Failure Code [DDNRKY] 718
Failure Code [DDNS00] 720
Failure Code [DDWLKA] 722
Failure Code [DDWLKB] 724
Failure Code [DF40KZ] 726
Failure Code [DFB1KZ] 729
Failure Code [DFB3L8] 731
Failure Code [DFB5KZ] 734
Failure Code [DGH2KA] 736
Failure Code [DGH2KB] 738
Failure Code [DHS1MA] 740
Failure Code [DHS5MA] 743
Failure Code [DHX1MA] 746
Failure Code [DJK100] 749
Failure Code [DJK1KN] 750
Failure Code [DKULKA] 751
Failure Code [DKULKB] 753
Failure Code [DKULKY] 755
Failure Code [DV00KB] 757
Failure Code [DV20KB] 758
Failure Code [DW43KA] 760
Failure Code [DW43KB] 762
Failure Code [DW43KY] 764
Failure Code [DW4CKY] 766
Failure Code [DXA8KA] 768
Failure Code [DXA8KB] 771
Failure Code [DXE7KA] 773
Failure Code [DXE7KB] 775
Failure Code [DXE7KY] 777
Failure Code [DXEAKA] 779
Failure Code [DXEAKB] 781
Failure Code [DXEAKY] 783
Failure Code [F7FQKR] 785
Failure Code [F7G0MC] 791
Failure Code [GBC3KA] 792
Failure Code [GBC3KB] 794
Failure Code [GBC3KY] 796
Failure Code [GBCQMA] 798
Failure Code [GBCYKA] 800
Failure Code [GF01KH] 802
Failure Code [GF01KL] 803
Failure Code [GF01KU] 804
Failure Code [GF02KG] 805
Failure Code [GF02KH] 806
Failure Code [GF02KL] 807
Failure Code [GF02KU] 808
Failure Code [GF02N7] 809
Failure Code [GF02N8] 810
Failure Code [GF02NA] 811
Failure Code [GF02NR] 812
Failure Code [GF02NS] 813
Failure Code [GF02NV] 814
Failure Code [GF02R3] 815
Failure Code [GF02ZS] 816
Failure Code [GF02ZT] 817
Failure Code [GF02ZU] 818
Failure Code [GF10KN] 819
Failure Code [GF11KG] 822
Failure Code [GF11KK] 824
Failure Code [GF12KA] 826
Failure Code [GF13KA] 828
Failure Code [GF14KA] 830
Failure Code [GF15KQ] 832
Failure Code [GF16KA] 833
Failure Code [GF16KB] 836
Failure Code [GF17MA] 839
Failure Code [GF18KQ] 842
Failure Code [GF1AMA] 843
Failure Code [GF1BMA] 844
Failure Code [GF1C00] 845
Failure Code [GF1CNS] 846
Failure Code [GF1EKT] 847
Failure Code [GF1FMA] 848
Failure Code [GF1JKA] 849
Failure Code [GF1LKB] 852
Failure Code [GF1MKB] 855
Failure Code [GF1NKB] 858
Failure Code [GF1QKR] 861
Failure Code [GF30KB] 863
Failure Code [GF31MA] 865
Failure Code [GF3200] 867
Failure Code [GF32NS] 868
Failure Code [GF33MA] 869
Failure Code [GFA0KB] 871
Failure Code [GFA0PK] 874
Failure Code [GFA8ZC] 875
Failure Code [GFA9KA] 876
Failure Code [GFA9KB] 878
Failure Code [GFAAKA] 879
Failure Code [GFACNU] 880
Failure Code [GFAG00] 881
Failure Code [GFAHKL] 883
Failure Code [GFAHKU] 884
Failure Code [GFAJKE] 885
Failure Code [GFAJKN] 887
Failure Code [GFAKKU] 889
Failure Code [GFALKN] 890
Failure Code [GFALNS] 892
Failure Code [GFALZC] 893
Failure Code [GFAMMN] 895
Failure Code [GFAMMR] 896
Failure Code [GFAMNS] 899
Failure Code [GFANKA] 900
Failure Code [GFAQKR] 902
Failure Code [GFBQKR] 904
Failure Code [GFBRKR] 910
Failure Code [GFD6MA] 912
Failure Code [GFDAKG] 913
Failure Code [GFDAKN] 915
Failure Code [GFDAKP] 917
Failure Code [GFDAKY] 919
Failure Code [GFDDKG] 921
Failure Code [GFDDKN] 923
Failure Code [GFDDKP] 926
Failure Code [GFDEKN] 929
Failure Code [GFDGKB] 932
Failure Code [GFDGKG] 933
Failure Code [GFDGKP] 934
Failure Code [GFDKKB] 935
Failure Code [GFDKKG] 936
Failure Code [GFDKKN] 937
Failure Code [GFDKKP] 938
Failure Code [GFDKKY] 939
Failure Code [GFDLKN] 940
Failure Code [GFDNKG] 941
Failure Code [GFDNKN] 943
Failure Code [GFDNKP] 945
Failure Code [GFDRKK] 946
Failure Code [GFDRKU] 947
Failure Code [GFDSKK] 949
Failure Code [GFDSKU] 950
Failure Code [GFDUN7] 951
Failure Code [GFDUN8] 952
Failure Code [GFDVN8] 953
Failure Code [GFEAKA] 954
Failure Code [GFEAKB] 955
Failure Code [GFEBKB] 956
Troubleshooting of Electrical System (E-Mode) 957
Electric Motor Does Not Start (Electric Motor Does Not Run) 957
Auto-Decelerator is Not Operated or Canceled with Lever 963
When Working Mode is Changed, Setting of Electric Motor and Hydraulic Pump is Not Changed 964
All Work Equipment, Swing, Travel Do Not Operate 965
All Work Equipment, Swing, Travel Cannot be Locked 968
Travel Speed Does Not Change Even When You Change Travel Speed 970
Travel Alarm Does Not Operate During Travel 972
Travel Alarm Does Not Stop When Machine Stops 974
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 976
Some Areas of Machine Monitor Screen are Not Shown 981
Function Switch Does Not Operate 982
Alarm Buzzer Does Not Operate 983
Alarm Buzzer Does Not Stop 985
Service Meter is Not Shown While Starting Switch is in OFF Position 986
Service Mode Cannot be Selected 987
“Travel” is Not Shown Correctly with Monitoring Function 988
“Swing or Arm IN” is Not Shown Correctly with Monitoring Function 989
Work Equipment is Not Shown Correctly with Monitoring Function 990
Horn Does Not Operate 992
Horn Does Not Stop 996
Working Lamp and Headlamp Do Not Come On (Canopy Spec) 998
KOMTRAX System Does Not Operate Correctly 1004
Battery is Not Charged 1005
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1007
Information Shown in Troubleshooting Table (H-Mode) 1007
All Work Equipment, Travel, Swing, Blade Do Not Operate 1008
All Work Equipment or Travel Does Not Operate 1009
Travel and Blade Do Not Operate 1010
Swing and Blade Do Not Operate 1011
All Work Equipment, Travel, Swing and Blade Speed or Power is Low 1012
All Work Equipment and Travel Speed or Power is Low 1013
Travel and Blade Speed or Power is Low 1014
Swing and Blade Speed or Power is Low 1015
Fine Control Performance or Response is Unsatisfactory 1016
There is an Unusual Noise from Around Main Pump 1017
Electric Motor Speed Drops Largely or Electric Motor Does Not Run 1018
All Work Equipment Speed or Power is Low 1020
All Work Equipment and Blade Speed or Power is Low 1021
Blade Does Not Operate 1022
All Work Equipment Do Not Operate 1023
All Work Equipment and Blade Do Not Operate 1024
Boom Speed or Power is Low 1025
Arm Speed or Power is Low 1027
Bucket Speed or Power is Low 1028
Blade Speed or Power is Low 1029
Boom Swing Speed or Power is Low 1031
Work Equipment Does Not Move in Single Operation 1032
Hydraulic Drift of Boom is Large 1034
Hydraulic Drift of Arm is Large 1035
Hydraulic Drift of Bucket is Large 1036
Hydraulic Drift of Blade is Large 1037
Time Lag of Work Equipment is Large 1039
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1040
Machine Does Not Travel Straight 1041
Machine Does Not Move Off Straight 1043
Machine is Not Steered Well or Steering Power is Low 1044
Travel Speed is Low 1046
Two Sides of Crawlers Do Not Move 1048
One of Tracks Does Not Run 1049
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1051
Upper Structure Does Not Swing in Two Directions of Right and Left 1052
Machine Swings Only in One Direction 1054
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 1056
Swing Acceleration or Swing Speed is Low in Only One Direction 1058
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1059
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1060
Shock is Large When Upper Structure Stops Swing Operation 1061
Large Unusual Noise is Made When Upper Structure Stops Swing Operation 1062
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1063
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1064
50 Disassembly and Assembly 1065
Table of Contents 1066
Precautions Before Work 1069
Precautions Before Work for Battery Type Mini Excavator 1069
Related Information on Disassembly and Assembly 1070
How to Read This Manual 1070
Coating Materials List 1071
Special Tool List 1076
Sketches of Special Tools 1080
Prepare 1081
Drain and Add Hydraulic Oil 1081
How to Drain Hydraulic Oil 1081
How to Add Hydraulic Oil 1083
Cooling System 1084
Remove and Install Hydraulic Oil Cooler Assembly 1084
How to Remove Hydraulic Oil Cooler Assembly 1084
How to Install Hydraulic Oil Cooler Assembly 1086
Power Train 1088
Remove and Install Travel Motor and Final Drive Assembly 1088
How to Remove Travel Motor and Final Drive Assembly 1088
How to Install Travel Motor and Final Drive Assembly 1090
Remove and Install Swing Motor and Swing Machinery Assembly 1092
How to Remove Swing Motor and Swing Machinery Assembly 1092
How to Install Swing Motor and Swing Machinery Assembly 1093
Disassemble and Assemble Swing Machinery Assembly 1094
How to Disassemble Swing Machinery Assembly 1094
How to Assemble Swing Machinery Assembly 1097
Remove and Install Swing Circle Assembly 1100
How to Remove Swing Circle Assembly 1100
How to Install Swing Circle Assembly 1101
Undercarriage and Frame 1102
Disassemble and Assemble Recoil Spring Assembly 1102
How to Disassemble Recoil Spring Assembly 1102
How to Assemble Recoil Spring Assembly 1104
Remove and Install Track Assembly 1106
How to Remove Track Assembly 1106
How to Install Track Assembly 1107
Disassemble and Assemble Idler Assembly 1108
How to Disassemble Idler Assembly 1108
How to Assemble Idler Assembly 1110
Disassemble and Assemble Track Roller Assembly 1112
How to Disassemble Track Roller Assembly 1112
How to Assemble Track Roller Assembly 1114
Disassemble and Assemble Carrier Roller Assembly 1115
How to Disassemble Carrier Roller Assembly 1115
How to Assemble Carrier Roller Assembly 1117
Remove and Install Revolving Frame Assembly 1118
How to Remove Revolving Frame Assembly 1118
How to Install Revolving Frame Assembly 1120
Remove and Install Protector 1122
How to Remove Protector 1122
How to Install Protector 1125
Hydraulic System 1128
Remove and Install Center Swivel Joint Assembly 1128
How to Remove Center Swivel Joint Assembly 1128
How to Install Center Swivel Joint Assembly 1130
Disassemble and Assemble Center Swivel Joint Assembly 1132
How to Disassemble Center Swivel Joint Assembly 1133
How to Assemble Center Swivel Joint Assembly 1134
Remove and Install Hydraulic Tank Assembly 1135
How to Remove Hydraulic Tank Assembly 1135
How to Install Hydraulic Tank Assembly 1140
Remove and Install Main Pump Assembly 1144
How to Remove Main Pump Assembly 1144
How to Install Main Pump Assembly 1146
Work Equipment 1148
Remove and Install Blade Assembly 1148
How to Remove Blade Assembly 1148
How to Install Blade Assembly 1149
Remove and Install Work Equipment Assembly 1150
How to Remove Work Equipment Assembly 1150
How to Install Work Equipment Assembly 1152
Remove and Install Boom Anti-Drop Valve Assembly 1154
How to Remove Boom Anti-Drop Valve Assembly 1154
How to Install Boom Anti-Drop Valve Assembly 1157
Remove and Install Arm Anti-Drop Valve Assembly 1158
How to Remove Arm Anti-Drop Valve Assembly 1158
How to Install Arm Anti-Drop Valve Assembly 1161
Disassemble and Assemble Anti-Drop Valve Assembly 1162
How to Disassemble Anti-Drop Valve Assembly 1162
How to Assemble Anti-Drop Valve Assembly 1163
Disassemble and Assemble Work Equipment Cylinder Assembly 1164
How to Disassemble Work Equipment Cylinder Assembly 1165
How to Assemble Work Equipment Cylinder Assembly 1168
CAB Related Parts 1172
Remove and Install Floor Frame Assembly 1172
How to Remove Floor Frame Assembly 1172
How to Install Floor Frame Assembly 1177
Remove and Install Operator Seat 1182
How to Remove Operator Seat 1182
How to Install Operator Seat 1184
Remove and Install Seat Belt 1186
How to Remove Seat Belt 1186
How to Install Seat Belt 1188
Electrical System 1190
Remove and Install Battery Assembly 1190
How to Remove Battery Assembly 1190
How to Install Battery Assembly 1196
Remove and Install Charge Inlet Assembly 1202
How to Remove Charge Inlet Assembly 1202
How to Install Charge Inlet Assembly 1205
Disassemble and Assemble Charge Inlet Assembly 1208
How to Disassemble Charge Inlet Assembly 1208
How to Assemble Charge Inlet Assembly 1210
Remove and Install Electric Motor Assembly 1212
How to Remove Electric Motor Assembly 1212
How to Install Electric Motor Assembly 1214
Remove and Install Controller Unit 1215
How to Remove Controller Unit 1215
How to Install Controller Unit 1218
Remove and Install Power Supply Controller 1221
How to Remove Power Supply Controller 1221
How to Install Power Supply Controller 1223
Remove and Install Contactor 1225
How to Remove Contactor 1225
How to Install Contactor 1227
Remove and Install Inverter 1229
How to Remove Inverter 1229
How to Install Inverter 1230
Remove and Install DC/DC Converter 1231
How to Remove DC/DC Converter 1231
How to Install DC/DC Converter 1234
Remove and Install BMS 1236
How to Remove BMS 1236
How to Install BMS 1237
Remove and Install Machine Controller 1238
How to Remove Machine Controller 1238
How to Install Machine Controller 1240
Remove and Install Machine Monitor Assembly 1241
How to Remove Machine Monitor Assembly 1241
How to Install Machine Monitor Assembly 1243
Remove and Install KOMTRAX Terminal 1245
How to Remove KOMTRAX Terminal 1245
How to Install KOMTRAX Terminal 1246
60 Maintenance Standard 1247
Table of Contents 1248
Explanation of Terms for Maintenance Standard 1249
Electric Motor and Cooling System 1251
Maintenance Standard for Electric Motor 1251
Maintenance Standard for Cooling System 1254
Power Train 1255
Maintenance Standard for Swing Circle 1255
Maintenance Standard for Swing Machinery 1256
Maintenance Standard for Sprocket 1258
Undercarriage and Frame 1259
Maintenance Standard for Track Frame and Idler Cushion 1259
Maintenance Standard for Idler 1261
Maintenance Standard for Track Roller 1263
Maintenance Standard for Carrier Roller 1264
Maintenance Standard for Rubber Shoes 1265
Hydraulic System 1266
Maintenance Standard for Hydraulic Tank 1266
Maintenance Standard for Main Pump 1267
Maintenance Standard for Main Pump Servo Valve 1268
Maintenance Standard for PC-EPC Valve 1269
Maintenance Standard for Swing Motor 1270
Maintenance Standard for Travel Motor 1272
Maintenance Standard for Control Valve 1273
Maintenance Standard for Boom Anti-Drop Valve 1283
Maintenance Standard for Arm Anti-Drop Valve 1285
Maintenance Standard for Work Equipment and Swing PPC Valve 1287
Maintenance Standard for Blade PPC Valve 1290
Maintenance Standard for Boom Swing PPC Valve 1292
Maintenance Standard for Travel PPC Valve 1294
Maintenance Standard for Center Swivel Joint 1297
Work Equipment 1298
Maintenance Standard for Work Equipment Linkage 1298
Dimensions of Arm 1304
Maintenance Standard for Boom Cylinder 1305
Maintenance Standard for Arm Cylinder 1306
Maintenance Standard for Bucket Cylinder 1307
Maintenance Standard for Blade Cylinder 1308
Maintenance Standard for Boom Swing Cylinder 1309
80 Others 1311
Table of Contents 1312
Precautions Before Work 1313
Stationary Charger 1314
Precautions for Stationary Battery Charger 1314
Structure and Operation of Stationary Charger 1315
Structure of Stationary Charger 1315
Specifications of Stationary Charger 1316
Function of Stationary Charger 1317
Input and Output Signals of Stationary Charger 1317
Examine and Adjust Stationary Battery Charger 1318
Clean and Replace Filter of Stationary Battery Charger 1318
Individual Charge Battery 1321
Troubleshooting for Stationary Battery Charger 1323
Related Information to Troubleshooting 1323
Troubleshooting by Failure Code (Display of Code) 1334
Disassemble and Assemble Stationary Charger 1367
Remove and Install Power Supply Module Cooling Fan 1367
Remove and Install Battery Charge Cable Assembly 1371
Remove and Install Power Supply Input Cable and Cable Gland 1377
Remove and Install AC/DC Power Supply 1379
Remove and Install Contactor 1384
Remove and Install Contactor Cooling Fan 1386
Remove and Install EMC Filter 1388
Remove and Install Fuse and Charge Relay 1390
Remove and Install Liquid Crystal Panel, Lamps, and Switches 1395
Remove and Install Indicator Cover 1405
Remove and Install Cable Holder 1407
Remove and Install Power Supply Plug Cap 1409
Remove and Install Charge Plug Cap 1411
Remove and Install Battery Charger Plug Unlock Pin 1413
Remove and Install Charge Plug End 1415
90 Circuit Diagrams 1421
Table of Contents 1422
How to Read the Codes for Electric Cable 1423
Hydraulic Circuit Diagram 1427
Symbols Used in Hydraulic Circuit Diagram 1427
Hydraulic Circuit Diagram 1431
Hydraulic Circuit Diagram (at Boom Raise Operation) 1433
Hydraulic Circuit Diagram (at Left Swing Operation) 1435
Hydraulic Circuit Diagram (at Boom Raise and Left Swing Operation) 1437
Electrical Circuit Diagram 1439
Symbols Used in Electric Circuit Diagram 1439
Electrical Circuit Diagram (1/6) 1443
Electrical Circuit Diagram (2/6) 1445
Electrical Circuit Diagram (3/6) 1447
Electrical Circuit Diagram (4/6) 1449
Electrical Circuit Diagram (5/6) 1451
Electrical Circuit Diagram (6/6) 1453
Index 1455

DESCRIPTION:

Komatsu PC33E-6 Electric Mini Excavator Shop Manual SEN06975-02 – PDF DOWNLOAD 

SERIAL NUMBERS 2001 and up

Structure of Shop Manual
This shop manual contains the necessary technical information required for the service in the workshop. The
contents of the manual are sorted in the categories as follows for the practical use.
00 Index and Foreword
This section shows the index, forward, safety, and basic information.
01 Specification
This section shows the specifications of the machine.
10 Structure and Function
This section shows the structure and function of each component. “Structure and Function” not only shows the
detailed information to help more understanding of the structure of each device, it also can be used as a reference
material for troubleshooting.
20 Standard Value Table
This section shows the standard value for the new machine and failure judgment criteria used in Testing and
Adjusting and Troubleshooting. This standard value table is used as the standard value during Testing and Adjusting,
and as the failure judgment during Troubleshooting.
30 Testing and Adjusting
This section shows the measurement tool required for Testing and Adjusting, measurement procedure, and adjustment
procedure for each part. For the standard value and failure judgment criteria for “Testing and Adjusting”,
see Standard Value Table.
40 Troubleshooting
This section shows the troubleshooting procedure for the defective part and remedy if a problem occurs. The
troubleshooting procedure is shown for each failure mode.
50 Disassembly and Assembly
This section gives information for 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 gives information about the maintenance standard for each component. The maintenance standard
shows the value of the judgment criteria value and remedy during the disassembly and maintenance.
80 Appendix
This section gives information of Structure and Function, Testing and Adjusting, and Troubleshooting of the devices
that is not shown in each section.

S.V 26/12/24