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Komatsu PC35R-8, PC45R-8 DELUXE F20932 and up F21251 and up Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC35R-8, PC45R-8 DELUXE F20932 and up F21251 and up Excavator Shop Manual
Book Code: WEBM003900
Covers Models and Serial Numbers:
Komatsu PC35R-8 S/N F20932 and up
Komatsu PC45R-8 S/N F21251 and up
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Description
Komatsu PC35R-8, PC45R-8 DELUXE F20932 and up F21251 and up Excavator Shop Manual
FILE DETAILS:
Komatsu PC35R-8, PC45R-8 DELUXE F20932 and up F21251 and up Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC35R-8, PC45R-8 DELUXE
Serial Number: F20932 and up, F21251 and up
Book Code: WEBM003900
Language: English
Pages: 286
File Format: Portable Document Format (PDF)
KOMATSU PC35R-8, PC45R-8 DELUXE F20932 AND UP F21251 AND UP EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC35R-8, PC45R-8 DELUXE F20932 and up F21251 and up Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC35R-8, PC45R-8 DELUXE F20932 and up F21251 and up Excavator Shop Manual
MAIN MENU.................................................................................... 0 COVER........................................................................................ 1 CONTENTS..................................................................................... 3 SAFETY....................................................................................... 7 FOREWORD..................................................................................... 9 HOW TO READ THE SHOP MANUAL.............................................................. 10 HOISTING INSTRUCTIONS.................................................................... 11 STANDARD TIGHTENING TORQUE............................................................... 12 COATING MATERIALS........................................................................ 14 ELECTRIC WIRE CODE....................................................................... 15 WEIGHT TABLE............................................................................. 16 TABLE OF OIL AND COOLANT QUANTITIES...................................................... 17 10. STRUCTURE AND FUNCTION................................................................... 21 P.T.O.................................................................................... 22 POWER TRAIN.............................................................................. 23 SWING CIRCLE............................................................................. 24 SWING MACHINERY.......................................................................... 25 FINAL DRIVE.............................................................................. 26 TRACK FRAME.............................................................................. 27 RECOIL SPRING............................................................................ 28 CARRIER ROLLER........................................................................... 29 TRACK ROLLER............................................................................. 29 STEEL SHOE............................................................................... 30 HYDRAULIC CIRCUIT DIAGRAM PC35R-8........................................................ 31 HYDRAULIC CIRCUIT DIAGRAM PC45R-8........................................................ 33 HYDRAULIC PUMP........................................................................... 35 CONTROL VALVE............................................................................ 42 CLSS..................................................................................... 50 SWIVEL JOINT............................................................................. 72 SWING MOTOR.............................................................................. 74 TRAVEL MOTOR............................................................................. 76 CYLINDERS................................................................................ 81 ACCUMULATOR.............................................................................. 85 PPC VALVES (WORK EQUIPMENT).............................................................. 86 PPC VALVE (HAMMER)....................................................................... 90 SOLENOID VALVE........................................................................... 93 ELECTRICAL DIAGRAM (1/3)................................................................. 95 ELECTRICAL DIAGRAM (2/3)................................................................. 97 ELECTRICAL DIAGRAM (3/3)................................................................. 99 20. TESTING AND ADJUSTMENTS..................................................................103 NORMAL OR STANDARD TECHNICAL DATA........................................................104 SPECIAL TOOLS............................................................................126 CHECKING THE ENGINE SPEED................................................................127 ADJUSTMENT OF VALVE CLEARANCE............................................................128 MEASUREMENT OF THE COMPRESSION PRESSURE..................................................129 CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....................................130 CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...........................................131 CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE.........................................133 ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER......................................134 ADJUSTING THE FLEXIBLE CABLES............................................................135 CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER.................................136 ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL.................................137 ADJUSTMENT OF THE PPC VALVE CLEARANCES...................................................138 ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVOCONTROL ENGAGEMENT..........139 CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION.........................................140 CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS........................141 CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....144 REGULATION OF THE PC VALVE...............................................................146 CONTROL AND REGULATION OF THE SERVOCONTROL POWER SUPPLY..................................147 ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...........................148 BLEEDING AIR FROM THE HYDRAULIC CIRCUITS.................................................149 CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSE OF A DRIFT...........................151 CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS.........................157 CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR.........................................158 METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT.................................159 30. REMOVAL AND INSTALLATION.................................................................163 HOW TO READ THE MANUAL...................................................................165 PRECAUTIONS TO BE TAKEN WHILE WORKING....................................................166 SPECIAL TOOLS............................................................................167 STARTER MOTOR............................................................................169 REMOVAL..............................................................................169 INSTALLATION.........................................................................169 ALTERNATOR...............................................................................170 REMOVAL..............................................................................170 INSTALLATION.........................................................................170 INJECTION PUMP...........................................................................171 REMOVAL..............................................................................171 INSTALLATION.........................................................................172 NOZZLE HOLDER............................................................................173 REMOVAL..............................................................................173 INSTALLATION.........................................................................173 WATER COOLANT PUMP.......................................................................174 REMOVAL..............................................................................174 INSTALLATION.........................................................................175 CYLINDER HEAD............................................................................176 REMOVAL..............................................................................176 INSTALLATION.........................................................................178 RADIATOR GROUP - OIL COOLER..............................................................179 REMOVAL..............................................................................179 INSTALLATION.........................................................................180 ENGINE HOOD..............................................................................181 REMOVAL..............................................................................181 INSTALLATION.........................................................................181 CANOPY...................................................................................182 REMOVAL..............................................................................182 INSTALLATION.........................................................................182 CAB......................................................................................183 REMOVAL..............................................................................183 INSTALLATION.........................................................................183 HEATING FAN..............................................................................184 REMOVAL..............................................................................184 INSTALLATION.........................................................................185 COUNTERWEIGHT............................................................................186 REMOVAL..............................................................................186 INSTALLATION.........................................................................186 FUEL TANK................................................................................187 REMOVAL..............................................................................187 INSTALLATION.........................................................................188 HYDRAULIC TANK...........................................................................189 REMOVAL..............................................................................189 INSTALLATION.........................................................................190 ENGINE-PUMP GROUP........................................................................191 REMOVAL..............................................................................191 INSTALLATION.........................................................................194 PUMP.....................................................................................195 REMOVAL..............................................................................195 INSTALLATION.........................................................................195 ENGINE-PUMP COUPLING.....................................................................196 REMOVAL..............................................................................196 INSTALLATION.........................................................................196 CONTROL VALVE............................................................................197 REMOVAL..............................................................................197 INSTALLATION.........................................................................198 LEFT-HAND PPC VALVE (ARM-BUCKET).........................................................199 REMOVAL..............................................................................199 INSTALLATION.........................................................................199 RIGHT-HAND PPC VALVE (BOOM-BUCKET).......................................................200 REMOVAL..............................................................................200 INSTALLATION.........................................................................200 SERVOCONTROL SOLENOID GROUP..............................................................201 REMOVAL..............................................................................201 INSTALLATION.........................................................................201 PLATFORM.................................................................................202 REMOVAL..............................................................................202 INSTALLATION.........................................................................205 SWIVEL JOINT.............................................................................206 REMOVAL..............................................................................206 INSTALLATION.........................................................................207 SWING MACHINERY..........................................................................208 REMOVAL..............................................................................208 INSTALLATION.........................................................................208 REVOLVING FRAME..........................................................................209 REMOVAL..............................................................................209 INSTALLATION.........................................................................210 SWING CIRCLE.............................................................................211 REMOVAL..............................................................................211 INSTALLATION.........................................................................211 RUBBER TRACK SHOES.......................................................................212 REMOVAL..............................................................................212 INSTALLATION.........................................................................212 STEEL TRACK SHOES........................................................................213 REMOVAL..............................................................................213 INSTALLATION.........................................................................213 SPROCKET WHEEL...........................................................................214 REMOVAL..............................................................................214 INSTALLATION.........................................................................214 FINAL DRIVE..............................................................................215 REMOVAL..............................................................................215 INSTALLATION.........................................................................215 IDLER AND RECOIL SPRING..................................................................216 REMOVAL..............................................................................216 INSTALLATION.........................................................................216 SPRING RECOIL AND THRUST CYLINDER GROUPS.................................................217 DISASSEMBLY..........................................................................217 ASSEMBLY.............................................................................218 IDLER....................................................................................220 DISASSEMBLY..........................................................................220 ASSEMBLY.............................................................................221 TRACK ROLLERS............................................................................222 REMOVAL..............................................................................222 INSTALLATION.........................................................................222 BOOM CYLINDER............................................................................223 REMOVAL..............................................................................223 INSTALLATION.........................................................................224 ARM CYLINDER.............................................................................225 REMOVAL..............................................................................225 INSTALLATION.........................................................................225 BUCKET CYLINDER..........................................................................226 REMOVAL..............................................................................226 INSTALLATION.........................................................................226 BOOM SWING CYLINDER......................................................................227 REMOVAL..............................................................................227 INSTALLATION.........................................................................228 BLADE CYLINDER...........................................................................229 REMOVAL..............................................................................229 INSTALLATION.........................................................................229 WORK EQUIPMENT CYLINDERS.................................................................230 DISASSEMBLY..........................................................................230 ASSEMBLY.............................................................................232 UPPER WORK EQUIPMENT.....................................................................236 REMOVAL..............................................................................236 INSTALLATION.........................................................................237 BUCKET...................................................................................238 REMOVAL..............................................................................238 INSTALLATION.........................................................................238 ARM......................................................................................239 REMOVAL..............................................................................239 INSTALLATION.........................................................................240 ARM ASSEMBLY.............................................................................241 REMOVAL..............................................................................241 INSTALLATION.........................................................................241 BOOM.....................................................................................242 REMOVAL..............................................................................242 INSTALLATION.........................................................................243 BOOM SWING SUPPORT.......................................................................244 REMOVAL..............................................................................244 INSTALLATION.........................................................................244 BLADE....................................................................................245 REMOVAL..............................................................................245 INSTALLATION.........................................................................245 40. STANDARD MAINTENANCE.....................................................................249 SWING CIRCLE.............................................................................250 SWING MACHINERY..........................................................................251 FINAL DRIVE..............................................................................252 SPROCKET.................................................................................253 IDLER....................................................................................254 STEEL SHOE...............................................................................255 PC35R................................................................................255 PC45R................................................................................256 CARRIER ROLLER...........................................................................257 TRACK ROLLER.............................................................................258 RUBBER SHOE..............................................................................259 TRACK FRAME..............................................................................260 HYDRAULIC PUMP...........................................................................262 CONTROL VALVE............................................................................263 SWIVEL JOINT.............................................................................269 SWING MOTOR..............................................................................270 TRAVEL MOTOR.............................................................................272 PC35R................................................................................272 PC45R................................................................................274 PPC VALVE (FOR BOOM, ARM, BUCKET, SWING).................................................276 PPC VALVE (FOR HAMMER)...................................................................277 CYLINDERS................................................................................278 PC35R................................................................................278 PC45R................................................................................280 WORK EQUIPMENT ..........................................................................282 PC35R-8..............................................................................282 PC45R................................................................................284
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