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KOMATSU PC35R-8 PC45R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F20518 & UP)(SN:F20666 & UP) KOMATSU PC35R-8 PC45R-8 – PDF DOWNLOAD
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- KOMATSU PC35R-8 PC45R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:F20666 & UP,F20518 & UP
- PUBLICATION NUMBER:WEBM003000
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Description
KOMATSU PC35R-8 PC45R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F20518 & UP)(SN:F20666 & UP) KOMATSU PC35R-8 PC45R-8
KOMATSU PC35R-8 PC45R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F20518 & UP)(SN:F20666 & UP) KOMATSU PC35R-8 PC45R-8 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC35R-8 PC45R-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F20518 & UP)(SN:F20666 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
- 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 sections 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 this section. - 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 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:F20518 & UP)(SN:F20666 & UP)
MAIN MENU.................................................................................... 0 COVER........................................................................................ 1 CONTENTS..................................................................................... 2 FOREWARD..................................................................................... 6 FOREWARD................................................................................. 8 HOW TO READ THE MANUAL................................................................... 9 HOISTING INSTRUCTIONS.................................................................... 10 STANDARD TIGHTENING TORQUE............................................................... 11 COATING MATERIALS........................................................................ 13 ELECTRIC WIRE CODE....................................................................... 14 WEIGHT TABLE............................................................................. 15 TABLE OF OIL AND COOLANT QUANTITIES...................................................... 16 10 STRUCTURE AND FUNCTION.................................................................... 19 P.T.O.................................................................................... 20 POWER TRAIN.............................................................................. 21 SWING CIRCLE............................................................................. 22 SWING MACHINERY.......................................................................... 23 FINAL DRIVE.............................................................................. 24 TRACK FRAME.............................................................................. 25 RECOIL SPRING............................................................................ 26 CARRIER ROLLER........................................................................... 27 TRACK ROLLER............................................................................. 27 STEEL SHOE............................................................................... 28 HYDRAULIC CIRCUIT DIAGRAM (PC35R)........................................................ 29 HYDRAULIC CIRCUIT DIAGRAM (PC45R)........................................................ 30 HYDRAULIC PUMP........................................................................... 31 CONTROL VALVE............................................................................ 38 CLSS..................................................................................... 46 SWIVEL JOINT............................................................................. 68 SWING MOTOR.............................................................................. 69 TRAVEL MOTOR............................................................................. 71 CYLINDERS................................................................................ 75 ACCUMULATOR.............................................................................. 78 PPC VALVES (WORK EQUIPMENT).............................................................. 79 PPC VALVE (HAMMER)....................................................................... 83 SOLENOID VALVE........................................................................... 86 ELECTRICAL DIAGRAM (1/3)................................................................. 87 ELECTRICAL DIAGRAM (2/3)................................................................. 88 ELECTRICAL DIAGRAM (3/3)................................................................. 89 20 TESTING AND ADJUSTMENTS................................................................... 91 NORMAL OR STANDARD TECHNICAL DATA........................................................ 92 SPECIAL TOOLS............................................................................114 CHECKING THE ENGINE SPEED................................................................115 ADJUSTMENT OF VALVE CLEARANCE............................................................116 MEASUREMENT OF THE COMPRESSOR PRESSURE...................................................117 CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....................................118 CONTROL AND ADJUSTMENT OF THE INJECTION TIMING...........................................119 CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE ........................................121 ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER.......................................122 ADJUSTING THE FLEXIBLE CABLES............................................................123 CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER.................................124 ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL.................................125 ADJUSTMENT OF THE PPC VALVE CLEARANCES...................................................126 ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT.........127 CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION............................128 CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUTIS........................129 CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....132 REGULATION OF THE PC VALVE...............................................................134 CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY..................................135 ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK...........................136 BLEEDING AIR FROM THE HYDRAULIC CIRCUITS.................................................137 CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT..........................139 CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS.........................145 CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR.........................................146 METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT.................................147 30 REMOVAL AND INSTALLATION..................................................................150 HOW TO READ THE MANUAL...................................................................152 PRECAUTIONS TO BE TAKEN WHILE WORKING....................................................153 SPECIAL TOOLS............................................................................154 STARTER MOTOR............................................................................156 REMOVAL..............................................................................156 INSTALLATION.........................................................................156 ALTERNATOR...............................................................................157 REMOVAL..............................................................................157 INSTALLATION.........................................................................157 INJECTION PUMP...........................................................................158 REMOVAL..............................................................................158 INSTALLATION.........................................................................159 NOZZLE HOLDER............................................................................160 REMOVAL..............................................................................160 INSTALLATION.........................................................................160 WATER COOLANT PUMP.......................................................................161 REMOVAL..............................................................................161 INSTALLATION.........................................................................162 CYLINDER HEAD............................................................................163 REMOVAL..............................................................................163 INSTALLATION.........................................................................165 OIL COOLER...............................................................................166 REMOVAL..............................................................................166 INSTALLATION.........................................................................166 OIL COOLER- RADIATOR.....................................................................167 REMOVAL..............................................................................167 INSTALLATION.........................................................................168 ENGINE HOOD..............................................................................169 REMOVAL..............................................................................169 INSTALLATION.........................................................................169 CANOPY...................................................................................170 REMOVAL..............................................................................170 INSTALLATION.........................................................................170 CAB......................................................................................171 REMOVAL..............................................................................171 INSTALLATION.........................................................................171 HEATING FAN..............................................................................172 REMOVAL..............................................................................172 INSTALLATION.........................................................................173 COUNTERWEIGHT............................................................................174 REMOVAL..............................................................................174 INSTALLATION.........................................................................174 FUEL TANK................................................................................175 REMOVAL..............................................................................175 INSTALLATION.........................................................................176 HYDRAULIC TANK...........................................................................177 REMOVAL..............................................................................177 INSTALLATION.........................................................................178 ENGINE-PUMP GROUP........................................................................179 REMOVAL..............................................................................179 INSTALLATION.........................................................................182 PUMP.....................................................................................183 REMOVAL..............................................................................183 INSTALLATION.........................................................................183 ENGINE-PUMP COUPLING.....................................................................184 REMOVAL..............................................................................184 INSTALLATION.........................................................................184 CONTROL VALVE............................................................................185 REMOVAL..............................................................................185 INSTALLATION.........................................................................186 LEFT-HAND PPC VALVE (ARM-BUCKET).........................................................187 REMOVAL..............................................................................187 INSTALLATION.........................................................................187 RIGHT-HAND PPC VALVE(BOOM-BUCKET)........................................................188 REMOVAL..............................................................................188 INSTALLATION.........................................................................188 SERVOCONTROL SOLENOID GROUP..............................................................189 REMOVAL..............................................................................189 INSTALLATION.........................................................................189 PLATFORM.................................................................................190 REMOVAL..............................................................................190 INSTALLATION.........................................................................193 SWIVEL JOINT.............................................................................194 REMOVAL..............................................................................194 INSTALLATION.........................................................................195 SWING MACHINERY..........................................................................196 REMOVAL..............................................................................196 INSTALLATION.........................................................................196 REVOLVING FRAME..........................................................................197 REMOVAL..............................................................................197 INSTALLATION.........................................................................198 SWING CIRCLE.............................................................................199 REMOVAL..............................................................................199 INSTALLATION.........................................................................199 RUBBER TRACK SHOES.......................................................................200 REMOVAL..............................................................................200 INSTALLATION.........................................................................200 STEEL TRACK-SHOES........................................................................201 REMOVAL..............................................................................201 INSTALLATION.........................................................................201 SPROCKET WHEEL...........................................................................202 REMOVAL..............................................................................202 INSTALLATION.........................................................................202 FINAL DRIVE..............................................................................203 REMOVAL..............................................................................203 INSTALLATION.........................................................................203 IDLER AND RECOIL SPRING ASSEMBLY.........................................................204 REMOVAL..............................................................................204 INSTALLATION.........................................................................204 SPRING RECOIL AND THRUST CYLINDER GROUPS.................................................205 DISASSEMBLY..........................................................................205 ASSEMBLY.............................................................................206 IDLER....................................................................................208 DISASSEMBLY..........................................................................208 ASSEMBLY.............................................................................209 TRACK ROLLERS............................................................................210 REMOVAL..............................................................................210 INSTALLATION.........................................................................210 BOOM CYLINDER............................................................................211 REMOVAL..............................................................................211 INSTALLATION.........................................................................212 ARM CYLINDER.............................................................................213 REMOVAL..............................................................................213 INSTALLATION.........................................................................213 BUCKET CYLINDER..........................................................................214 REMOVAL..............................................................................214 INSTALLATION.........................................................................214 BOOM SWING CYLINDER......................................................................215 REMOVAL..............................................................................215 INSTALLATION.........................................................................216 BLADE CYLINDER...........................................................................217 REMOVAL..............................................................................217 INSTALLATION.........................................................................217 WORKING EQUIPMENT CYLINDERS..............................................................218 DISASSEMBLY..........................................................................218 ASSEMBLY.............................................................................220 UPPER WORKING EQUIPMENT..................................................................224 REMOVAL..............................................................................224 INSTALLATION.........................................................................225 BUCKET...................................................................................226 REMOVAL..............................................................................226 INSTALLATION.........................................................................226 ARM......................................................................................227 REMOVAL..............................................................................227 INSTALLATION.........................................................................228 ARM ASSEMBLY.............................................................................229 REMOVAL..............................................................................229 INSTALLATION.........................................................................229 BOOM.....................................................................................230 REMOVAL..............................................................................230 INSTALLATION.........................................................................231 BOOM SWING SUPPORT.......................................................................232 REMOVAL..............................................................................232 INSTALLATION.........................................................................232 BLADE....................................................................................233 REMOVAL..............................................................................233 INSTALLATION.........................................................................233 40 STANDARD MAINTENANCE......................................................................235 SWING CIRCLE.............................................................................236 SWING MACHINERY..........................................................................237 FINAL DRIVE..............................................................................238 SPROCKET.................................................................................239 IDLER....................................................................................240 STEEL SHOE...............................................................................241 CARRIER ROLLER...........................................................................243 TRACK ROLLER.............................................................................244 RUBBER SHOE..............................................................................245 TRACK FRAME..............................................................................246 HYDRAULIC PUMP...........................................................................248 CONTROL VALVE............................................................................249 SWIVEL JOINT.............................................................................255 SWING MOTOR..............................................................................256 TRAVEL MOTOR.............................................................................257 PPC VALVE................................................................................261 PPC VALVE (HAMMER).......................................................................262 CYLINDER.................................................................................263 WORK EQUIPMENT...........................................................................267
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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