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Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 PDF
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Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 PDF

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Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 – PDF DOWNLOAD

MACHINE MODEL    SERIAL No.
РС40-5                        8501 and up   

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Description

Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 – PDF DOWNLOAD 

Language : English
Pages : 209
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL No.
РС40-5                        8501 and up   

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

TABLE OF CONTENTS:

Komatsu PC40-5 Hydraulic Excavator Shop Manual SEBM02240503 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL No.
РС40-5                        8501 and up   

COVER 1
CONTENTS 2
10 ENGINE 15
12 TESTING AND ADJUSTING 15
TESTING AND ADJUSTING DATA 16
TESTING AND ADJUSTING TOOL 16
ADJUSTING VALVE CLEARANCE 17
MEASURING EXHAUST GAS COLOR 18
MEASURING COMPRESSION PRESSURE 19
MEASURING BLOW-BY PRESSURE 20
ADJUSTING FUEL INJECTION TIMING 21
TESTING AND ADJUSTING FAN BELT TENSION 22
BLEEDING AIR FROM FUEL LINE 22
13 DISASSEMBLY AND ASSEMBLY 23
STARTING MOTOR 24
REMOVAL 24
INSTALLATION 24
ALTERNATOR 24
REMOVAL 24
INSTALLATION 24
FAN PULLEY 24
REMOVAL 24
INSTALLATION 24
WATER PUMP 24
REMOVAL 24
INSTALLATION 24
THERMOSTAT 26
REMOVAL 26
INSTALLATION 26
NOZZLE HOLDER 26
REMOVAL 26
INSTALLATION 26
FUEL INJECTION PUMP 28
REMOVAL 28
INSTALLATION 28
CYLINDER HEAD 30
REMOVAL 30
INSTALLATION 32
RADIATOR 34
REMOVAL 34
INSTALLATION 34
ENGINE 36
REMOVAL 36
INSTALLATION 40
20 POWER TRAIN 44
21 STRUCTURE AND FUNCTION 44
POWER TRAIN 45
SWING CIRCLE 46
SWING MACHINERY 47
SPROCKET 48
23 DISASSEMBLY AND ASSEMBLY 49
SWING CIRCLE 50
REMOVAL 50
INSTALLATION 52
SWING MACHINERY 54
REMOVAL 54
INSTALLATION 54
DISASSEMBLY 56
ASSEMBLY 58
24 MAINTENANCE STANDARD 60
SWING CIRCLE 61
SWING MACHINERY 62
SPROCKET 63
30 UNDERCARRIAGE 64
31 STRUCTURE AND FUNCTION 64
TRACK FRAME AND RECOIL SPRING 65
IDLER 66
TRACK ROLLER 66
TRACK SHOE 67
33 DISASSEMBLY AND ASSEMBLY 68
RECOIL SPRING 69
REMOVAL 69
INSTALLATION 69
DISASSEMBLY 69
ASSEMBLY 69
IDLER 71
REMOVAL 71
INSTALLATION 71
DISASSEMBLY 71
ASSEMBLY 71
TRACK ROLLER 73
REMOVAL 73
INSTALLATION 73
DISASSEMBLY 73
ASSEMBLY 73
TRACK SHOE 75
REMOVAL 75
INSTALLATION 75
34 MAINTENANCE STANDARD 77
TRACK FRAME AND RECOIL SPRING 78
TRACK ROLLER 79
TRACK SHOE 80
IDLER 81
60 HYDRAULIC SYSTEM 82
61 STRUCTURE AND FUNCTION 82
HYDRAULIC PIPING 83
HYDRAULIC CIRCUIT SCHEMATICS 85
HYDRAULIC CIRCUIT DIAGRAM 86
HYDRAULIC TANK 87
6-SPOOL CONTROL VALVE 88
3-SPOOL CONTROL VALVE 90
HYDRAULIC TRIPLE GEAR PUMP 91
MAIN RELIEF VALVE 92
SAFETY VALVE 93
CENTER SWIVEL JOINT 96
SWING MOTOR 97
TRAVEL MOTOR 99
VALVE CONTROL 105
62 TESTING AND ADJUSTING 106
TABLE OF JUDGEMENT STANDARD VALUE 107
TESTING AND ADJUSTING TOOL 114
TESTING OPERATING FORCE OF CONTROL LEVER 115
TESTING TRAVEL OF CONTROL LEVER 115
TESTING TRAVEL OF CONTROL VALVE SPOOL 116
TESTING AND ADJUSTING HYDRAULIC PRESSURE 117
MEASURING DELIVERY OF PUMP 119
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR 121
MEASURING OIL LEAKAGE FORM CYLINDER 122
TROUBLESHOOTING 123
PREPARATION OF TROUBLESHOOTING 124
HOW TO USE DIAGNOSTIC TABLE 126
PREVENTING RECURRENCE OF THE SAME TROUBLE 128
DIAGNOSTIC TABLE 129
1 BUCKET CURL (DUMP) LACKS POWER OR SPEED 129
2 ARM (BOOM) LACKS POWER OR SPEED 130
3 IMPOSSIBLE TO CURL OR DUMP BUCKET 131
4 IMPOSSIBLE TO MOVE WORK EQUIPMENT (ARM,BOOM) 132
5 HYDRAULIC DRIFT OF WORK EQUIPMENT IS EXCESSIVE (BOOM,ARM,BUCKET,BLADE) 133
6 BLADE,BOOM SWING SPEED TOO LOW 134
7 BLADE,BOOM SWING DO NOT MOVE 135
8 LEFT (OR RIGHT) SWING LACKS POWER OR SPEED 136
9 IMPOSSIBLE TO SWING TO LEFT (OR RIGHT) 137
10 HYDRAULIC DRIFT OF SWING ON SLOPES IS EXCESSIVE 138
11 SWING BRAKE ANGLE IS EXCESSIVE 139
12 MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING 140
13 IMPOSSIBLE TO TRAVEL FORWARD (OR REVERSE) 141
63 DISASSEMBLY AND ASSEMBLY 142
HYDRAULIC PUMP 143
REMOVAL 143
INSTALLATION 143
6-SPOOL CONTROL VALVE 145
REMOVAL 145
INSTALLATION 145
3-SPOOL CONTROL VALVE 145
REMOVAL 145
INSTALLATION 145
CONTROL VALVE 147
DISASSEMBLY 147
ASSEMBLY 147
MAIN RELIEF VALVE 149
REMOVAL 149
INSTALLATION 149
CENTER SWIVEL JOINT 151
REMOVAL 151
INSTALLATION 151
DISASSEMBLY 153
ASSEMBLY 153
SWING MOTOR 155
REMOVAL 155
INSTALLATION 155
TRAVEL MOTOR 155
REMOVAL 155
INSTALLATION 155
DISASSEMBLY 157
ASSEMBLY 162
BOOM CYLINDER 175
REMOVAL 175
INSTALLATION 175
ARM CYLINDER 175
REMOVAL 175
INSTALLATION 175
BUCKET CYLINDER 177
REMOVAL 177
INSTALLATION 177
BLADE CYLINDER 177
REMOVAL 177
INSTALLATION 177
BOOM SWING CYLINDER 179
REMOVAL 179
INSTALLATION 179
HYDRAULIC CYLINDER 181
DISASSEMBLY 181
ASSEMBLY 183
64 MAINTENANCE STANDARD 187
6-SPOOL CONTROL VALVE 188
3-SPOOL CONTROL VALVE 189
HYDRAULIC CYLINDER 190
TRIPLE GEAR PUMP 192
70 WORK EQUIPMENT 193
71 STRUCTURE AND FUNCTION 193
WORK EQUIPMENT 194
73 DISASSEMBLY AND ASSEMBLY 196
WORK EQUIPMENT 197
REMOVAL 197
INSTALLATION 197
BLADE 197
REMOVAL 197
INSTALLATION 197
ARM AND BUCKET 199
REMOVAL 199
INSTALLATION 199
BUCKET 199
REMOVAL 199
INSTALLATION 199
ARM 201
REMOVAL 201
INSTALLATION 201
BOOM 201
REMOVAL 201
INSTALLATION 201
FLOOR FRAME 203
REMOVAL 203
INSTALLATION 203
74 MAINTENANCE STANDARD 205
WORK EQUIPMENT 206
80 ELECTRICAL SYSTEM 208
81 STRUCTURE AND FUNCTION 208
ELECTRICAL CIRCUIT DIAGRAM 209

S.V  21/12/24 

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