Komatsu PC40MR-3 Hydraulic Excavator Service Repair Manual WEN00005 PDF

Description

Komatsu PC40MR-3 Hydraulic Excavator Shop Manual WEN00005 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC40MR-3 Hydraulic Excavator Shop Manual WEN00005 – PDF DOWNLOAD 

Language : English
Pages : 560
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC40MR-3 Hydraulic Excavator Shop Manual WEN00005 – PDF DOWNLOAD 

SERIAL NUMBERS 15001 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC40MR-3 Hydraulic Excavator Shop Manual WEN00005 – PDF DOWNLOAD 

SERIAL NUMBERS 15001 and up

Cover 1
00 Index and foreword 3
Index 4
Table of contents 4
Foreword and general information 9
Safety notice 9
How to read the shop manual 14
Explanation of terms for maintenance standard 16
Handling of electric equipment and hydraulic component 18
Handling of connectors newly used for engines 27
How to read electric wire code 30
Precautions when carrying out operation 33
Method of disassembling and connecting push-pull type coupler 36
Standard tightening torque table 39
Conversion table 43
01 Specification 49
Specification and technical data 51
Specification dimension drawing 51
Working range drawing 52
Specifications 53
Weight table 56
Table of fuel, coolant and lubricants 58
10 Structure, function and maintenance standard 59
Engine and cooling system 61
PTO 61
Cooling system 62
Power train 64
Power train 64
Swing circle 65
Swing machinery 66
Undercarriage and frame 68
Track frame 68
Idler cushion 69
Idler 70
Track roller 72
Carrier roller 73
Sprocket 74
Track shoe 75
Hydraulic system 78
Hydraulic components layout drawing 78
Hydraulic tank, filter 79
Center swivel joint 81
Travel motor 82
Hydraulic cylinder 90
Solenoid valve 93
Multi-control valve (If equipped) 96
Hydraulic pump 98
Control valve 106
CLSS 118
Operation for each function and valve 122
Swing motor 142
PPC valve 149
Work equipment 162
Work equipment 162
Dimensions of each part of work equipment 166
Cab and its attachments 169
Floor 169
Electrical system 170
Engine control system 170
Electric control system 172
KOMTRAX system 177
Component parts of system 180
Monitor system 181
Sensors 184
20 Standard value table 187
Standard service value table 189
Standard service value table for engine related parts 189
Standard service value table for chassis related parts 190
30 Testing and adjusting 201
Related information on testing and adjusting 203
Tools for testing, adjusting, and troubleshooting 203
Engine and cooling system 206
Testing engine speed 206
Testing exhaust gas color 207
Testing and adjusting valve clearance 208
Testing compression pressure 210
Testing engine oil pressure 211
Testing and adjusting fuel injection timing 212
Testing and adjusting alternator belt tension 216
Testing and adjusting air conditioner compressor belt tension 217
Adjusting fuel control lever 218
Power train 219
Testing clearance in swing circle bearings 219
Undercarriage and frame 220
Testing and adjusting track shoe tension 220
Hydraulic system 221
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits 221
Testing and adjusting LS differential pressure 226
Adjusting PC valve 229
Testing and adjusting control pump circuit oil pressure 230
Testing solenoid valve output pressure 232
Testing PPC valve output pressure 233
Adjusting PPC valve 235
Testing swing holding brake release pressure 236
Testing and adjusting travel deviation 237
Testing oil leakage from work equipment cylinder 239
Bleeding air from each part 241
Releasing residual pressure from hydraulic circuit 243
Releasing residual pressure from hydraulic tank 244
Pressurizing hydraulic tank 244
Cab and its attachments 245
How to open and close (tilt) floor 245
Electrical system 250
How to start operation of KOMTRAX terminal 250
Lamp display of KOMTRAX terminal 254
Removal and installation of KOMTRAX terminal 257
Preparation work for troubleshooting of electrical system 258
Inspection procedures for diode 259
40 Troubleshooting 261
General information on troubleshooting 264
Points to remember when performing troubleshooting 264
How to proceed in troubleshooting 266
Checks before troubleshooting 268
Classification and procedures of troubleshooting 269
Information contained in troubleshooting table 270
Connection table of connector by No of pins 274
T- branch box and T- branch adapter table 311
User code and failure code list 315
Fuse locations 316
Troubleshooting by failure code 318
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller 318
Failure code [DBH1KK] Unswitched power supply error 320
Failure code [DBH2KK] Solenoid power supply error 322
Failure code [DBH5KP] 5V sensor power supply output 0 error 324
Failure code [DBH6KP] 5V sensor power supply output 1 error 325
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault) 326
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit) 328
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault) 330
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit) 332
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit) 334
Failure code [D1E0KB] Motor power supply relay error (Ground fault) 336
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit) 338
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault) 340
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit) 342
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault) 344
Failure code [DY10MA] Fuel control motor operation error 346
Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side) 348
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side) 350
Troubleshooting of electrical system (E-mode) 353
Before carrying out troubleshooting of electrical system 353
E-1 Engine does not start 354
E-2 Engine does not stop 362
E-3 When starting switch is turned ON, any item does not operate 364
E-4 When starting switch is turned ON, some items do not operate 366
E-5 Alarm buzzer is abnormal 367
E-6 Engine oil pressure caution is turned ON 369
E-7 Charge level caution is turned ON 370
E-8 Preheating system does not operate or preheater does not become hot 372
E-9 Coolant temperature gauge is abnormal 374
E-10 Fuel level gauge is abnormal 378
E-11 Service meter does not operate while engine is running 382
E-12 2nd travel speed is not selected 385
E-13 Working lamp does not light up 388
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves 390
E-15 Windshield wiper does not operate 392
E-16 Windshield washer does not operate 394
E-17 Defective air conditioner 396
E-18 KOMTRAX system does not operate normally 404
Troubleshooting of hydraulic and mechanical system (H-mode) 407
Information contained in troubleshooting table 407
H-1 Speed or power of whole work equipment, travel, swing, and blade is low 408
H-2 Engine speed lowers extremely or engine stalls 412
H-3 Whole work equipment, travel system, swing system, and blade do not work 413
H-4 Abnormal sound comes out from around hydraulic pump 417
H-5 Fine control performance or response is low 417
H-6 Speed or power of boom is low 418
H-7 Speed or power of arm is low 419
H-8 Speed or power of bucket is low 420
H-9 Speed or power of boom swing is low 421
H-10 Work equipment does not move singly 421
H-11 Work equipment hydraulic drift is large 422
H-12 Time lag of work equipment is large 424
H-13 In compound operation of work equipment, speed of part loaded more is low 424
H-14 Machine deviates during travel 425
H-15 Travel speed or travel power is low (while work equipment is normal) 427
H-16 Machine is not steered well or steering power is low 428
H-17 Travel speed does not change 429
H-18 Travel motor does not work 430
H-19 Speed or power of swing is low 432
H-20 Machine does not swing 434
H-21 Swing acceleration performance is low 436
H-22 Machine overruns when it stops swinging 438
H-23 Large shock is made when machine stops swinging 439
H-24 When upper structure stops swinging, it makes large sound 439
H-25 Hydraulic drift of swing is large 440
H-26 Speed or power of blade is low 441
H-27 Blade does not move 442
H-28 Hydraulic drift of blade is large 443
Troubleshooting of engine (S-mode) 445
Method of using troubleshooting charts 445
S-1 Starting performance is poor 448
S-2 Engine does not start 449
S-3 Engine does not pick up smoothly 452
S-4 Engine stops during operations 453
S-5 Engine does not rotate smoothly 454
S-6 Engine lacks output (or lacks power) 455
S-7 Exhaust smoke is black (incomplete combustion) 456
S-8 Oil consumption is excessive (or exhaust smoke is blue) 457
S-9 Oil becomes contaminated quickly 458
S-10 Fuel consumption is excessive 459
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 460
S-12 Oil pressure drops 461
S-13 Oil level rises (Entry of coolant/fuel) 462
S-14 Coolant temperature becomes too high (overheating) 463
S-15 Abnormal noise is made 464
S-16 Vibration is excessive 465
50 Disassembly and assembly 467
General information on disassembly and assembly 469
How to read this manual 469
Coating materials list 471
Special tool list 474
Sketches of special tools 477
Engine and cooling system 478
Removal and installation of fuel injection pump assembly 478
Removal and installation of radiator assembly 480
Removal and installation of hydraulic oil cooler assembly 482
Removal and installation of engine and hydraulic pump assembly 486
Power train 491
Removal and installation of swing motor and swing machinery assembly 491
Disassembly and assembly of swing motor and swing machinery assembly 492
Removal and installation of swing circle assembly 497
Undercarriage and frame 498
Removal and installation of track shoe assembly 498
Disassembly and assembly of idler assembly 499
Disassembly and assembly of recoil spring assembly 501
Disassembly and assembly of track roller assembly 504
Disassembly and assembly of carrier roller assembly 505
Removal and installation of revolving frame assembly 506
Hydraulic system 508
Removal and installation of center swivel joint assembly 508
Disassembly and assembly of center swivel joint assembly 510
Removal and installation of work equipment pump assembly 512
Disassembly and assembly of control valve assembly 514
Disassembly and assembly of hydraulic cylinder assembly 515
Work equipment 520
Removal and installation of work equipment assembly 520
Cab and its attachments 522
Removal and installation of operator’s cab glass (stuck glass) 522
Removal and installation of front window assembly 531
Removal and installation of floor frame assembly (Canopy specification) 532
Removal and installation of operator cab and floor frame assembly (Operator cab specification) 535
Electrical system 538
Removal and installation of air conditioner unit assembly (If equipped) 538
Removal and installation of KOMTRAX terminal 541
90 Diagrams and drawings 543
Hydraulic diagrams and drawings 545
Symbols used in hydraulic circuit diagrams 545
Hydraulic circuit diagram 547
Electrical diagrams and drawings 549
Symbols used in electric circuit diagrams 549
Electrical circuit diagram 553
Connector list and stereogram 556
Index 557

S.V 12/12/24