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komatsu pc30mr manual

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  • COVER

  • CONTENTS

  • 01 GENERAL

    • SPECIFICATION DIMENSION DRAWING

    • WORKING RANGE DRAWING

    • SPECIFICATIONS

    • WEIGHT TABLE

    • LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS

  • 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

    • PTO

    • COOLING SYSTEM

    • POWER TRAIN

    • SWING CIRCLE

    • SWING MACHINERY

    • TRACK FRAME

    • IDLER CUSHION

    • IDLER

    • TRACK ROLLER

    • CARRIER ROLLER

    • SPROCKET

    • TRACK SHOE

    • HYDRAULIC COMPONENTS LAYOUT DRAWING

    • HYDRAULIC TANK

    • CENTER SWIVEL JOINT

    • TRAVEL MOTOR

    • HYDRAULIC CYLINDER

    • SOLENOID VALVE

    • MULTI-CONTROL VALVE

    • HYDRAULIC PUMP

    • CONTROL VALVE

    • CLSS

    • OPERATION FOR EACH FUNCTION AND VALVE

    • SWING MOTOR

    • PPC VALVE

    • WORK EQUIPMENT

    • DIMENSIONS OF EACH PART OF WORK EQUIPMENT

    • FLOOR

    • AIR CONDITIONER

    • ENGINE CONTROL

    • ELECTRIC CONTROL SYSTEM

    • COMPONENT PARTS OF SYSTEM

    • MONITOR SYSTEM

    • MONITOR PANEL

    • SENSORS

  • 20 TESTING AND ADJUSTING

    • STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

    • STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

    • TESTING AND ADJUSTING

      • LIST OF TESTING,ADJUSTING, AND TROUBLESHOOTING TOOLS

      • MEASURING ENGINE SPEED

      • MEASUREMENT OF EXHAUST GAS COLOR

      • ADJUSTING VALVE CLEARANCE

      • MEASURING COMPRESSION PRESSURE

      • MEASURING ENGINE OIL PRESSURE

      • TESTING AND ADJUSTING FUEL INJECTION TIMING

      • TESTING AND ADJUSTING ALTERNATOR BELT TENSION

      • TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION

      • ADJUSTING FUEL CONTROL LEVER

      • TESTING AND ADJUSTING TRACK SHOE TENSION

      • MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

      • MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING,AND BLADE CIRCUITS

      • MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE

      • ADJUSTING PC VALVE

      • MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE)

      • MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

      • MEASURING SOLENOID VALVE OUTPUT PRESSURE

      • MEASURING PPC VALVE OUTPUT PRESSURE

      • ADJUSTING PPC VALVE

      • MEASURING SWING HOLDING BRAKE RELEASE PRESSURE

      • TESTING AND ADJUSTING TRAVEL DEVIATION

      • MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER

      • BLEEDING AIR FROM EACH PART

      • RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

      • RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK

      • PRESSURIZING HYDRAULIC TANK

      • HOW TO OPEN AND CLOSE (TILT) FLOOR

      • INSPECTION PROCEDURES FOR DIODE

    • TROUBLESHOOTING

      • POINTS TO REMEMBER WHEN TROUBLESHOOTING

      • SEQUENCE OF EVENTS IN TROUBLESHOOTING

      • POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

      • CHECKS BEFORE TROUBLESHOOTING

      • CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING

      • TYPES AND LOCATIONS OF CONNECTORS

      • CONNECTOR ARRANGEMENT DIAGRAM

      • CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

      • T-ADAPTER-BOXES AND T-ADAPTER TABLE

      • TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)

        • BEFORE STARTING E-MODE TROUBLESHOOTING

        • INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

        • E-1 ENGINE DOES NOT START

        • E-2 ENGINE DOES NOT STOP

        • E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES

        • E-4 WINDSHIELD WIPER DOES NOT OPERATE

        • E-5 WINDSHIELD WASHER DOES NOT OPERATE

        • E-6 TRAVEL ALARM DOES NOT SOUND

        • E-7 DEFECTIVE AIR CONDITIONER

      • TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)

        • INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

        • H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL,SWING,AND BLADE IS LOW

        • H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS

        • H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK

        • H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP

        • H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW

        • H-6 SPEED OR POWER OF BOOM IS LOW

        • H-7 SPEED OR POWER OF ARM IS LOW

        • H-8 SPEED OR POWER OF BUCKET IS LOW

        • H-9 SPEED OR POWER OF BOOM SWING IS LOW

        • H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY

        • H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE

        • H-12 TIME LAG OF WORK EQUIPMENT IS LARGE

        • H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW

        • H-14 MACHINE DEVIATES DURING TRAVEL

        • H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL)

        • H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW

        • H-17 TRAVEL SPEED DOES NOT CHANGE

        • H-18 TRAVEL MOTOR DOES NOT WORK

        • H-19 SPEED OR POWER OF SWING IS LOW

        • H-20 MACHINE DOES NOT SWING

        • H-21 SWING ACCELERATION PERFORMANCE IS LOW

        • H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING

        • H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING

        • H-24 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING,IT MAKES LARGE SOUND

        • H-25 HYDRAULIC DRIFT OF SWING IS LARGE

        • H-26 SPEED OR POWER OF BLADE IS LOW

        • H-27 BLADE DOES NOT MOVE

        • H-28 HYDRAULIC DRIFT OF BLADE IS LARGE

      • TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE)

        • BEFORE STARTING M-MODE TROUBLESHOOTING

        • INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

        • SYSTEM DIAGRAM RELATED TO MONITOR PANEL

        • M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE

        • M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE

        • M-3 ALARM BUZZER IS ABNORMAL

        • M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON

        • M-5 CHARGE LEVEL CAUTION IS TURNED ON

        • M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT

        • M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL

        • M-8 FUEL LEVEL GAUGE IS ABNORMAL

        • M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING

        • M-10 2ND TRAVEL SPEED IS NOT SELECTED

        • M-11 WORKING LAMP DOES NOT LIGHT UP

      • TROUBLESHOOTING OF ENGINE (S-MODE)

        • METHOD OF USING TROUBLESHOOTING CHARTS

        • S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)

        • S-2 ENGINE DOES NOT START

        • S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)

        • S-4 ENGINE STOPS DURING OPERATIONS

        • S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)

        • S-6 ENGINE LACKS OUTPUT OR LACKS POWER

        • S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

        • S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE

        • S-9 OIL BECOMES CONTAMINATED QUICKLY

        • S-10 FUEL CONSUMPTION IS EXCESSIVE

        • S-11 OIL IS IN COOLANT, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN

        • S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)

        • S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)

        • S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)

        • S-15 ABNORMAL NOISE IS MADE

        • S-16 VIBRATION IS EXCESSIVE

  • 30 DISASSEMBLY AND ASSEMBLY

    • HOW TO READ THIS MANUAL

    • PRECAUTIONS WHEN PERFORMING OPERATION

    • SPECIAL TOOL LIST

    • SKETCHES OF SPECIAL TOOLS

    • REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

    • REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY

    • REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY

    • REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY

    • REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY

    • REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY

    • REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY

    • REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY

    • REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY

    • REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY

    • DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY

    • REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY

    • REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)

    • REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY

  • 90 OTHERS

    • HYDRAULIC CIRCUIT DIAGRAM PC27MR-2

    • HYDRAULIC CIRCUIT DIAGRAM PC30MR-2

    • HYDRAULIC CIRCUIT DIAGRAM PC35MR-2

    • HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2

    • HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2 (ADDITIONAL ATTACHMENT CIRCUIT)

    • ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (1/2)

    • ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (2/2)

    • ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (1/2)

    • ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (2/2)

    • ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (1/2)

    • ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (2/2)

Nội dung

tài liệu bổ ích cho những ai đang cần để sửa chữa máy xúc đào komatsu pc 30mr..tài liệu bao gồm tất cả hệ thống thủy lực rất chi tiết dễ đọc và dễ hiểu..................................................................………….

SEBM032411 MACHINE MODEL SERIAL NUMBER PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 15001 and up 20001 and up 5001 and up 8001 and up 5001 and up • This shop manual may contain attachments and optional equipment that are not available in your area Please consult your local Komatsu distributor for those items you may require Materials and specifications are subject to change without notice • PC27MR-2 mount the 3D82AE-5M engine PC30MR-2 mount the 3D84E-5N engine PC35MR-2 mount the S3D84E-5PBA and 3D88E-5P engine PC40, 50MR-2 mounts the 4D88E-5X engine For details of the engine, see the 68E-88E Series Engine Shop Manual © 2007 All Rights Reserved Printed in Japan 04-07(02) 00-1 (11) CONTENTS No of page 01 GENERAL 01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 10-1 20 TESTING AND ADJUSTING .20-1 30 DISASSEMBLY AND ASSEMBLY 30-1 90 OTHERS 90-1 00-2 (2) PC30 – 50MR-2 The affected pages are indicated by the use of the following marks It is requested that necessary actions be taken to these pages according to the table below Mark Indication Action required Q Page to be newly added Add q Page to be replaced Replace ( ) Page to be deleted Discard Pages having no marks are those previously revised or made aditions LIST OF REVISED PAGES Mark Page Revision Mark number q 00-1 00-2 q 00-2-1 q 00-2-2 q 00-2-3 (11) (2) (11) (11) (11) q 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22 q q q q q q q 01-1 01-2 01-3 01-3-1 01-3-2 01-4 01-4-1 01-4-2 01-4-4 01-5 01-6 01-7 01-8 01-9 01-9-2 PC30 – 50MR-2 q q q q q q q Q Q Q Q (8) (11) (11) (11) (8) (11) (9) (3) (11) (9) (1) (11) (9) (1) (11) Page 01-9-3 01-9-4 01-10 01-11 01-12 01-13 01-14 01-15 01-16 01-17 01-18 01-19 01-20 01-21 01-22 01-23 01-24 01-25 10-1 10-2 10-3 10-3-2 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-12-2 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 Revision Mark number (9) (8) (11) (9) (1) (11) (9) (1) (11) (11) (11) (11) (11) (11) (11) (11) (11) (11) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) Page 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-33 10-33-2 10-34 10-35 10-36 10-37 10-38 10-39 10-40 10-41 10-42 10-43 10-44 10-44-1 10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-52 10-53 10-54 10-55 10-56 10-57 10-58 10-59 10-60 Revision Mark number (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (1) Page 10-61 10-61-1 10-61-2 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-70-1 10-70-2 10-70-3 10-70-4 10-70-5 10-70-6 10-70-7 10-70-8 10-70-9 10-70-10 10-70-11 10-70-12 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-79-1 10-79-2 10-80 10-81 10-82 10-83 10-84 10-85 Revision Mark number (1) (1) (1) (3) (3) (1) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (1) (3) (1) (3) (3) (1) (1) (1) Revision number Page 10-86 10-87 10-88 10-89 10-90 10-90-2 10-90-3 10-91 10-92 10-93 10-94 10-94-1 10-94-2 10-95 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-103 10-104 10-105 10-106 10-108 10-109 10-110 10-110-2 10-111 10-112 10-113 10-114 10-115 10-116 10-117 10-118 10-119 10-120 10-121 10-122 (3) (1) (3) (3) (3) (3) (3) (1) (1) (1) (1) (1) (3) (3) (3) (3) (3) (3) (3) (3) (3) 00-2-1 (11) Mark Page 10-123 10-124 10-126 10-127 10-128 10-129 10-130 10-131 10-132 10-133 10-134 10-136 10-136-2 10-137 10-138 10-139 10-140 10-141 10-142 10-143 10-143-1 10-143-2 10-144 10-145 10-146 10-147 10-148 10-149 10-150 10-151 10-152 10-153 10-154 10-155 10-156 10-156-1 10-157 10-158 10-159 10-160 10-161 10-162 10-162-2 10-163 10-164 q 10-165 q 10-165-1 10-166 10-167 10-168 10-169 00-2-2 (11) Revision number Mark (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (9) (3) (3) (3) (3) (3) (3) (3) (3) (11) (11) (10) (10) (3) Page Revision number Mark 10-170 10-171 10-172 10-173 10-174 10-175 10-176 10-177 10-178 10-179 10-180 10-181 10-182 (10) 20-1 20-2 20-3 20-4 20-4-1 20-4-2 20-5 20-5-1 20-5-2 20-5-3 20-5-4 20-5-6 20-6 20-7 20-8 20-9 20-10 20-11 20-12 20-13 20-14 20-15 20-16 20-17 20-18 20-19 20-20 20-21 20-22 20-23 20-24 20-25 20-101 20-102 20-103 20-104 20-105 (1) (9) (9) (9) (9) (9) (9) (9) (4) (4) (4) (9) (9) (4) (4) (4) (9) (9) (4) (4) (4) (9) (9) (7) (7) (4) (1) (1) (1) (4) (4) (4) (6) (9) (6) (9) (6) (10) (3) (3) (3) (10) (3) q q q q Page 20-106 20-107 20-109 20-110 20-111 20-112 20-112-1 20-113 20-113-1 20-114 20-116 20-116-1 20-117 20-118 20-119 20-120 20-121 20-122 20-123 20-124 20-125 20-126 20-127 20-128 20-129 20-130 20-131 20-132 20-133 20-134 20-134-1 20-135 20-136 20-137 20-138 20-139 20-140 20-141 20-142 20-143 20-144 20-145 20-146 20-146-1 20-146-2 20-146-3 20-146-4 20-147 20-201 20-202 20-203 Revision number Mark (6) (6) (6) (9) (4) (4) (4) (6) (4) (9) (9) (4) (6) (4) (6) (4) (4) (1) (6) (4) (9) (4) (4) (6) (6) (6) (6) (6) (6) (4) (4) (1) (4) (6) (9) (1) (4) (1) (1) (9) (9) (9) (9) (11) (11) (11) (11) (1) (1) (1) (1) Page 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20-211 20-212 20-213 20-214 20-215 q 20-216 20-217 20-218 q 20-219 20-220 20-221 20-222 20-223 20-224 20-225 20-226 20-227 20-228 20-229 20-230 20-231 20-232 20-233 20-234 20-235 20-236 20-237 20-238 20-239 20-240 20-241 20-242 20-243 20-244 20-245 20-246 20-247 20-248 20-249 20-250 20-251 20-251-1 20-252 20-253 Revision number Mark (1) (1) (1) (1) (1) (1) (1) (1) (1) (9) (1) (4) (11) (4) (4) (11) (1) (4) (4) (1) (4) (1) (1) (1) (1) (1) (1) (1) (1) (4) (1) (1) (1) (1) (1) (6) (1) (1) (1) (1) (1) (1) (1) (4) (1) (1) (1) (1) (6) (1) (1) q q q q q q q q q Page 20-254 20-301 20-302 20-303 20-304 20-305 20-306 20-307 20-308 20-309 20-310 20-311 20-312 20-313 20-314 20-315 20-316 20-317 20-318 20-319 20-320 20-321 20-322 20-323 20-324 20-325 20-326 20-327 20-328 20-329 20-330 20-331 20-332 20-333 20-334 20-335 20-336 20-337 20-401 20-402 20-403 20-404 20-405 20-406 20-407 20-408 20-409 20-410 20-411 20-412 20-413 Revision number (6) (4) (4) (4) (11) (1) (11) (11) (4) (11) (4) (1) (4) (11) (1) (11) (11) (11) (1) (11) (1) (4) (4) (4) (1) (1) (1) (1) (1) (1) (4) (4) (4) (4) (4) (4) (4) (4) (4) (1) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) PC30 – 50MR-2 Mark Page Revision number Mark 20-414 20-415 20-416 20-417 20-418 20-419 20-420 20-421 20-422 20-423 20-424 20-425 20-426 20-427 20-428 20-429 20-430 20-431 20-432 20-433 20-434 20-435 20-436 20-501 20-502 20-503 20-504 20-505 20-506 20-507 20-508 20-509 20-510 20-511 20-512 20-513 20-514 20-515 20-516 20-517 20-518 20-519 20-520 20-521 20-522 20-523 20-524 20-525 20-526 20-527 20-528 PC30 – 50MR-2 (4) (4) (4) (4) (1) (4) (4) (4) (4) (4) (1) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (1) (4) (4) (4) (1) (9) (1) (9) (1) (1) (1) (4) (4) (1) (1) (4) (1) (4) (1) (4) (1) (4) (4) (1) (4) (4) (1) (1) Page 20-529 20-530 20-531 20-532 20-533 20-534 20-535 20-536 20-601 20-602 20-603 20-604 20-605 20-606 20-607 20-608 20-609 20-610 20-611 20-612 20-613 20-614 20-615 20-616 20-617 20-618 20-619 20-620 20-621 20-622 20-623 20-624 30-1 30-2 30-3 30-4 q 30-5 Q 30-5-1 30-6 30-7 30-8 30-9 30-10 30-10-1 30-10-2 30-11 30-12 30-13 30-15 30-16 Revision number Mark (1) (4) (4) (1) (4) (1) (1) (1) (9) (1) (1) (1) (1) (9) (1) (1) (1) (1) (9) (9) (9) (9) (1) (9) (1) (9) (9) (9) (9) (9) (1) (9) (5) (2) (2) (9) (11) (11) (5) (5) (6) (6) (5) (10) (10) (9) (6) (9) (9) (6) Page 30-17 30-18 q 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 q 30-41 30-42 30-43 q 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 Revision number Mark (6) (9) (11) (10) (10) (9) (2) (2) (9) (7) (2) (5) (5) (2) (5) (5) (5) (2) (6) (6) (2) (5) (5) (11) (10) (10) (11) (5) (5) (2) (2) (5) (5) (5) (5) (2) (5) (5) (5) (2) (6) (6) (5) (5) (6) (6) (5) (5) (5) (5) (5) Page Revision number Mark 30-69 30-70 30-71 30-72 30-73 (5) (5) (5) (5) (5) 90-1 90-3 90-5 90-7 90-9 90-11 q 90-13 90-15 90-17 90-19 q 90-21 90-23 (6) (6) (6) (6) (6) (6) (11) (6) (10) (6) (11) (6) Page Revision number 00-2-3 (11) SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose To prevent injury to workers, the symbol k is used to mark safety precautions in this manual The cautions accompanying these symbols should always be followed carefully If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual carefully BEFORE operating the machine Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine 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 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, hand shield, cap and other clothes suited for welding work 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 Keep all tools in good condition and learn the correct way to use them 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 Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 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 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 00-3 SAFETY 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 14.When raising heavy components, use a hoist or crane Check that the wire rope, chains and hooks are free from damage Always use lifting equipment which has ample capacity Install the lifting equipment at the correct places Use a hoist or crane and operate slowly to prevent the component from hitting any other part Do not work with any part still raised by the hoist or crane 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides Slowly release the pressure, then slowly loosen the bolts to remove 16.When removing components, be careful not to break or damage the wiring Damaged wiring may cause electrical fires 17.When removing piping, stop the fuel or oil from spilling out If any fuel or oil drips onto the floor, wipe it up immediately Fuel or oil on the floor can cause you to slip, or can even start fires 18.As a general rule, not use gasoline to wash parts In particular, use only the minimum of gasoline when washing electrical parts 00-4 SAFETY NOTICE 19.Be sure to assemble all parts again in their original places Replace any damaged parts with new parts • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated 20.When installing high pressure hoses, make sure that they are not twisted Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits Also, check that connecting parts are correctly installed 21.When assembling or installing parts, always use the specified tightening torques When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly 22.When aligning two holes, never insert your fingers or hand Be careful not to get your fingers caught in a hole 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements 24.Take care when removing or installing the tracks of track-type machines When removing the track, the track separates suddenly, so never let anyone stand at either end of the track FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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 In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards 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" with "Causes" are also included in this section DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts The contents of this section may be described in STRUCTURE AND FUNCTION OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams In addition, this section may give the specifications of attachments and options together NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice Use the specifications given in the book with the latest date 00-5 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL REVISED EDITION MARK VOLUMES Shop manuals are issued as a guide to carrying out repairs They are divided as follows: When a manual is revised, an edition mark ((1)(2)(3) ) is recorded on the bottom of the pages Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models REVISIONS } These various volumes are designed to avoid duplicating the same information Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors Get the most up-todate information before you start any work FILING METHOD See the page number on the bottom of the page File the pages in correct order Following examples show how to read the page number Example (Chassis volume): 10 - Item number (10 Structure and Function) Consecutive page number for each item Example (Engine volume): 12 - Unit number (1 Engine) Item number (2 Testing and Adjusting) Consecutive page number for each item Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number File as in the example Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5 00-6 Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols Symbol Item Remarks k Safety Special safety precautions are necessary when performing the work Caution Special technical precautions or other precautions for preserving standards are necessary when performing the work Weight Weight of parts of systems Caution necessary when selecting hoisting wire, or when working posture is important, etc Tightening torque Places that require special attention for the tightening torque during assembly Coat Places to be coated with adhesives and lubricants, etc Oil, water Places where oil, water or fuel must be added, and the capacity Drain Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained a DISASSEMBLY AND ASSEMBLY a Apply adhesive (20) higher than bothsided adhesive tape (10) a Apply the adhesive evenly Install the sliding sash assembly 1) Clean the sash sticking face on the cab side and the sash flange sticking face with cleaning solvent according to steps and above 2) Apply the primer according step above a Use the right primer for the right sash a When sash has metallic shine: Primer: SUNSTAR PRIMER GP-402 for sash a When sash is painted black and does not have metallic shine: Primer: SUNSTAR PRIMER 435-95 for painted surface a Do not apply the primer to the following water draining area 3) Install the both-sided adhesive tape according to step above a To drain water from around the sash, avoid installing both-sided adhesive tape (10) of the bottom side to the area of dimension (v) • Dimension (u): 150 mm, (v): 50 mm OPERATOR'S CAB GLASS 5) Install sliding sash assembly (1) to operator's cab (13) a Press the sash assembly firmly to eliminate clearance from its periphery a If the adhesive is projected, wipe it off immediately before it is set 6) After installing the sliding sash assembly, fix it with bands, etc for about 10 hours Install the window glass and clear plate 1) Clean the glass sticking face on the cab side and the sticking face of the glass with cleaning solvent according to steps and above 2) Apply the primer according step above 3) Install the both-sided adhesive tape according to step above 4) Apply the adhesive according to step above 5) Stick the glass to the cab a Since the window glass cannot be removed and stuck again, stick it very carefully a Stick the glass within minutes after applying the adhesive 6) After sticking the window glass, press all around it until it is stuck to the both-sided adhesive tape a Press the corners of the window glass firmly, in particular a You can perform this work efficiently by pulling the window glass from inside of the operator's cab with lifter X2 4) Apply the adhesive according to step above a Do not apply the adhesive to the above water draining area PC30 – 50MR-2 30-71 (5) DISASSEMBLY AND ASSEMBLY (The figure shows the operator's cab of PC200-7.) a Make a clearance of the following dimension in each corner joint of the rear glass and fix the joint with caulking material (21) • Dimension (w): mm Caulking material: GE TOSHIBA SILICONE TOS SEAL 381 OPERATOR'S CAB GLASS a When caulking, neatly arrange the form of the adhesive at the right and left ends with a rubber spatula Adhesive: Sikaflex 256HV manufactured by Sika Japan a Apply caulking material all around the glass to fill part (x) between the glass and center trim seal 7) After sticking the glass, fix it with bands, etc for about 10 hours Protect the stuck window glass 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%) 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually a After installing front window glass (8), install the center trim seal to its bottom 30-72 (5) PC30 – 50MR-2 FRONT WINDOW DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY k Lower the work equipment to the ground and stop the engine a To replace the front window glass, the front window assembly must be removed from the operator's cab The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below REMOVAL Lower the front window assembly Holding the handle, release the latch and remove the front window assembly (6) Remove wiper motor (1) and wiper blade (2) a Remove the coiled cable for the wiper from the sash and secure it in the operator's cab INSTALLATION Remove rollers (3) (right and left) from the bottom of the sash • Carry out installation in the reverse order to removal Remove bolt (4) and separate pull-up link (5) from the sash and set it up toward the ceiling PC30 – 50MR-2 30-73 (5) 90 OTHERS HYDRAULIC CIRCUIT DIAGRAM PC27MR-2 90- PC30MR-2 90- PC35MR-2 90- PC40MR, 50MR-2 90- PC40MR, 50MR-2 (Additional attachment circuit) .90-11 ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (1/2) 90-13 PC27MR, 30MR-2 (2/2) 90-15 PC35MR-2 (1/2) 90-17 PC35MR-2 (2/2) 90-19 PC40MR, 50MR-2 (1/2) 90-21 PC40MR, 50MR-2 (2/2) 90-23 PC30 – 50MR-2 90-1 (6) HYDRAULIC CIRCUIT DIAGRAM PC27MR-2 PC30 – 50MR-2 90-3 (6) HYDRAULIC CIRCUIT DIAGRAM PC30MR-2 PC30 – 50MR-2 90-5 (6) HYDRAULIC CIRCUIT DIAGRAM PC35MR-2 PC30 – 50MR-2 90-7 (6) HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2 *1: Shows PC50MR-2 PC30 – 50MR-2 90-9 (6) HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2 (Additional attachment circuit) PC30 – 50MR-2 90-11 (6) ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (1/2) PC30 – 50MR-2 90-13 (11) ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (2/2) PC30 – 50MR-2 90-15 (6) ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (1/2) PC30 – 50MR-2 90-17 (10) ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (2/2) PC30 – 50MR-2 90-19 (6) ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (1/2) PC30 – 50MR-2 90-21 (11) ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (2/2) PC30 – 50MR-2 90-23 (6) ... SHOP MANUAL HOW TO READ THE SHOP MANUAL REVISED EDITION MARK VOLUMES Shop manuals are issued as a guide to carrying out repairs They are divided as follows: When a manual is revised, an edition... in this shop manual are subject to change at any time and without any advance notice Use the specifications given in the book with the latest date 00-5 FOREWORD HOW TO READ THE SHOP MANUAL HOW... 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

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