Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 Excavator Shop Manual PDF

Description

Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 Hydraulic Excavator Shop Manual SEBM032409 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 Hydraulic Excavator Shop Manual SEBM032409 – PDF DOWNLOAD 

Language : English
Pages : 630
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 Hydraulic Excavator Shop Manual SEBM032409 – PDF DOWNLOAD 

SERIAL NUMBERS

PC27MR-2 15001 and up
PC30MR-2 20001 and up
PC35MR-2 5001 and up
PC40MR-2 8001 and up
PC50MR-2 5001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 7
SAFETY NOTICE 7
FOREWORD 9
GENERAL 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 12
COATING MATERIALS 14
STANDARD TIGHTENING TORQUE 16
ELECTRIC WIRE CODE 19
CONVERSION TABLE 20
UNITS 26
01 GENERAL 27
SPECIFICATION DIMENSION DRAWING 28
WORKING RANGE DRAWING 30
SPECIFICATIONS 32
WEIGHT TABLE 52
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 56
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 59
PTO 60
COOLING SYSTEM 61
POWER TRAIN 64
SWING CIRCLE 66
SWING MACHINERY 67
TRACK FRAME 71
IDLER CUSHION 73
IDLER 74
TRACK ROLLER 76
CARRIER ROLLER 78
SPROCKET 79
TRACK SHOE 80
HYDRAULIC COMPONENTS LAYOUT DRAWING 88
HYDRAULIC TANK 90
CENTER SWIVEL JOINT 93
TRAVEL MOTOR 96
HYDRAULIC CYLINDER 104
SOLENOID VALVE 111
MULTI-CONTROL VALVE 115
HYDRAULIC PUMP 116
CONTROL VALVE 134
CLSS 171
OPERATION FOR EACH FUNCTION AND VALVE 174
SWING MOTOR 219
PPC VALVE 231
WORK EQUIPMENT 239
DIMENSIONS OF EACH PART OF WORK EQUIPMENT 242
FLOOR 253
AIR CONDITIONER 254
ENGINE CONTROL 255
ELECTRIC CONTROL SYSTEM 257
COMPONENT PARTS OF SYSTEM 265
MONITOR SYSTEM 266
MONITOR PANEL 267
SENSORS 269
20 TESTING AND ADJUSTING 271
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 272
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 277
TESTING AND ADJUSTING 303
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS 304
MEASURING ENGINE SPEED 306
MEASUREMENT OF EXHAUST GAS COLOR 307
ADJUSTING VALVE CLEARANCE 308
MEASURING COMPRESSION PRESSURE 310
MEASURING ENGINE OIL PRESSURE 311
TESTING AND ADJUSTING FUEL INJECTION TIMING 312
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 315
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 316
ADJUSTING FUEL CONTROL LEVER 317
TESTING AND ADJUSTING TRACK SHOE TENSION 318
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 319
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING, AND BLADE CIRCUITS 320
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE 326
ADJUSTING PC VALVE 330
MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE) 331
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 332
MEASURING SOLENOID VALVE OUTPUT PRESSURE 334
MEASURING PPC VALVE OUTPUT PRESSURE 336
ADJUSTING PPC VALVE 340
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE 341
TESTING AND ADJUSTING TRAVEL DEVIATION 342
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER 344
BLEEDING AIR FROM EACH PART 346
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 349
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK 350
PRESSURIZING HYDRAULIC TANK 0
HOW TO OPEN AND CLOSE (TILT) FLOOR 351
INSPECTION PROCEDURES FOR DIODE 355
TROUBLESHOOTING 357
POINTS TO REMEMBER WHEN TROUBLESHOOTING 358
SEQUENCE OF EVENTS IN TROUBLESHOOTING 359
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 360
CHECKS BEFORE TROUBLESHOOTING 368
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 369
TYPES AND LOCATIONS OF CONNECTORS 372
CONNECTOR ARRANGEMENT DIAGRAM 378
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 386
T-ADAPTER BOXES AND T-ADAPTER TABLE 409
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 412
BEFORE STARTING E-MODE TROUBLESHOOTING 413
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 414
E-1 ENGINE DOES NOT START 415
E-2 ENGINE DOES NOT STOP 423
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES 427
E-4 WINDSHIELD WIPER DOES NOT OPERATE 431
E-5 WINDSHIELD WASHER DOES NOT OPERATE 433
E-6 TRAVEL ALARM DOES NOT SOUND 437
E-7 DEFECTIVE AIR CONDITIONER 441
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 450
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 451
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW 452
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS 456
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK 457
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP 461
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW 461
H-6 SPEED OR POWER OF BOOM IS LOW 462
H-7 SPEED OR POWER OF ARM IS LOW 463
H-8 SPEED OR POWER OF BUCKET IS LOW 464
H-9 SPEED OR POWER OF BOOM SWING IS LOW 465
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY 465
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE 466
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE 467
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW 467
H-14 MACHINE DEVIATES DURING TRAVEL 468
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL) 470
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 471
H-17 TRAVEL SPEED DOES NOT CHANGE 472
H-18 TRAVEL MOTOR DOES NOT WORK 473
H-19 SPEED OR POWER OF SWING IS LOW 475
H-20 MACHINE DOES NOT SWING 477
H-21 SWING ACCELERATION PERFORMANCE IS LOW 479
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING 481
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING 482
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND 482
H-25 HYDRAULIC DRIFT OF SWING IS LARGE 483
H-26 SPEED OR POWER OF BLADE IS LOW 484
H-27 BLADE DOES NOT MOVE 485
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE 485
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE) 486
BEFORE STARTING M-MODE TROUBLESHOOTING 487
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 488
SYSTEM DIAGRAM RELATED TO MONITOR PANEL 489
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE 491
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE 493
M-3 ALARM BUZZER IS ABNORMAL 494
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON 496
M-5 CHARGE LEVEL CAUTION IS TURNED ON 497
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT 501
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL 503
M-8 FUEL LEVEL GAUGE IS ABNORMAL 508
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING 512
M-10 2ND TRAVEL SPEED IS NOT SELECTED 514
M-11 WORKING LAMP DOES NOT LIGHT UP 519
TROUBLESHOOTING OF ENGINE (S-MODE) 522
METHOD OF USING TROUBLESHOOTING CHARTS 523
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 527
S-2 ENGINE DOES NOT START 529
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR) 532
S-4 ENGINE STOPS DURING OPERATIONS 533
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 534
S-6 ENGINE LACKS OUTPUT OR LACKS POWER 535
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 536
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE 537
S-9 OIL BECOMES CONTAMINATED QUICKLY 538
S-10 FUEL CONSUMPTION IS EXCESSIVE 539
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 540
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 541
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 542
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 543
S-15 ABNORMAL NOISE IS MADE 544
S-16 VIBRATION IS EXCESSIVE 545
30 DISASSEMBLY AND ASSEMBLY 546
HOW TO READ THIS MANUAL 547
PRECAUTIONS WHEN PERFORMING OPERATION 549
SPECIAL TOOL LIST 551
SKETCHES OF SPECIAL TOOLS 555
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 556
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 558
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY 565
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 572
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 573
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 575
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 578
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 580
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 581
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 584
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 586
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 590
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 591
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 597
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY 599
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY 601
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 602
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 603
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 607
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) 610
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY 618
90 OTHERS 619
HYDRAULIC CIRCUIT DIAGRAM 620
HYDRAULIC CIRCUIT DIAGRAM PC27MR-2 620
HYDRAULIC CIRCUIT DIAGRAM PC30MR-2 621
HYDRAULIC CIRCUIT DIAGRAM PC35MR-2 622
HYDRAULIC CIRCUIT DIAGRAM PC40, 50MR-2 623
HYDRAULIC CIRCUIT DIAGRAM PC40, 50MR-2 (ADDITIONAL ATTACHMENT CIRCUIT) 624
ELECTRICAL CIRCUIT DIAGRAM 625
ELECTRICAL CIRCUIT DIAGRAM PC27, PC30MR-2 (1/2) 625
ELECTRICAL CIRCUIT DIAGRAM PC27, PC30MR-2 (2/2) 626
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (1/2) 627
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (2/2) 628
ELECTRICAL CIRCUIT DIAGRAM PC40, 50MR-2 (1/2) 629
ELECTRICAL CIRCUIT DIAGRAM PC40, 50MR-2 (2/2) 630

DESCRIPTION:

Komatsu PC27MR-2 PC30MR-2 PC35MR-2 PC40MR-2 PC50MR-2 Hydraulic Excavator Shop Manual SEBM032409 – PDF DOWNLOAD 

SERIAL NUMBERS

PC27MR-2 15001 and up
PC30MR-2 20001 and up
PC35MR-2 5001 and up
PC40MR-2 8001 and up
PC50MR-2 5001 and up

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.

S.V 31/12/24