This Complete Service Repair Workshop Manual PDF Download for the PC25-1, PC30-7, PC40-7, PC45-1 Komatsu Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PC25-1 – S/N: 1001 and up
Komatsu PC30-7 – S/N: 18001 and up
Komatsu PC40-7 – S/N: 18001 and up
Komatsu PC45-1 – S/N: 1001 and up
TABLE OF CONTENTS :
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM020S0707
Total Pages : 387
This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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CONTENTS
SAFETY
SAFETY NOTICE
FOREWARD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
WEIGHT TABLE
WEIGHT TABLE
LIST OF LUBRICANT AND WATER
10 STRUCTURE AND FUNCTION
POWER TRAIN
SWING CIRCLE
SWING MACHINERY
TRACK FRAME AND RECOIL SPRING
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK AND FUEL TANK
HYDRAULIC PUMP
CONTROL PUMP
7 – SPOOL CONTROL VALVE
2 – SPOOL CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
HYDRAULIC CYLINDER
VALVE CONTROL
PPC VALVE
SOLENOID VALVE
WORK EQUIPMENT
HYDRAULIC BREAKER
ELECTRICAL CIRCUIT DIAGRAM
MONITOR SYSTEM
20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TOOL FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
ADJUSTING FUEL CONTROL LEVER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING CONTROL CIRCUIT PRESSURE
MEASURING OUTPUT PRESSURE OF PPC VALVE
ADJUSTING PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
ADJUSTING BLADE CONTROL LEVER
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
BLEEDING AIR FROM HYDRAULIC CIRCUIT
RELEASING REMAINING FROM HYDRAULIC CIRCUIT
TESTING HYDRAULIC BREAKER GAS PRESSURE
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
POSITION OF CONNECTORS FOR TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
E-1 THE ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF
E-2 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELEASED
E-3 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED
E-4 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS DEPRESSED
E-5 TRAVEL SPEED INCREASES EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS NOT DEPRESSED
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW
a) NONE OF WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS SLOW
b) ONLY TRAVEL IS NORMAL, OR DROP IN SPEED IS COMPARATIVELY SMALL
H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER
H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER
H-8 EXCESSIVE HYDRAULIC DRIFT
H-9 EXCESSIVE TIME LAG
H-10 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE
a) DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND REVERSE
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE
H-11 EXCESSIVE DEVIATION WHEN STARTING (PC30, 40)
H-12 TRAVEL LACKS POWER (OR SPEED IS SLOW)
H-13 TRAVEL SPEED DOES NOT SWITCH
H-14 MACHINE DOES NOT MOVE (ONE SIDE ONLY)
H-15 TRAVEL LEVER IS HEAVY
H-16 DOES NOT SWING
H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING
H-22 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)
M-1 MONITOR PANEL DOES NOT WORK
M-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON, OR ALL LAMPS STAY
M-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)
M-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)
M-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING
M-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)
M-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)
M-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING
M-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY
a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE
b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY. ENTERS RED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING
M-10 ABNORMALITY IN FUEL GAUGE DISPLAY
a) ALL SEGMENTS OF FUEL GAUGE GO OUT
b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN
c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED
M-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND
M-12 ABNORMALITY IN SERVICE METER DISPLAY
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING
b) SERVICE METER PILOT LAMP DOES NOT FLASH
M-13 NIGHT LIGHTING DOES NOT LIGHT UP
a) WHEN LAMP SWITCH IS AT POSITION 1 OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP
b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP IS NOT BLOWN BEFORE STARTING TROUBLESHOOTING
M-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)
TROUBLESHOOTING OF HYDRAULIC BREAKER
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
WEIGHT TABLE
TIGHTENING TORQUES AND STANDARD VALUES TABLE
LUBRICANT AND COOLANT TABLE
ENGINE, HYDRAULIC PUMP ASSEMBLY
REMOVAL
INSTALLATION
HYDRAULIC PUMP ASSEMBLY
HYDRAULIC PUMP ASSEMBLY (PC30-7)
DISASSEMBLY
ASSEMBLY
HYDRAULIC PUMP ASSEMBLY (PC45-1)
DISASSEMBLY
ASSEMBLY
GEAR PUMP ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR ASSEMBLY
TRAVEL MOTOR ASSEMBLY (PC25-1, PC30-7, PC40-7)
DISASSEMBLY
ASSEMBLY
TRAVEL MOTOR ASSEMBLY (PC45-1)
DISASSEMBLY
ASSEMBLY
SWING MOTOR ASSEMBLY
DISASSEMBLY
ASSEMBLY
SWING MACHINERY ASSEMBLY
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME ASSEMBLY
REMOVAL AND INSTALLATION
RECOIL SPRING ASSEMBLY
DISASSEMBLY
ASSEMBLY
2 SPOOL CONTROL VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
7 SPOOL CONTROL VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
PPC VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT ASSEMBLY
REMOVAL AND INSTALLATION
BUCKET ASSEMBLY
REMOVAL AND INSTALLATION
HYDRAULIC BREAKER ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC BREAKER BUSHING
REMOVAL
CHISEL
REMOVAL AND INSTALLATION
40 MAINTENANCE STANDARD
SWING CIRCLE
SWING MACHINERY
SPROCKET
TRACK FRAME AND RECOIL FRAME
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
HYDRAULIC PUMP
7 SPOOL CONTROL VALVE
2 SPOOL CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
HYDRAULIC BREAKER
PISTON, CHISEL
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