Komatsu PC27MR-2, PC30MR-2, PC35MR-2, PC40MR-2, PC50MR-2 Hydraulic Excavator Service Shop Manual

This Complete Service Repair Workshop Manual PDF Download for the PC27MR-2, PC30MR-2, PC35MR-2, PC40MR-2, PC50MR-2 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 PC27MR-2 – S/N: 15001 and up
Komatsu PC30MR-2 – S/N: 20001 and up
Komatsu PC35MR-2 – S/N: 5001 and up
Komatsu PC40MR-2 – S/N: 8001 and up
Komatsu PC50MR-2 – S/N: 5001 and up

TABLE OF CONTENTS :

– GENERAL
– STRUCTURE, FUNCTION
– MAINTENANCE STANDARD
– TESTING AND ADJUSTING
– DISASSEMBLY AND ASSEMBLY
– OTHERS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM032411
Total Pages : 630

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

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)

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