Komatsu PC30MR-5 PC35MR-5 Compact Hydraulic Excavator Shop Manual SEN06591-09 – PDF DOWNLOAD

Komatsu PC30MR-5 PC35MR-5 Compact Hydraulic Excavator Shop Manual SEN06591-09 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC30MR-5 PC35MR-5 Compact Hydraulic Excavator Shop Manual SEN06591-09 – PDF DOWNLOAD

Language : English
Pages : 1506
Downloadable : Yes
File Type : PDF
Size: 38.8 MB

TABLE OF CONTENTS:

Komatsu PC30MR-5 PC35MR-5 Compact Hydraulic Excavator Shop Manual SEN06591-09 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 15
FOREWORD, SAFETY, BASIC INFORMATION 21
HOW TO READ THE SHOP MANUAL 21
SAFETY NOTICE FOR OPERATION 23
PRECAUTIONS TO PREVENT FIRE 31
ACTIONS IF FIRE OCCURS 33
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 34
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 35
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 38
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 45
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 48
PRACTICAL USE OF KOMTRAX 49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 52
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 54
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 58
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 64
HOW TO READ ELECTRICAL WIRE CODE 65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 69
STANDARD TIGHTENING TORQUE TABLE 72
CONVERSION TABLE 79
01 SPECIFICATIONS 85
CONTENTS 86
ABBREVIATION LIST 87
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
SPECIFICATION DRAWING: PC30MR-5 93
SPECIFICATION DRAWING: PC35MR-5 95
WORKING RANGE DRAWINGS 96
WORKING RANGE DRAWINGS: PC30MR-5 96
WORKING RANGE DRAWINGS: PC35MR-5 97
SPECIFICATIONS 98
SPECIFICATIONS: PC30MR-5 98
SPECIFICATIONS: PC35MR-5 102
WEIGHT TABLE 106
WEIGHT TABLE: PC30MR-5 106
WEIGHT TABLE: PC35MR-5 108
TABLE OF FUEL, COOLANT, AND LUBRICANTS 110
10 STRUCTURE AND FUNCTION 111
CONTENTS 112
ABBREVIATION LIST 114
BOOT-UP SYSTEM 120
LAYOUT DRAWING OF BOOT-UP SYSTEM 120
SYSTEM OPERATING LAMP SYSTEM 121
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 121
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 121
QUICK RELEASE BATTERY TERMINAL (-) 123
FUNCTION OF QUICK RELEASE BATTERY TERMINAL (-) 123
ENGINE SYSTEM 124
LAYOUT DRAWING OF ENGINE SYSTEM 124
ENGINE CONTROL SYSTEM 125
ENGINE CONTROL SYSTEM DIAGRAM 125
FUNCTION OF ENGINE CONTROL SYSTEM 127
AUTO-DECELERATION SYSTEM 133
AUTO-DECELERATION SYSTEM DIAGRAM 133
FUNCTION OF AUTO-DECELERATION SYSTEM 133
OPERATION OF AUTO-DECELERATION SYSTEM 134
OVERHEAT PREVENTION SYSTEM 135
OVERHEAT PREVENTION SYSTEM DIAGRAM 135
FUNCTION OF OVERHEAT PREVENTION SYSTEM 136
AUTOMATIC IDLE STOP SYSTEM 137
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 137
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 137
COMPONENT PARTS OF ENGINE SYSTEM 139
PTO 139
COOLING SYSTEM 140
LAYOUT DRAWING OF COOLING SYSTEM 140
SPECIFICATIONS OF COOLING SYSTEM 141
CONTROL SYSTEM 142
LAYOUT DRAWING OF CONTROL SYSTEM 142
MACHINE MONITOR SYSTEM 143
MACHINE MONITOR SYSTEM DIAGRAM 143
KOMTRAX SYSTEM 144
KOMTRAX SYSTEM DIAGRAM 144
FUNCTION OF KOMTRAX SYSTEM 144
COMPONENT PARTS OF CONTROL SYSTEM 145
MACHINE MONITOR 145
KOMTRAX TERMINAL 153
MACHINE CONTROLLER 155
RESISTOR FOR PC-EPC VALVE 159
FUEL CONTROL DIAL 160
HYDRAULIC SYSTEM 162
LAYOUT DRAWING OF HYDRAULIC SYSTEM 162
CLSS 165
STRUCTURE OF CLSS 165
FUNCTION OF CLSS 166
ENGINE AND PUMP COMBINED CONTROL SYSTEM 168
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 168
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 169
COMPONENT PARTS OF HYDRAULIC SYSTEM 171
HYDRAULIC TANK 171
MAIN PUMP 175
CONTROL VALVE 186
WORK EQUIPMENT SYSTEM 228
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 228
STRUCTURE OF VALVE CONTROL 231
PPC LOCK SYSTEM 233
PPC LOCK SYSTEM DIAGRAM 233
FUNCTION OF PPC LOCK SYSTEM 234
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 235
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 235
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 235
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 236
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 236
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 237
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 238
WORK EQUIPMENT AND SWING PPC VALVE 238
ATTACHMENT PPC VALVE 243
BLADE PPC VALVE 245
BOOM SWING PPC VALVE 247
BIPARTITE SOLENOID VALVE 249
MULTI-CONTROL VALVE 252
PILOT CIRCUIT ACCUMULATOR 253
SWING SYSTEM 254
LAYOUT DRAWING OF SWING SYSTEM 254
COMPONENT PARTS OF SWING SYSTEM 255
SWING MOTOR 255
SWING MACHINERY 260
SWING CIRCLE 262
TRAVEL SYSTEM 263
LAYOUT DRAWING OF TRAVEL SYSTEM 263
TRAVEL CONTROL SYSTEM DIAGRAM 265
FUNCTION OF TRAVEL CONTROL SYSTEM 265
COMPONENT PARTS OF TRAVEL SYSTEM 267
TRAVEL MOTOR 267
TRAVEL PPC VALVE 275
CENTER SWIVEL JOINT 277
UNDERCARRIAGE AND FRAME 278
LAYOUT DRAWING OF UNDERCARRIAGE 278
SPECIFICATIONS OF UNDERCARRIAGE 278
IDLER CUSHION 279
STRUCTURE OF IDLER CUSHION 279
SPECIFICATIONS OF IDLER CUSHION 279
WORK EQUIPMENT 280
STRUCTURE OF WORK EQUIPMENT 280
FUNCTION OF WORK EQUIPMENT 281
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 282
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 282
CAB AND ITS ATTACHMENTS 283
ROPS CAB 283
STRUCTURE OF ROPS CAB 283
FUNCTION OF ROPS CAB 284
TILT TYPE FLOOR 285
STRUCTURE OF TILT TYPE FLOOR 285
FUNCTION OF TILT TYPE FLOOR 285
20 STANDARD VALUE TABLE 287
CONTENTS 288
ABBREVIATION LIST 289
STANDARD VALUE TABLE FOR ENGINE 295
STANDARD VALUE TABLE FOR ENGINE: PC30MR-5 295
STANDARD VALUE TABLE FOR ENGINE: PC35MR-5 297
STANDARD VALUE TABLE FOR MACHINE 299
STANDARD VALUE TABLE FOR MACHINE: PC30MR-5 299
STANDARD VALUE TABLE FOR MACHINE: PC35MR-5 314
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 329
30 TESTING AND ADJUSTING 333
CONTENTS 334
ABBREVIATION LIST 337
RELATED INFORMATION ON TESTING AND ADJUSTING 343
TOOLS FOR TESTING AND ADJUSTING 343
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 347
ENGINE AND COOLING SYSTEM 349
TEST ENGINE SPEED 349
METHOD FOR TESTING ENGINE SPEED 349
TEST EXHAUST GAS COLOR 352
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 352
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 353
TEST AND ADJUST VALVE CLEARANCE 354
METHOD FOR TESTING VALVE CLEARANCE 354
METHOD FOR ADJUSTING VALVE CLEARANCE 355
TEST COMPRESSION PRESSURE 357
METHOD FOR TESTING COMPRESSION PRESSURE 357
TEST ENGINE OIL PRESSURE 360
METHOD FOR TESTING ENGINE OIL PRESSURE 360
TEST AND ADJUST FUEL INJECTION TIMING 362
METHOD FOR TESTING FUEL INJECTION TIMING 362
METHOD FOR ADJUSTING FUEL INJECTION TIMING 364
BLEED AIR FROM FUEL SYSTEM 367
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 367
TEST FUEL CIRCUIT FOR LEAKAGE 368
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 368
TEST AND ADJUST ALTERNATOR BELT TENSION 369
METHOD FOR TESTING ALTERNATOR BELT TENSION 369
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION 369
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 370
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 370
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 370
POWER TRAIN 371
TEST SWING CIRCLE BEARING CLEARANCE 371
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 371
UNDERCARRIAGE AND FRAME 372
TEST AND ADJUST TRACK TENSION 372
METHOD FOR TESTING TRACK TENSION 372
METHOD FOR ADJUSTING TRACK TENSION 372
HYDRAULIC SYSTEM 373
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 373
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 373
METHOD FOR RELEASING REMAINING PRESSURE IN PPC ACCUMULATOR CIRCUIT 373
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 373
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 378
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 378
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 379
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 379
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 390
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 392
METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE 392
METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE 397
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 399
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 399
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 401
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 403
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 403
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 405
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 405
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 407
METHOD FOR ADJUSTING LS VALVE 408
TEST OUTLET PRESSURE OF SOLENOID VALVE 410
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR 410
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL 412
OPERATING CONDITION OF SOLENOID VALVE 412
TEST PPC VALVE OUTLET PRESSURE 414
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR 414
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 417
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 419
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 419
TEST SWING PARKING BRAKE RELEASE PRESSURE 420
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE 420
TEST AND ADJUST TRAVEL DEVIATION 421
METHOD FOR TESTING TRAVEL DEVIATION 421
ADJUST TRAVEL DEVIATION 421
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 424
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 424
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 424
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 425
TEST OIL LEAKAGE 426
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 426
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 427
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 428
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 428
BLEED AIR FROM HYDRAULIC CIRCUIT 430
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 431
PRESSURIZE HYDRAULIC TANK 433
METHOD FOR PRESSURIZING HYDRAULIC TANK 433
CAB AND ITS ATTACHMENTS 434
OPENING AND CLOSING FLOOR UNIT 434
METHOD FOR OPENING FLOOR UNIT 435
METHOD FOR CLOSING FLOOR UNIT 440
ELECTRICAL SYSTEM 444
SET AND OPERATE MACHINE MONITOR 444
OPERATOR MODE 447
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 447
CHECKING FUNCTION OF SERVICE METER 447
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 447
SERVICE MODE 450
METHOD FOR OPERATING SERVICE MODE 450
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 451
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 453
ABNORMALITY RECORD MENU 459
METHOD FOR CONFIRMING MAINTENANCE RECORD 462
METHOD FOR OPERATING MAINTENANCE MODE SETTING 463
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 467
DEFAULT MENU 469
ADJUSTMENT MENU 474
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING 478
KOMTRAX SETTINGS MENU 480
METHOD FOR DISPLAYING SERVICE MESSAGE 482
METHOD FOR STARTING UP KOMTRAX TERMINAL 484
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 489
HANDLE QUICK RELEASE BATTERY TERMINAL (-) 490
TEST DIODES 491
METHOD FOR TESTING DIODE USING DIGITAL TESTER 491
METHOD FOR TESTING DIODE USING ANALOG TESTER 491
Pm CLINIC 492
Pm CLINIC SERVICE 492
Pm CLINIC CHECK SHEET: PC30MR-5 493
Pm CLINIC CHECK SHEET: PC35MR-5 501
40 TROUBLESHOOTING 509
CONTENTS 510
ABBREVIATION LIST 515
RELATED INFORMATION ON TROUBLESHOOTING 521
GENERAL TROUBLESHOOTING POINTS 521
SEQUENCE OF EVENTS IN TROUBLESHOOTING 522
CHECKS BEFORE TROUBLESHOOTING 524
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 526
WALK-AROUND CHECK 526
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 528
CHECK FUEL LEVEL AND TYPE 528
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 529
TEST FUEL MAIN FILTER CARTRIDGE 529
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 532
CHECK COOLANT LEVEL (RESERVOIR TANK) 532
CHECK CLOGGING OF AIR CLEANER 533
CLEAN OUTER ELEMENT (SINGLE ELEMENT) 534
REPLACE SINGLE ELEMENT 536
CHECK HYDRAULIC OIL LEVEL 537
CHECK HYDRAULIC OIL STRAINER 541
CHECK HYDRAULIC FILTER 543
CHECK OIL LEVEL IN FINAL DRIVE CASE 544
BLEED AIR FROM FUEL SYSTEM 544
BLEED AIR FROM HYDRAULIC SYSTEM 544
ELECTRICAL EQUIPMENT – CHECK METHOD 545
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 552
PROCEDURE FOR TESTING AND TROUBLESHOOTING 556
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 559
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 563
CONNECTORS LIST AND LAYOUT 565
CONNECTOR CONTACT IDENTIFICATION 576
CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) 616
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 618
FUSE LOCATION TABLE 624
FAILURE CODES TABLE 630
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 636
FAILURE CODE [989L00] 636
FAILURE CODE [989M00] 637
FAILURE CODE [989N00] 638
FAILURE CODE [B@BCNS] 639
FAILURE CODE [D19JKZ] 640
FAILURE CODE [D19JKZ] 643
FAILURE CODE [D811MC] 646
FAILURE CODE [D862KA] 647
FAILURE CODE [D8ALKA] 648
FAILURE CODE [D8ALKB] 650
FAILURE CODE [D8AQKR] 652
FAILURE CODE [DAF0KT] 657
FAILURE CODE [DAF0MB] 658
FAILURE CODE [DAF0MC] 659
FAILURE CODE [DAF3KK] 660
FAILURE CODE [DAF9KQ] 665
FAILURE CODE [DAFGMC] 666
FAILURE CODE [DAFLKA] 667
FAILURE CODE [DAFLKB] 669
FAILURE CODE [DAFQKR] 671
FAILURE CODE [DB2QKR] 672
FAILURE CODE [DBH0MC] 677
FAILURE CODE [DBH2KK] 678
FAILURE CODE [DBH2KK] 681
FAILURE CODE [DBH5KP] 684
FAILURE CODE [DBH5KP] 686
FAILURE CODE [DBH9KQ] 688
FAILURE CODE [DBHLKA] 691
FAILURE CODE [DBHLKB] 693
FAILURE CODE [DBHQKR] 695
FAILURE CODE [DBHQKR] 700
FAILURE CODE [DDNRKA] 705
FAILURE CODE [DDNRKY] 708
FAILURE CODE [DDNS00] 711
FAILURE CODE [DDWLKA] 714
FAILURE CODE [DDWLKB] 716
FAILURE CODE [DFB1KZ] 718
FAILURE CODE [DFB3L8] 720
FAILURE CODE [DFB5KZ] 722
FAILURE CODE [DHS1MA] 724
FAILURE CODE [DHS5MA] 726
FAILURE CODE [DKULKA] 728
FAILURE CODE [DKULKB] 731
FAILURE CODE [DKULKY] 734
FAILURE CODE [DV00KB] 737
FAILURE CODE [DV20KB] 738
FAILURE CODE [DW43KA] 740
FAILURE CODE [DW43KB] 742
FAILURE CODE [DW43KY] 744
FAILURE CODE [DW4CKY] 745
FAILURE CODE [DXA8KA] 748
FAILURE CODE [DXA8KB] 752
FAILURE CODE [DXE7KA] 756
FAILURE CODE [DXE7KB] 758
FAILURE CODE [DXE7KY] 760
FAILURE CODE [DXEAKA] 761
FAILURE CODE [DXEAKB] 763
FAILURE CODE [DXEAKY] 765
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 766
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 766
E-2 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 773
E-3 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 780
E-4 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 782
E-5 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 784
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 788
E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 791
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 794
E-9 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 795
E-10 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 796
E-11 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 797
E-12 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 798
E-13 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 799
E-14 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 801
E-15 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 802
E-16 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 803
E-17 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 804
E-18 FUNCTION SWITCH DOES NOT OPERATE 805
E-19 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 806
E-20 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 807
E-21 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 808
E-22 ALARM BUZZER DOES NOT SOUND 811
E-23 ALARM BUZZER CANNOT BE CANCELED 813
E-24 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 815
E-25 SERVICE MODE CANNOT BE SELECTED 816
E-26 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 817
E-27 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 821
E-28 ALARM DOES NOT SOUND DURING TRAVEL 824
E-29 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 826
E-30 HORN DOES NOT SOUND 827
E-31 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC) 831
E-32 HORN DOES NOT STOP SOUNDING 835
E-33 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER SPEC) 838
E-34 WORKING LAMP AND HEADLAMP DO NOT LIGHT UP (CANOPY SPEC) 841
E-35 NONE OF WORKING LAMP, HEADLAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP (CAB SPEC) 846
E-36 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 851
E-37 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 854
E-38 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 857
E-39 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 858
E-40 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 859
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 861
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 862
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 862
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 863
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 864
H-3 TRAVEL OR BLADE DOES NOT OPERATE 865
H-4 SWING OR BLADE DOES NOT OPERATE 866
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 867
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 868
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 869
H-8 SWING AND BLADE SPEED OR POWER IS LOW 870
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 871
H-10 UNUSUAL NOISE IS HEARD FROM AROUND MAIN PUMP 872
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 873
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 875
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 876
H-14 BLADE DOES NOT OPERATE 877
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 878
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 879
H-17 SPEED OR POWER OF BOOM IS LOW 880
H-18 SPEED OR POWER OF BOOM IS LOW (PIPING SPECIFICATION) 882
H-19 ARM SPEED OR POWER IS LOW 884
H-20 BUCKET SPEED OR POWER IS LOW 885
H-21 BLADE SPEED OR POWER IS LOW 886
H-22 BOOM SWING SPEED OR POWER IS LOW 888
H-23 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 889
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE 890
H-25 HYDRAULIC DRIFT OF ARM IS LARGE 891
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE 892
H-27 HYDRAULIC DRIFT OF BLADE IS LARGE 893
H-28 TIME LAG OF WORK EQUIPMENT IS LARGE 895
H-29 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 896
H-30 MACHINE DOES NOT TRAVEL STRAIGHT 897
H-31 MACHINE DOES NOT MOVE OFF STRAIGHT 899
H-32 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 900
H-33 TRAVEL SPEED IS LOW 902
H-34 BOTH SIDES OF CRAWLERS DO NOT MOVE 904
H-35 ONE OF TRACKS DOES NOT RUN 905
H-36 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 907
H-37 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 908
H-38 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT (AIR CONDITIONER EQUIPPED MODEL) 910
H-39 SWINGS ONLY IN ONE DIRECTION 912
H-40 SWINGS ONLY IN ONE DIRECTION (AIR CONDITIONER EQUIPPED MODEL) 914
H-41 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 916
H-42 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) (AIR CONDITIONER EQUIPPED MODEL) 918
H-43 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 920
H-44 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) (AIR CONDITIONER EQUIPPED MODEL) 921
H-45 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 922
H-46 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) (AIR CONDITIONER EQUIPPED MODEL) 923
H-47 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 924
H-48 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 925
H-49 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 926
H-50 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 927
H-51 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 928
H-52 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) (AIR CONDITIONER EQUIPPED MODEL) 929
TROUBLESHOOTING OF ENGINE (S-MODE) 930
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 930
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 931
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 932
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 933
S-4 ENGINE STARTABILITY IS POOR 934
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 936
S-6 ENGINE STOPS DURING OPERATION 937
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 939
S-8 ENGINE LACKS POWER 940
S-9 ENGINE OIL CONSUMPTION IS EXCESSIVE 942
S-10 OIL BECOMES CONTAMINATED QUICKLY 943
S-11 FUEL CONSUMPTION IS EXCESSIVE 944
S-12 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 945
S-13 OIL PRESSURE DROPS 946
S-14 FUEL MIXES INTO ENGINE OIL 948
S-15 WATER MIXES INTO ENGINE OIL (MILKY) 949
S-16 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 950
S-17 UNUSUAL NOISE IS HEARD 951
S-18 VIBRATION IS EXCESSIVE 952
S-19 AIR CANNOT BE BLED FROM FUEL CIRCUIT 953
50 DISASSEMBLY AND ASSEMBLY 955
CONTENTS 956
ABBREVIATION LIST 959
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 965
HOW TO READ THIS MANUAL 965
COATING MATERIALS LIST 967
SPECIAL TOOLS LIST 971
SKETCHES OF SPECIAL TOOLS 977
ENGINE AND COOLING SYSTEM 978
REMOVE AND INSTALL RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 978
METHOD FOR REMOVING RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 978
METHOD FOR INSTALLING RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 985
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 991
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 991
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 999
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 1007
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 1007
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 1009
REMOVE AND INSTALL FUEL TANK ASSEMBLY 1011
METHOD FOR REMOVING FUEL TANK ASSEMBLY 1011
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 1013
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1016
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 1016
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 1017
POWER TRAIN 1019
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1019
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1019
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1021
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1023
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 1023
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 1024
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 1026
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 1026
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 1029
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 1033
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 1033
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 1033
UNDERCARRIAGE AND FRAME 1035
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 1035
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 1035
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 1036
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 1038
METHOD FOR SEPARATING TRACK ASSEMBLY 1038
METHOD FOR INSTALLING TRACK ASSEMBLY 1038
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 1040
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 1040
METHOD FOR ASSEMBLING IDLER ASSEMBLY 1041
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 1044
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 1044
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 1045
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 1047
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 1047
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 1048
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 1050
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 1050
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 1051
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 1053
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 1053
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 1057
HYDRAULIC SYSTEM 1060
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 1060
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 1060
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 1062
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1064
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1065
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1066
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1067
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 1067
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 1070
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 1073
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 1073
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 1076
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY 1079
METHOD FOR REMOVING ACCUMULATOR ASSEMBLY 1079
METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY 1079
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1081
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1081
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1082
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1084
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1084
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1085
WORK EQUIPMENT 1087
REMOVE AND INSTALL BLADE ASSEMBLY 1087
METHOD FOR REMOVING BLADE ASSEMBLY 1087
METHOD FOR INSTALLING BLADE ASSEMBLY 1088
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1089
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 1089
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 1091
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 1093
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 1094
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 1097
CAB AND ITS ATTACHMENTS 1102
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY (CAB SPEC) 1102
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY (CAB SPEC) 1102
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY (CAB SPEC) 1108
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY (CANOPY SPEC) 1113
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC) 1113
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY (CANOPY SPEC) 1118
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1123
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 1124
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 1125
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1133
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 1133
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 1134
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 1136
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 1136
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 1140
REMOVE AND INSTALL OPERATOR’S SEAT 1145
METHOD FOR REMOVING OPERATOR’S SEAT 1145
METHOD FOR INSTALLING OPERATOR’S SEAT 1145
REMOVE AND INSTALL SEAT BELT 1147
METHOD FOR REMOVING SEAT BELT 1147
METHOD FOR INSTALLING SEAT BELT 1147
ELECTRICAL SYSTEM 1148
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 1148
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 1148
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 1149
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 1150
METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY 1150
METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY 1151
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 1153
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 1153
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 1154
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 1156
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 1156
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 1158
REMOVE AND INSTALL QUICK RELEASE BATTERY TERMINAL (-) 1160
METHOD FOR INSTALLING QUICK RELEASE BATTERY TERMINAL (-) 1160
METHOD FOR REMOVING QUICK RELEASE BATTERY TERMINAL (-) 1161
60 MAINTENANCE STANDARD 1163
CONTENTS 1164
ABBREVIATION LIST 1165
ENGINE AND COOLING SYSTEM 1171
MAINTENANCE STANDARD FOR PTO 1171
MAINTENANCE STANDARD OF COOLING SYSTEM 1172
POWER TRAIN 1173
MAINTENANCE STANDARD OF SWING CIRCLE 1173
MAINTENANCE STANDARD OF SWING MACHINERY 1174
MAINTENANCE STANDARD OF SPROCKET 1176
UNDERCARRIAGE AND FRAME 1177
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1177
MAINTENANCE STANDARD OF IDLER 1179
MAINTENANCE STANDARD OF TRACK ROLLER 1181
MAINTENANCE STANDARD OF CARRIER ROLLER 1182
MAINTENANCE STANDARD OF TRACK SHOE 1183
MAINTENANCE STANDARD OF DOUBLE SHOE 1185
MAINTENANCE STANDARD OF ROAD LINER 1186
MAINTENANCE STANDARD FOR RUBBER SHOE 1187
HYDRAULIC SYSTEM 1188
MAINTENANCE STANDARD OF HYDRAULIC TANK 1188
MAINTENANCE STANDARD OF MAIN PUMP 1189
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE 1190
MAINTENANCE STANDARD OF PC-EPC VALVE 1191
MAINTENANCE STANDARD OF SWING MOTOR 1192
MAINTENANCE STANDARD OF TRAVEL MOTOR 1194
MAINTENANCE STANDARD OF CONTROL VALVE 1195
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1204
MAINTENANCE STANDARD OF BLADE PPC VALVE 1207
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 1209
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1211
MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE 1214
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 1216
WORK EQUIPMENT 1217
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1217
DIMENSION OF ARM 1227
DIMENSIONS OF BUCKET 1229
MAINTENANCE STANDARD OF BOOM CYLINDER 1231
MAINTENANCE STANDARD OF ARM CYLINDER 1233
MAINTENANCE STANDARD OF BUCKET CYLINDER 1235
MAINTENANCE STANDARD OF BLADE CYLINDER 1236
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 1238
80 APPENDIX 1241
CONTENTS 1242
ABBREVIATION LIST 1243
AIR CONDITIONER SYSTEM 1249
PRECAUTIONS FOR REFRIGERANT 1249
AIR CONDITIONER COMPONENT 1250
SPECIFICATIONS OF AIR CONDITIONER 1251
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 1252
OUTLINE OF REFRIGERATION CYCLE 1253
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1255
AIR CONDITIONER UNIT 1255
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 1255
COMPRESSOR 1257
STRUCTURE OF COMPRESSOR 1257
SPECIFICATIONS OF COMPRESSOR 1257
FUNCTION OF COMPRESSOR 1257
CONDENSER 1259
STRUCTURE OF CONDENSER 1259
SPECIFICATIONS OF CONDENSER 1259
FUNCTION OF CONDENSER 1259
RECEIVER DRIER 1261
STRUCTURE OF RECEIVER DRIER 1261
SPECIFICATIONS OF RECEIVER DRIER 1261
FUNCTION OF RECEIVER DRIER 1261
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1262
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1264
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1267
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 1271
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM) 1274
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS) 1278
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 1279
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 1280
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 1281
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1282
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1283
HANDLE COMPRESSOR OIL 1285
90 CIRCUIT DIAGRAMS 1287
CONTENTS 1288
ABBREVIATION LIST 1291
HYDRAULIC CIRCUIT DIAGRAM 1297
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1297
HYDRAULIC CIRCUIT DIAGRAM: PC30MR-5 1301
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC30MR-5 (1/2) 1303
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC30MR-5 (2/2) 1305
HYDRAULIC CIRCUIT DIAGRAM: PC35MR-5 1307
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC35MR-5 (1/2) 1309
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS): PC35MR-5 (2/2) 1311
ELECTRICAL CIRCUIT DIAGRAM 1313
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1313
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 – 52907)(1/5) 1317
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 – 52907)(2/5) 1319
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 – 52907)(3/5) 1321
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 – 52907)(4/5) 1323
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 50001 – 52907)(5/5) 1325
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(1/5) 1327
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(2/5) 1329
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(3/5) 1331
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(4/5) 1333
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 52908 AND UP)(5/5) 1335
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 – 31037)(1/5) 1337
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 – 31037)(2/5) 1339
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 – 31037)(3/5) 1341
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 – 31037)(4/5) 1343
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 30001 – 31037)(5/5) 1345
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(1/5) 1347
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(2/5) 1349
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(3/5) 1351
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(4/5) 1353
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (SERIAL NUMBER: 31038 AND UP)(5/5) 1355
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(1/5) 1357
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(2/5) 1359
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(3/5) 1361
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(4/5) 1363
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(5/5) 1365
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(1/5) 1367
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(2/5) 1369
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(3/5) 1371
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(4/5) 1373
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(5/5) 1375
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(1/5) 1377
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(2/5) 1379
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(3/5) 1381
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(4/5) 1383
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(5/5) 1385
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(1/5) 1387
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(2/5) 1389
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(3/5) 1391
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(4/5) 1393
ELECTRICAL CIRCUIT DIAGRAM (FOR CANOPY SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(5/5) 1395
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 – 52848)(1/6) 1397
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 – 52848)(2/6) 1399
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 – 52848)(3/6) 1401
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 – 52848)(4/6) 1403
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 – 52848)(5/6) 1405
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 50001 – 52848)(6/6) 1407
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(1/6) 1409
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(2/6) 1411
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(3/6) 1413
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(4/6) 1415
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(5/6) 1417
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 52849 AND UP)(6/6) 1419
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 – 31023)(1/6) 1421
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 – 31023)(2/6) 1423
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 – 31023)(3/6) 1425
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 – 31023)(4/6) 1427
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 – 31023)(5/6) 1429
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 30001 – 31023)(6/6) 1431
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(1/6) 1433
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(2/6) 1435
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(3/6) 1437
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(4/6) 1439
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(5/6) 1441
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (SERIAL NUMBER: 31024 AND UP)(6/6) 1443
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(1/6) 1445
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(2/6) 1447
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(3/6) 1449
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(4/6) 1451
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(5/6) 1453
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 50001 – 52556)(6/6) 1455
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(1/6) 1457
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(2/6) 1459
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(3/6) 1461
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(4/6) 1463
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(5/6) 1465
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 52557 AND UP)(6/6) 1467
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(1/6) 1469
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(2/6) 1471
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(3/6) 1473
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(4/6) 1475
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(5/6) 1477
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30001 – 30888)(6/6) 1479
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(1/6) 1481
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(2/6) 1483
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(3/6) 1485
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(4/6) 1487
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(5/6) 1489
ELECTRICAL CIRCUIT DIAGRAM (FOR CAB SPEC MACHINE WITH QUICK COUPLER) (SERIAL NUMBER: 30889 AND UP)(6/6) 1491
INDEX 1493

DESCRIPTION:

Komatsu PC30MR-5 PC35MR-5 Compact Hydraulic Excavator Shop Manual SEN06591-09 – PDF DOWNLOAD

SERIAL NUMBERS

PC30MR-50001 and up
PC35MR-30001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.

00 INDEX AND FOREWORD:

This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

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