Komatsu PC27MRX-1 PC30MRX-1 PC35MRX-1 PC40MRX-1 PC45MRX-1 Excavator Workshop Service Repair Manual PDF - MKMTSPC27MRX45MRX.zip
A full factory-level service and repair manual featuring Electrical Wiring Diagrams for the Komatsu Hydraulic Excavator models PC27MRX-1, PC30MRX-1, PC35MRX-1, PC40MRX-1, and PC45MRX-1, packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
The workshop service and repair manual for Komatsu Hydraulic Excavators PC27MRX-1, PC30MRX-1, PC35MRX-1, PC40MRX-1, and PC45MRX-1 contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,477 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...27
GENERAL ASSEMBLY DRAWING...28
SPECIFICATIONS...38
WEIGHT TABLE...66
LIST OF LUBRICANT AND WATER...76
10 STRUCTURE AND FUNCTION...78
ENGINE CONTROL...79
PTO...81
RADIATOR AND OIL COOLER...83
POWER TRAIN...87
SWING CIRCLE...90
SWING MACHINERY...91
TRACK FRAME...93
IDLER CUSHION...95
HYDRAULIC PIPING...97
VALVE CONTROL...101
HYDRAULIC TANK...107
CLSS...111
HYDRAULIC PUMP(PISTON PUMP)...186
LS/PC VALVE AND SERVO PISTON...201
SOLENOID VALVE...206
CONTROL VALVE...209
SWING MOTOR...229
CENTER SWIVEL JOINT...237
TRAVEL MOTOR...240
PPC VALVE...264
SERVICE PPC VALVE...273
WORK EQUIPMENT...277
AIR CONDITIONER...278
ACTUAL ELECTRIC WIRING DIAGRAM...279
MACHINE MONITOR SYSTEM...283
20 TESTING AND ADJUSTING...290
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...291
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...296
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...337
TESTING AND ADJUSTING...339
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...340
MEASURING ENGINE SPEED...341
MEASURING EXHAUST COLOR...342
ADJUSTING VALVE CLEARANCE...343
MEASURING COMPRESSION PRESSURE...344
MEASURING ENGINE OIL PRESSURE...346
TESTING AND ADJUSING FUEL INJECTION TIMING...347
TESTING AND ADJUSTING FAN BELT TENSION...348
ADJUSTING FUEL CONTROL LEVER...350
MEASURING SPROCKET WEAR...352
TESTING AND ADJUSTING TRACK SHOE TENSION...353
HYDRAULIC EQUIPMENT ADJUSTING CONTROL LEVERS AND PEDAL...354
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT...357
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE...367
ADJUSTING PC VALVE...372
TESTING CONTROL CIRCUIT PRESSURE...373
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE...375
MEASURING OUTPUT PRESSURE OF SOLENOID VALVE...377
MEASURING OUTPUT PRESSURE OF PPC VALVE...380
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE...382
TESTING SWING HOLDING BRAKE INLET PORT PRESSURE...383
TESTING AND ADJUSTING TRAVEL DEVIATION...387
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER...389
BLEEDING AIR...391
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...393
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK...393
PRESSURIZING HYDRAULIC TANK...393
TESTING AND ADJUSTING HYDRAULIC BREAKER SERVICE VALVE...394
TESTING AND CHARGING PRESSURE OF HYDRAULIC BREAKER GAS(N2)...395
ELECTRICAL RELATED PARTS PROCEDURE FOR CHECKING DIODE...398
TROUBLESHOOTING...399
POINTS TO REMEMBER WHEN TROUBLESHOOTING...400
SEQUENCE OF EVENTS IN TROUBLESHOOTING...401
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...402
CHECKS BEFORE TROUBLESHOOTING ...410
CONNECTOR TYPES AND MOUNTING LOCATIONS...411
CONNECTOR PIN ALLOCATION DRAWING...415
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...421
METHOD OF USING TROUBLESHOOTING CHARTS...435
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)...437
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...438
E-1 ENGINE DOES NOT START...447
a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)...447
b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)...450
E-2 ENGINE DOES NOT STOP...466
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED...470
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED...474
E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED...478
E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED...481
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE)...484
TABLE OF FAILURE MODES AND CAUSES...485
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER ...489
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS...492
H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE...495
H-4 ABNORMAL NOISE GENERATED(FROM AROUND PUMP)...496
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...497
H-6 BOOM IS SLOW OR LACKS POWER...498
H-7 ARM IS SLOW OR LACKS POWER...500
H-8 BUCKET IS SLOW OR LACKS POWER...502
H-9 BOOM SWING IS SLOW OR LACKS POWER...504
H-10 BLADE IS SLOW OR LACKS POWER...507
H-11 BOOM,ARM,BUCKET DO NOT MOVE(BOOM SWING,BLADE,TRAVEL AND SWING ARE NORMAL)...508
H-12 EXCESSIVE HYDRAULIC DRIFT(BOOM,ARM,BUCKET,BOOM SWING,BLADE)...509
a)BOOM...509
b)ARM,BUCKET,BOOM SWING...509
c)BLADE...509
H-13 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING)...510
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...510
H-15 TRAVEL DEVIATION...511
a) WHEN THERE IS DEVIATION DURING NORMAL TRAVEL...511
b) THERE IS DEVIATION WHEN MACHINE MOVES OFF...511
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER...515
H-17 STEERING DOES NOT TURN EASILY...516
H-18 TRAVEL SPEED DOES NOT SWITCH...516
H-19 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)...516
H-20 SWING SPEED IS SLOW OR LACKS POWER...517
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS...517
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY(LEFT OR RIGHT)...517
H-21 DOES NOT SWING...519
a) DOES NOT SWING IN EITHER DIRECTION...519
b) DOES NOT SWING IN ONE DIRECTION(LEFT OR RIGHT)...519
H-22 SWING ACCELERATION IS POOR...520
a) ACCELERATION IS POOR IN BOTH DIRECTIONS...520
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY(LEFT OR RIGHT)...520
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...521
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS(LEFT AND RIGHT)...521
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY(LEFT OR RIGHT)...521
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING(IN ONE DIRECTION ONLY)...522
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...522
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING...522
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)...523
M-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...524
M-1 WHEN STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN...528
M-2 WHEN STARTING SWITCH IS TURNED ON,EVEN WHEN SELF CHECK IS COMPLETED(ALL LAMPS LIGHT UP FOR 3 SECONDS),LAMPS DO NOT GO OUT...530
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS...531
a) NO GAUGE LAMPS LIGHT UP(FUEL,COOLANT TEMPERATURE)...531
b) CAUTION LAMPS(ENGINE OIL PRESSURE,BATTERY CHARGE),PILOT LAMP(PREHEATING) DO NOT LIGHT UP...531
M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS),EVEN IF STARTING SWITCH IS TURNED TO START,SELF CHECK IS NOT COMPLETED FOR 3 SECONDS...531
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...532
M-6 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP...533
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT,PREHEATING PILOT LAMP DOES NOT LIGHT UP...534
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP...535
M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP...536
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE...537
a) LEVEL DOES NOT RISE FROM SEGMENT C...537
b) LEVEL DOES NOT GO DOWN FROM SEGMENT H,OR ALL SEGMENTS GO OUT...537
c) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY...538
M-11 ABNORMALITY IN FUEL GAUGE...543
a) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT...543
b) LEVEL DOES NOT GO DOWN FROM SEGMENT F...543
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY...544
M-12 DEFECTIVE OPERATION OF ALARM BUZZER...547
a) BUZZER DOES NOT SOUND...547
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP...547
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE...550
a) WHEN CHARGE CAUTION LAMP DOSE NOT LIGHT UP...550
b) WHEN CHARGE CAUTION LAMP LIGHTS UP...550
c) PILOT LAMP DOES NOT FLASH(SERVICE METER IS ACTUATED)...550
M-14 NIGHT LIGHTING DOES NOT LIGHT UP...551
a) GAUGE LIGHTING DOES NOT LIGHT UP...551
b) SERVICE METER LIGHTING DOES NOT LIGHT UP...551
30 DISASSEMBLY AND ASSEMBLY...555
METHOD OF USING MANUAL...557
PRECAUTIONS WHEN CARRYING OUT OPERATION...558
SPECIAL TOOL LIST...560
SKETCHES OF SPECIAL TOOLS...565
STARTING MOTOR...571
REMOVAL AND INSTALLATION...571
ALTERNATOR...573
REMOVAL AND INSTALLATION...573
FUEL INJECTION PUMP...576
REMOVAL...576
INSTALLATION...577
NOZZLE HOLDER...580
REMOVAL AND INSTALLATION ...580
WATER PUMP...582
REMOVAL AND INSTALLATION...582
THERMOSTAT...583
REMOVAL AND INSTALLATION...583
ENGINE FRONT SEAL...584
REMOVAL AND INSTALLATION...584
ENGINE REAR SEAL...585
REMOVING...585
INSTALLATION...586
CYLINDER HEAD ...587
REMOVAL...587
INSTALLATION...589
RADIATOR,HYDRAULIC COOLER...590
REMOVAL...590
INSTALLATION...591
ENGINE,MAIN PUMP...595
REMOVAL...595
INSTALLATION...598
DAMPER...603
REMOVAL AND INSTALLATION...603
CENTER SWIVEL JOINT...604
REMOVAL AND INSTALLATION...604
DISASSEMBLY AND ASSEMBLY...608
TRAVEL MOTOR ...612
REMOVAL AND INSTALLATION...612
TRAVEL MOTOR(PHV-500(FOR PC40MRX-1))...613
DISASSEMBLY AND ASSEMBLY...613
SPROCKET...628
REMOVAL AND INSTALLATION...628
SWING MOTOR,SWING MACHINERY...629
REMOVAL AND INSTALLATION...629
DISASSEMBLY...634
ASSEMBLY...637
SWING MOTOR...640
DISASSEMBLY...640
ASSEMBLY...645
REVOLVING FRAME...653
REMOVAL...653
INSTALLATION...654
SWING CIRCLE...656
REMOVAL AND INSTALLATION...656
IDLER...657
REMOVAL AND INSTALLATION...657
DISASSEMBLY...658
ASSEMBLY...659
RECOIL SPRING...660
REMOVAL AND INSTALLTION...660
DISASSEMBLY...661
ASSEMBLY...663
TRACK ROLLER...665
REMOVAL AND INSTALLATION...665
DISASSEMBLY...666
ASSEMBLY...667
CARRIER ROLLER...668
REMOVAL AND INSTALLATION...668
DISASSEMBLY AND ASSEMBLY...669
RUBBER SHOE...670
REMOVAL AND INSTALLATION...670
HYDRAULIC TANK...671
REMOVAL AND INSTALLATION...671
FUEL TANK ...676
REMOVAL...676
INSTALLATION...677
MAIN PUMP...679
REMOVAL AND INSTALLATION ...679
MAIN PUMP(LPV30 (FOR PC30MRX-1))...680
DISASSEMBLY...680
ASSEMBLY...688
MAIN PUMP(LPD25+25(FOR PC40MRX-1))...699
DISASSEMBLY...699
ASSEMBLY...708
SWING GEAR PUMP...721
REMOVAL AND INSTALLATION...721
PPC PUMP...722
REMOVAL AND INSTALLATION...722
MAIN CONTROL VALVE...724
REMOVAL ...724
INSTALLATION...725
DISASSEMBLY...730
ASSEMBLY...736
WORK EQUIPMENT LEFT PPC VALVE(FOR ARM,SWING CONTROL)...759
REMOVAL AND INSTALLATION...759
WORK EQUIPMENT RIGHT PPC VALVE(FOR BOOM AND BUCKET CONTROL)...761
REMOVAL AND INSTALLATION...761
WORK EQUIPMENT PPC VALVE...763
DISASSEMBLY...763
ASSEMBLY...764
BOOM CYLINDER...765
REMOVAL AND INSTALLATION...765
ARM CYLINDER...768
REMOVAL AND INSTALLATION...768
BUCKET CYLINDER...771
REMOVAL AND INSTALLATION...771
SWING CYLINDER...774
REMOVAL AND INSTALLATION...774
BLADE CYLINDER ...780
REMOVAL AND INSTALLATION...780
HYDRAULIC CYLINDER...783
DISASSEMBLY...783
ASSEMBLY...786
WORK EQUIPMENT...790
REMOVAL AND INSTALLATION...790
BUCKET...793
REMOVAL AND INSTALLATION...793
ARM...795