Komatsu PC27MR-3, PC30MR-3, PC35MR-3 SEN04063-07 (Preview)
COVER
00 Index and foreword
100 Index
Composition of shop manual
Table of contents
200 Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
100 Specification and technical data
Specification dimension drawing
Working range drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
100 Engine and cooling system
PTO
Cooling system
200 Power train
Power train
Swing circle
Swing machinery
300 Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
410 Hydraulic system, Part 1
Hydraulic components layout drawing
Hydraulic tank, filter
Center swivel joint
Travel motor
Hydraulic cylinder
Solenoid valve
Multi-control valve
420 Hydraulic system, Part 2
Hydraulic pump
Control valve
430 Hydraulic system, Part 3
CLSS
Operation for each function and valve
Swing motor
PPC valve
500 Work equipment
Work equipment
Dimensions of each part of work equipment
600 Cab and its attachments
Floor
Air conditioner
700 Electrical system
Engine control system
Electric control system
Auto-deceleration function
Attachment proportional switch, breaker operation switch, work mode selection, flow control function
KOMTRAX system
Component parts of system
Monitor system
Sensors
20 Standard value table
100 Standard service value table
Standard service value table for engine related parts
Standard service value table for chassis related parts
30 Testing and adjusting
100 Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing 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 clearance in swing circle bearings
Testing and adjusting track shoe tension
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits
Testing and adjusting LS differential pressure
Adjusting PC valve
Testing and adjusting control pump circuit oil pressure
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting PPC valve
Testing swing holding brake release pressure
Testing and adjusting travel deviation
Testing 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
Function and flow of operator and service mode
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Removal and installation of KOMTRAX terminal
Preparation work for troubleshooting of electrical system
40 Troubleshooting
010 Failure code table and fuse locations
User code and failure code list
Fuse locations
100 General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Information contained in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
110 Troubleshooting by failure code
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller
Failure code [DBH1KK] Unswitched power supply error
Failure code [DBH2KK] Solenoid power supply error
Failure code [DBH5KP] 5V sensor power supply output 0 error
Failure code [DBH6KP] 5V sensor power supply output 1 error
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit)
Failure code [DDWLKB] Breaker switch error (Hot short circuit)
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault)
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit)
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)
Failure code [D1E0KB] Motor power supply relay error (Ground fault)
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)
Failure code [DY10MA] Fuel control motor operation error
Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side)
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection)
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit)
200 Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
E-1 Engine does not start
E-2 Engine does not stop
E-3 When starting switch is turned ON, any item does not operate
E-4 When starting switch is turned ON, some items do not operate
E-5 Alarm buzzer is abnormal
E-6 Engine oil pressure caution is turned ON
E-7 Charge level caution is turned ON
E-8 Preheating system does not operate or preheater does not become hot1
E-9 Coolant temperature gauge is abnormal
E-10 Fuel level gauge is abnormal
E-11 Service meter does not operate while engine is running
E-12 2nd travel speed is not selected
E-13 Working lamp does not light up
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves
E-15 Windshield wiper does not operate
E-16 Windshield washer does not operate
E-17 Defective air conditioner
E-18 KOMTRAX system does not operate normally
300 Troubleshooting of hydraulic and mechanical system (H-mode)
Information contained in troubleshooting table
H1 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 When upper structure 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
400 Troubleshooting of engine (S-mode)
Method of using troubleshooting charts
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
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 coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
100 General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
200 Engine and cooling system
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
300 Power train
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
400 Undercarriage and frame
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 revolving frame assembly
500 Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
600 Work equipment
Removal and installation of work equipment assembly
700 Cab and its attachments
Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
800 Electrical system
Removal and installation of air conditioner unit assembly (If equipped)
90 Diagrams and drawings
100 Hydraulic diagrams and drawings
Hydraulic circuit diagram
200 Electrical diagrams and drawings
Electrical circuit diagram
Connector list and stereogram
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