Komatsu PC30R-8, PC35R-8, PC40R-8, PC45R-8 Hydraulic Excavator Shop Manual SEBM012604

Description

• Model List:
  • PC30R-8 Hydraulic Excavator
  • PC35R-8 Hydraulic Excavator
  • PC40R-8 Hydraulic Excavator
  • PC45R-8 Hydraulic Excavator

• 0.1. HOW TO READ THE SHOP MANUAL
• 0.2. HOISTING INSTRUCTIONS
• 0.3. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 0.4. COATING MATERIALS
• 0.5. STANDARD TIGHTENING TORQUE
• 0.6. ELECTRIC WIRE CODE
• 0.7. CONVERSION TABLE
• 0.8. UNITS
• 1. GENERAL
• 1.1. GENERAL ASSEMBLY DRAWING
• 1.2. SPECIFICATIONS
• 1.3. WEIGHT TABLE
• 1.4. LIST OF LUBRICANT AND WATER
• 2. STRUCTURE AND FUNCTION
• 2.1. PTO (COUPLING)
• 2.2. RADIATOR, OIL COOLER
• 2.3. ENGINE CONTROL
• 2.4. POWER TRAIN
• 2.5. SWING CIRCLE
• 2.6. SWING MACHINERY
• 2.7. TRACK FRAME, RECOIL SPRING
• 2.8. HYDRAULIC PIPING
• 2.9. HYDRAULIC CIRCUIT DIAGRAM
• 2.10. HYDRAULIC PUMP
• 2.11. CENTER SWIVEL JOINT
• 2.12. SWING MOTOR
• 2.13. TRAVEL MOTOR
• 2.14. SPOOL CONTROL VALVE
• 2.15. CLSS
• 2.16. MULTICONTROL VALVE
• 2.17. ELECTRICAL WIRING DIAGRAM
• 2.18. VALVE CONTROL
• 2.19. WORK EQUIPMENT, SWING PPC VALVE
• 2.20. SOLENOID VALVE
• 2.21. WORK EQUIPMENT
• 2.22. MACHINE MONITOR SYSTEM
• 2.23. ELECTRICAL CIRCUIT DIAGRAM
• 2.24. HYDRAULIC CYLINDER
• 3. TESTING AND ADJUSTING
• 3.1. STANDARD VALUE TABLE
• 3.1.1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
• 3.1.2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• 3.1.3. STANDARD VALUE TABLE FOR ELECTRICAL PARTS
• 3.2. TESTING AND ADJUSTING
• 3.2.1. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 3.2.2. MEASURING ENGINE SPEED
• 3.2.3. MEASURING EXHAUST COLOR
• 3.2.4. ADJUSTING VALVE CLEARANCE
• 3.2.5. MEASURING COMPRESSION PRESSURE
• 3.2.6. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 3.2.7. MEASURING ENGINE OIL PRESSURE
• 3.2.8. TESTING AND ADJUSTING FAN BELT TENSION
• 3.2.9. ADJUSTING CONTROL LEVERS AND PEDALS
• 3.2.10. MEASURING SPROCKET WEAR
• 3.2.11. TESTING AND ADJUSTING TRACK SHOE TENSION
• 3.2.12. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
• 3.2.13. TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
• 3.2.14. ADJUSTING PC VALVE
• 3.2.15. TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
• 3.2.16. TESTING OUTPUT PRESSURE OF SOLENOID VALVE
• 3.2.17. TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE (PC20R)
• 3.2.18. ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
• 3.2.19. TESTING AND ADJUSTING TRAVEL DEVIATION
• 3.2.20. TESTING OIL LEAKAGE
• 3.2.21. RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
• 3.2.22. RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK
• 3.2.23. PRESSURIZING HYDRAULIC TANK
• 3.2.24. BLEEDING AIR
• 3.3. TROUBLESHOOTING
• 3.3.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 3.3.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 3.3.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 3.3.4. CHECKS BEFORE TROUBLESHOOTING
• 3.3.5. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 3.3.6. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 3.3.7. METHOD OF USING TROUBLESHOOTING CHARTS
• 3.3.8. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 3.3.9. TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
• 3.3.10. TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
• 4. DISASSEMBLY AND ASSEMBLY
• 4.1. METHOD OF USING MANUAL
• 4.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 4.3. SPECIAL TOOL LIST
• 4.4. SKETCHES OF SPECIAL TOOLS
• 4.5. STARTING MOTOR (REMOVAL, INSTALLATION)
• 4.6. ALTERNATOR (REMOVAL, INSTALLATION)
• 4.7. FUEL INJECTION PUMP (REMOVAL)
• 4.8. FUEL INJECTION PUMP (INSTALLATION)
• 4.9. NOZZEL HOLDER (REMOVAL, INSTALLATION)
• 4.10. WATER PUMP (REMOVAL)
• 4.11. WATER PUMP (INSTALLATION)
• 4.12. THERMOSTAT (REMOVAL, INSTALLATION)
• 4.13. ENGINE FRONT SEAL (REMOVAL, INSTALLATION)
• 4.14. ENGINE REAR SEAL (REMOVAL)
• 4.15. ENGINE REAR SEAL (INSTALLATION)
• 4.16. CYLINDER HEAD (REMOVAL)
• 4.17. CYLINDER HEAD (INSTALLATION)
• 4.18. RADIATOR, HYDRAULIC COOLER (REMOVAL
• 4.19. RADIATOR, HYDRAULIC COOLER (INSTALLATION)
• 4.20. ENGINE, HYDRAULIC PUMP (REMOVAL)
• 4.21. ENGINE, HYDRAULIC PUMP (INSTALLATION)
• 4.22. FUEL TANK (REMOVAL, INSTALLATION)
• 4.23. DAMPER (REMOVAL, INSTALLATION)
• 4.24. CENTER SWIVEL JOINT (REMOVAL, INSTALLATION)
• 4.25. CENTER SWIVEL JOINT (DISASSEMBLY, ASSEMBLY)
• 4.26. TRAVEL MOTOR (REMOVAL, INSTALLATION)
• 4.27. PHV300 (FOR PC30R8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR
• 4.28. PHV350 (FOR PC35R8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR
• 4.29. PHV500 (FOR PC40R8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR
• 4.30. GM06VL (FOR PC45R8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR
• 4.30.1. SAFETY
• 4.30.2. SECTIONAL DRAWING OF ASSEMBLY
• 4.30.3. PARTS LIST
• 4.30.4. TOOLS
• 4.30.5. TIGHTENING TORQUE
• 4.30.6. DISASSEMBLY
• 4.30.7. MAINTENANCE STANDARDS TABLE
• 4.30.8. ASSEMBLY
• 4.30.9. DIMENSIONS TABLE OF CLEARANCE ADJUSTMENT PARTS
• 4.30.10. PERFORMANCE CONFIRMATION TEST
• 4.31. SPROCKET (REMOVAL, INSTALLATION)
• 4.32. SWING MOTOR, SWING MACHINERY (REMOVAL)
• 4.33. SWING MOTOR, SWING MACHINERY (INSTALLATION)
• 4.34. SWING MOTOR, SWING MACHINERY (DISASSEMBLY)
• 4.35. SWING MOTOR, SWING MACHINERY (ASSEMBLY)
• 4.36. DISASSEMBLY SWING MOTOR ASSEMBLY LMF 16AB
• 4.37. ASSEMBLY SWING MOTOR ASSEMBLY LMF 16AB
• 4.38. REVOLVING FRAME (REMOVAL)
• 4.39. REVOLVING FRAME (INSTALLATION)
• 4.40. SWING CIRCLE (REMOVAL, INSTALLATION)
• 4.41. IDLER (REMOVAL, INSTALLATION)
• 4.42. IDLER (DISASSEMBLY)
• 4.43. IDLER (ASSEMBLY)
• 4.44. RECOIL SPRING (REMOVAL, INSTALLATION)
• 4.45. RECOIL SPRING (DISASSEMBLY)
• 4.46. RECOIL SPRING (ASSEMBLY)
• 4.47. TRACK ROLLER (REMOVAL, INSTALLATION)
• 4.48. TRACK ROLLER (DISASSEMBLY)
• 4.49. TRACK ROLLER (ASSEMBLY)
• 4.50. CARRIER ROLLER (REMOVAL, INSTALLATON)
• 4.51. CARRIER ROLLER (DISASSEMBLY, ASSEMBLY)
• 4.52. RUBBER SHOE (REMOVAL, INSTALLATION)
• 4.53. STEEL SHOE (REMOVAL, INSTALLATION)
• 4.54. HYDRAULIC TANK (REMOVAL, INSTALLATION)
• 4.55. HYDRAULIC COOLER (REMOVAL, INSTALLATION)
• 4.56. HYDRAULIC PUMP (REMOVAL, INSTALLATION)
• 4.57. DISASSEMBLY OF MAIN PUMP ASSEMBLY (LPV 45)
• 4.58. ASSEMBLY OF MAIN PUMP ASSEMBLY (LPV 45)
• 4.59. CONTROL VALVE (REMOVAL)
• 4.60. CONTROL VALVE (INSTALLATION)
• 4.61. CONTROL VALVE (DISASSEMBLY)
• 4.62. CONTROL VALVE (ASSEMBLY)
• 4.63. SPOOL SOLENOID VALVE (REMOVAL, INSTALLATION)
• 4.64. LEFT PPC VALVE (REMOVAL, INSTALLATION)
• 4.65. RIGHT PPC VALVE (REMOVAL, INSTALLATION)
• 4.66. PPC VALVE (DISASSEMBLY)
• 4.67. PPC VALVE (ASSEMBLY)
• 4.68. BOOM CYLINDER (REMOVAL)
• 4.69. BOOM CYLINDER (INSTALLATION)
• 4.70. ARM CYLINDER (REMOVAL)
• 4.71. ARM CYLINDER (INSTALLATION)
• 4.72. BUCKET CYLINDER (REMOVAL)
• 4.73. BUCKET CYLINDER (INSTALLATION)
• 4.74. BOOM SWING CYLINDER (REMOVAL)
• 4.75. BOOM SWING CYLINDER (INSTALLATION)
• 4.76. BLADE CYLINDER (REMOVAL)
• 4.77. BLADE CYLINDER (INSTALLATION)
• 4.78. HYDRAULIC CYLINDER (DISASSEMBLY)
• 4.79. HYDRAULIC CYLINDER (ASSEMBLY)
• 4.80. WORK EQUIPMENT (REMOVAL)
• 4.81. WORK EQUIPMENT (INSTALLATION)
• 4.82. BUCKET (REMOVAL, INSTALLATION)
• 4.83. ARM (REMOVAL)
• 4.84. ARM (INSTALLATION)
• 4.85. BUCKET, ARM (REMOVAL)
• 4.86. BUCKET, ARM (INSTALLATION)
• 4.87. BOOM (REMOVAL)
• 4.88. BOOM (INSTALLATION)
• 4.89. BOOM SWING BRACKET (REMOVAL)
• 4.90. BOOM SWING BRACKET (INSTALLATION)
• 4.91. BLADE (REMOVAL)
• 4.92. BLADE (INSTALLATION)
• 4.93. OPERATORS CAB (REMOVAL, INSTALLATION)
• 4.94. CANOPY (REMOVAL, INSTALLATION)
• 4.95. FLOOR FRAME (REMOVAL, INSTALLATION)
• 5. MAINTENANCE STANDARD
• 5.1. SWING CIRCLE
• 5.2. SWING MACHINERY
• 5.3. SPROCKET
• 5.4. TRACK FRAME, RECOIL SPRING
• 5.5. IDLER
• 5.6. TRACK ROLLER
• 5.7. CARRIER ROLLER
• 5.8. TRACK SHOE
• 5.9. CENTER SWIVEL JOINT
• 5.10. HYDRAULIC PUMP
• 5.11. WORK EQUIPMENT, SWING PPC VALVE
• 5.12. SWING MOTOR
• 5.13. SPOOL CONTROL VALVE
• 5.14. HYDRAULIC CYLINDER
• 5.15. WORK EQUIPMENT
• 6. OTHER
• 6.1. HYDRAULIC CIRCUIT DIAGRAM PC30R8
• 6.2. HYDRAULIC CIRCUIT DIAGRAM PC35R8
• 6.3. HYDRAULIC CIRCUIT DIAGRAM PC40R8
• 6.4. HYDRAULIC CIRCUIT DIAGRAM PC45R8
• 6.5. ELECTRICAL CIRCUIT DIAGRAM
• 6.6. HYDRAULIC PIPING DRAWING
• 6.7. SYSTEM DIAGRAM DRAWING