Day: June 8, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC75R, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC75R-2 workshop service repair manual includes:
* 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.

WEBM004000 – Hydraulic Excavator PC75R-2 Shop Manual.pdf
WEAM002800A – Hydraulic Excavator PC75R-2 Operation & Maintenance Manual.pdf
WEAM002801 – Hydraulic Excavator PC75R-2 Operation & Maintenance Manual.pdf
WEAM003900 – Hydraulic Excavator PC75R-2 Operation & Maintenance Manual.pdf

Total Pages: 1,040 pages
File Format: PDF
Language: English

WEAM002800A – Hydraulic Excavator PC75R-2 Operation & Maintenance Manual….2
COVER….2
1.1 FOREWORD….5
1.2 INFORMATION ON SAFETY….6
1.3 INTRODUCTION….8
1.3.1 INTENDED USES….8
1.3.2 IMPROPER OR UNAUTHORIZED USE….8
1.3.3 MAIN CHARACTERISTICS….9
1.3.4 RUNNING-IN….9
1.4 PRODUCT IDENTIFICATION….10
1.4.1 MACHINE SERIAL NUMBER….10
1.4.2 MACHINE IDENTIFICATION PLATE….10
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL….11
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER….11
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER….12
1.4.6 CAB SERIAL NUMBER….12
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS….13
CONTENTS….14
SAFETY AND ACCIDENT PREVENTION….21
2.1 SAFETY PLATES….22
2.1.1 POSITION OF THE SAFETY PLATES….22
2.1.2 POSITION OF THE PICTOGRAMS….38
2.1.3 PICTOGRAMS AND RELEVENT MEANINGS….39
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED….41
2.2 GENERAL PRECAUTIONS….42
2.2.1 GENERAL SAFETY RULES….42
2.2.2 SAFETY DEVICES AND GUARDS….42
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS….42
2.2.4 UNAUTHORIZED MODIFICATIONS….43
2.2.5 LEAVING THE OPERATOR'S SEAT….43
2.2.6 GETTING ON AND OFF THE MACHINE….44
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL….44
2.2.8 PREVENTING BURNS….45
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER….45
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….46
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT….46
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE….46
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT….46
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….47
2.3.1 SAFETY ON THE WORK SITE….47
2.3.2 FIRE PREVENTION….47
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB….47
2.3.4 ROOM VENTILATION….48
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS….48
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS-CHECKING THE WINDSHIELD WIPER BLADES….48
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING….49
2.4.1 STARTING THE ENGINE….49
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE….49
2.4.3 CHECKS FOR TRAVELLING IN REVERSE….49
2.4.4 MOVING THE MACHINE….50
2.4.5 MOVING THE SLOPES….51
2.4.6 WORKING ON SLOPES….52
2.4.7 UNAUTHORIZED OPERATIONS….52
2.4.8 PREVENTING ELECTROCUTION….53
2.4.9 VISIBILITY….54
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES….54
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….54
2.4.12 WORKING ON LOOSE GROUND….54
2.4.13 PARKING THE MACHINE….55
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES….56
2.5.1 LOADING AND UNLOADING THE MACHINE….56
2.5.2 SHIPPING….56
2.6 BATTERY….57
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES….57
2.6.2 STARTING WITH BOOSTER CABLES….57
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY….58
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE….59
2.8.1 WARNING PLATES….59
2.8.2 TOOLS….59
2.8.3 PERSONNEL….60
2.8.4 EQUIPMENT….60
2.8.5 WORKING UNDER THE MACHINE….60
2.8.6 KEEPING THE MACHINE CLEAN….60
2.8.7 USE OF THE ENGINE DURING MAINTENANCE….61
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY….61
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION….61
2.8.10 RULES FOR REFUELLING AND ADDING OIL….62
2.8.11 CHECKING THE COOLAND LEVEL IN THE RADIATOR….62
2.8.12 USING LAMPS….62
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR….63
2.8.14 PRECAUTIONS CONCERNING THE STARTER….63
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES….64
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS….64
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES….64
2.8.18 COOLING FAN AND FAN BELT….65
2.8.19 WASTE MATERIALS….65
DESCRIPTION AND USE OF THE MACHINE….67
3.1 SAFETY LOCKS….68
3.1.1 MACHINE LOCKS….68
3.2 GENERAL VIEWS….69
3.2.1 FRONT GENERAL VIEW (MONOBOOM)….69
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)….70
3.2.3 CAB INSIDE GENERAL VIEW….71
3.3 INSTRUMENTS AND CONTROLS….73
3.3.1 INSTRUMENTS, WARNING LIGHTS AND PUSH BUTTONS….73
3.3.2 MACHINE CONTROLS….82
3.4 FUSES AND RELAYS….93
3.4.1 CENTRAL UNIT FUSES AND RELAYS….93
3.4.1.1 CENTRAL UNIT FUSES….94
3.4.1.2 CENTRAL UNIT RELAYS….95
3.4.2 ENGINE LINE FUSES AND RELAYS….96
3.4.2.1 ENGINE LINE FUSES….96
3.4.2.2 ENGINE LINE RELAYS….97
3.5 GAURDS AND DRIVER'S SEAT….98
3.5.1 ENGINE HOOD….98
3.5.2 SIDE COVER….98
3.5.3 CAB….99
3.5.4 VENTILATION AND HEATING….103
3.5.5 SEAT….104
3.5.6 SAFETY BELT….105
3.5.7 EMERGENCY EXIT….105
3.5.8 TECHNICAL DOCUMENTATION CASE….106
3.5.9 FIRE EXTINGUISHER….106
3.5.10 FIRST AID KIT….106
3.6 USE OF THE MACHINE….107
3.6.1 CHECKS BEFORE STARTING THE ENGINE….107
3.6.1.1 VISUAL CHECKS….107
3.6.1.2 DAILY CHECKS….107
3.6.1.3 OPERATIONAL CHECKS….108
3.6.2 STARTING THE ENGINE….109
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES….109
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES….110
3.6.3 WARMING THE ENGINE….111
3.6.4 HEATING THE HYDRAULIC OIL….111
3.6.5 HOW TO MOVE THE MACHINE….111
3.6.5.1 STEERING (CHANGING DIRECTION)….113
3.6.5.2 MOVING ON SLOPES….114
3.6.5.3 MAXIMUM IMMERSION DEPTH….115
3.7 PARKING THE MACHINE….116
3.7.1 PARKING ON LEVEL GROUND….116
3.7.2 PARKING ON SLOPES….117
3.8 STOPPING THE ENGINE….118
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES….119
3.9.1 LOADING AND UNLOADING THE MACHINE….119
3.9.2 TRANSPORT….120
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON….121
3.10.1 FUEL AND LUBRICANTS….121
3.10.2 COOLANT….121
3.10.3 BATTERY….122
3.10.4 OTHER PRECAUTIONS….122
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK….122
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON….123
3.12 USING THE WORK EQUIPMENT….124
3.12.1 ORGANIZING THE WORK AREA….124
3.12.2 POSITIONING THE BUCKET ACCORDING T OTHE WORK TO BE CARRIED OUT….124
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS….125
3.12.4 DIGGING METHOD….126
3.12.5 CHANGING THE BUCKET….127
3.13 LONG PERIODS OF INACTIVITY….128
3.13.1 BEFORE THE PERIOD OF INACTIVITY….128
3.13.2 DURING THE PERIOD OF INACTIVITY….129
3.13.3 AFTER THE PERIOD OF INACTIVITY….129
3.14 TROUBLESHOOTING….130
3.14.1 HOW TO REMOVE THE MACHINE….130
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED….130
3.14.3 IF THE BATTERY IS DEPLETED….131
3.14.3.1 STARTING WITH BOOSTER CABLES….132
3.14.4 OTHER TROUBLES….133
3.14.4.1 ELECTRICAL CIRCUIT….133
3.14.4.2 HYDRAULIC SYSTEM….134
3.14.4.3 ENGINE….135
MAINTENANCE….137
4.1 GUIDE TO MAINTENANCE….138
4.2 MAINTENANCE NOTES….140
4.2.1 NOTES REGARDING THE ENGINE….140
4.2.1.1 ENGINE OIL….140
4.2.1.2 COOLANT….140
4.2.1.3 FUEL….141
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM….141
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM….142
4.2.4 NOTES REGARDING LUBRICATION….142
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING….143
4.3 FUEL, COOLANT AND LUBRICANTS….144
4.4 NUT AND BOLT TIGHTENING TORQUES….148
4.4.1 STANDARD TIGHTENING TORQUES….148
4.4.2 SPECIFIC TIGHTENING TORQUES….148
4.5 LUBRICATION….149
4.5.1 LUBRICATION DIAGRAM….149
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY….150
4.6.1 CRITICAL PARTS FOR SAFETY….151
4.7 MAINTENANCE PLAN….154
4.7.1 WHEN REQUIRED….157
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE….157
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER….158
4.7.1.c WASHING THE COOLING CIRCUIT….159
4.7.1.d CLEANING THE WATER SEPARATOR….160
4.7.1.e CHECKING THE STEEL TRACK TENSION….161
4.7.1.f CHECKING THE SHOE FASTENING….163
4.7.1.g CHECKING THE RUBBER TRACKS….164
4.7.1.h CHECKING THE RUBBER TRACK TENSION….166
4.7.1.i CHANGING THE RUBBER TRACK….168
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER….170
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER….170
4.7.2.b CHANGING THE HYDRAULIC OIL….170
4.7.3 CHECKS BEFORE STARTING….171
4.7.3.a VARIOUS CHECKS….171
4.7.3.b CHECKING THE COOLANT LEVEL….171
4.7.3.c CHECKING THE FUEL LEVEL….172
4.7.3.d CHECKING THE ENGINE OIL LEVEL….172
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT….173
4.7.3.f. DRAINING THE WATER SEPARATOR….174
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION….175
4.7.4.a LUBRICATING THE JOINTS….175
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION….178
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION….178
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL….178
4.7.6.b LUBRICATING THE SWING JOINT….178
4.7.6.c CHECKING THE ELECTRICAL SYSTEM….179
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION….180
4.7.7.a LUBRICATING THE BALL-BEARING RING….180
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION….181
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION….181
4.7.9.a ADJUSTING THE FAN BELT TENSION….181
4.7.9.b CHECKING THE BATTERY ELECTROLYTE LEVEL….182
4.7.9.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS….183
4.7.9.d CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR….183
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION….184
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION….184
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER….184
4.7.11.b CHANGING THE SERVO CONTROL FILTER….185
4.7.11.c CHANGING THE ENGINE OIL….186
4.7.11.d CHANGING THE ENGINE OIL FILTER….187
4.7.11.e CHANGING THE FUEL FILTER….188
4.7.11.f DRAINING THE FUEL TANK….189
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS….189
4.7.11.h CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL….190
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION….191
4.7.12.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS….191
4.7.12.b CHANGING THE OIL IN THE SWING REDUCTION GEAR….192
4.7.12.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE….192
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION….193
4.7.13.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER….193
4.7.13.b CHANGING THE COOLANT….196
4.7.13.c CHANGING THE BALL-BEARING RING PINION LUBRICANT….197
4.7.13.d CHECKING THE ALTERNATOR AND THE STARTER….197
TECHNICAL DATA….199
5.1 TECHNICAL DATA….200
5.1.1 STANDARD OVERALL DIMENSIONS….200
5.1.2 TECHNICAL CHARACTERISTICS….201
5.1.3 LIFTING CAPACITIES….202
5.1.3.1 LIFTING CAPACITY TABLE….202
5.1.3.2 LIFTING CAPACITY WITH RAISED BLADE….203
5.1.3.3 LIFTING CAPACITY WITH LOWERED BLADE….204
AUTHORIZED OPTIONAL EQUIPMENT….205
6.1 AUTHORIZED OPTIONAL EQUIPMENT….206
6.1.1 PRECAUTIONS REGARDING SAFETY….206
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT….207
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT….208
6.2 APPARNGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER….209
6.2.1 DESCRIPTION AND OPERATION….209
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED….209
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER….213
6.2.3.1 INSTALLING THE HAMMER….213
6.2.3.2 REMOVING THE HAMMER….214
6.2.4 MAINTENANCE….214
6.3 CLAMSHELL BUCKET….215
6.3.1 DESCRIPTION AND OPERATION….215
6.3.2 INSTALLING THE CLAMSHELL BUCKET….216
6.3.3 MAINTENANCE….218
WEAM002801 – Hydraulic Excavator PC75R-2 Operation & Maintenance Manual….220
COVER….220
1.1 FOREWARD….221
1.2 INFORMATION ON SAFETY….222
1.3 INTRODUCTION….224
1.3.1 INTENDED USES….224
1.3.2 IMPROPER OR UNAUTHORIZED USE….224
1.3.3 MAIN CHARACTERISTICS….225
1.3.4 RUNNING-IN….225
1.4 PRODUCT IDENTIFICATION….226
1.4.1 MACHINE SERIAL NUBER….226
1.4.2 MACHINE IDENTIFICATION PLATE….226
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL….227
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER….227
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER….228
1.4.6 CAB SERIAL NUMBER….228
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS….229
CONTENTS….230
SAFETY AND ACCIDENT PREVENTION….237
2.1 SAFETY PLATES….238
2.1.1 POSITION OF THE SAFETY PLATES….238
2.1.2 POSITION OF THE PICTOGRAMS….254
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS….255
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED….257
2.2 GENERAL PRECAUTIONS….258
2.2.1 GENERAL SAFETY RULES….258
2.2.2 SAFETY DEVICES AND GUARDS….258
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS….258
2.2.4 UNAUTHORIZED MODIFICATIONS….259
2.2.5 LEAVING THE OPERATOR'S SEAT….259
2.2.6 GETTING ON AND OFF THE MACHINE….260
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL….260
2.2.8 PREVENTING BURNS….261
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER….261
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….262
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT….262
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE….262
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT….262
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….263
2.3.1 SAFETY ON THE WORK SITE….263
2.3.2 FIRE PREVENTION….263
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB….263
2.3.4 ROOM VENTILATION….264
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS….264
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS – CHECKING THE WINDSHIELD WIPER BLADES….264
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING….265
2.4.1 STARTING THE ENGINE….265
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE….265
2.4.3 CHECKS FOR TRAVELLING IN REVERSE….265
2.4.4 MOVING THE MACHINE….266
2.4.5 MOVING ON SLOPES….267
2.4.6 WORKING ON SLOPES….268
2.4.7 UNAUTHORIZED OPERATIONS….268
2.4.8 PREVENTING ELECTROCUTION….269
2.4.9 VISIBILITY….270
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES….270
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….270
2.4.12 WORKING ON LOOSE GROUND….270
2.4.13 PARKING THE MACHINE….271
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES….272
2.5.1 LOADING AND UNLOADING THE MACHINE….272
2.5.2 SHIPPING….272
2.6 BATTERY….273
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES….273
2.6.2 STARTING WITH BOOSTER CABLES….273
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY….274
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE….275
2.8.1 WARNING PLATES….275
2.8.2 TOOLS….275
2.8.3 PERSONNEL….276
2.8.4 EQUIPMENT….276
2.8.5 WORKING UNDER THE MACHINE….276
2.8.6 KEEPING THE MACHINE CLEAN….276
2.8.7 USE OF THE ENGINE DURING MAINTENANCE….277
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY….277
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION….277
2.8.10 RULES FOR REFUELLING AND ADDING OIL….278
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR….278
2.8.12 USING LAMPS….278
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR….279
2.8.14 PRECAUTIONS CONCERNING THE STARTER….279
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES….280
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS….280
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES….280
2.8.18 COOLING FAN AND FAN BELT….281
2.8.19 WASTE MATERIALS….281
2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES….281
THE MACHINE AND ITS OPERATIONS….283
3.1 SAFETY LOCKS….284
3.1.1 MACHINE LOCKS….284
3.2 GENERAL VIEWS….285
3.2.1 FRONT GENERAL VIEW (MONOBOOM)….285
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)….286
3.2.3 CAB INSIDE GENERAL VIEW….287
3.3 INSTRUMENTS AND CONTROLS….289
3.3.1 INSTRUMENTS….289
3.3.2 WARNING LIGHTS….291
3.3.3 SWITCHES AND PUSH BUTTONS….293
3.3.4 ELECTRICAL ACCESSORIES….300
3.3.5 MACHINE CONTROLS….302
3.4 FUSES AND RELAYS….313
3.4.1 CENTRAL UNIT FUSES AND RELAYS….313
3.4.1.1 CENTAL UNIT FUSES….314
3.4.1.2 CENTRAL UNIT RELAYS….315
3.4.2 ENGINE LINE FUSES AND RELAYS….316
3.4.2.1 ENGINE LINE FUSES….316
3.4.2.2 ENGINE LINE RELAYS….317
3.5 GUARDS AND DRIVER'S SEAT….318
3.5.1 ENGINE HOOD….318
3.5.2 SIDE COVER….318
3.5.3 CAB….319
3.5.4 VENTILATION AND HEATING….323
3.5.5 SEAT….324
3.5.6 SAFETY BELT….325
3.5.7 EMERGENCY EXIT….325
3.5.8 TECHNICAL DOCUMENTATION CASE….326
3.5.9 FIRE EXTINGUISHER….326
3.5.10 FIRST AID KIT….326
3.6 USE OF THE MACHINE….327
3.6.1 CHECKS BEFORE STARTING THE ENGINE….327
3.6.1.1 VISUAL CHECKS….327
3.6.1.2 DAILY CHECKS….327
3.6.1.3 OPERATIONAL CHECKS….328
3.6.2 STARTING THE ENGINE….329
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES….329
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES….330
3.6.3 WARMING THE ENGINE….331
3.6.4 HEATING THE HYDRAULIC OIL….331
3.6.5 HOW TO MOVE THE MACHINE….331
3.6.5.1 STEERING (CHANGING DIRECTION)….333
3.6.5.2 MOVING ON SLOPES….334
3.6.5.3 MAXIMUM IMMERSION DEPTH….335
3.7 PARKING THE MACHINE….336
3.7.1 PARKING ON LEVEL GROUND….336
3.7.2 PARKING ON SLOPES….337
3.8 STOPPING THE ENGINE….338
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES….339
3.9.1 LOADING AND UNLOADING THE MACHINE….339
3.9.2 TRANSPORT….340
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON….341
3.10.1 FUEL AND LUBRICANTS….341
3.10.2 COOLANT….341
3.10.3 BATTERY….342
3.10.4 OTHER PRECAUTIONS….342
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK….342
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON….343
3.12 USING THE WORK EQUIPMENT….344
3.12.1 ORGANIZING THE WORK AREA….344
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT….344
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS….345
3.12.4 DIGGING METHOD….346
3.12.5 CHANGING THE BUCKET….347
3.13 LONG PERIODS OF INACTIVITY….348
3.13.1 BEFORE THE PERIOD OF INACTIVITY….348
3.13.2 DURING THE PERIOD OF INACTIVITY….349
3.13.3 AFTER THE PERIOD OF INACTIVITY….349
3.14 TROUBLESHOOTING….350
3.14.1 HOW TO REMOVE THE MACHINE….350
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED….350
3.14.3 IF THE BATTERY IS DEPLETED….351
3.14.3.1 STARTING WITH BOOSTER CABLES….352
3.14.4 OTHER TROUBLES….353
3.14.4.1 ELECTRICAL CIRCUIT….353
3.14.4.2 HYDRAULIC SYSTEM….354
3.14.4.3 ENGINE….355
MAINTENANCE….357
4.1 GUIDE TO MAINTENANCE….358
4.2 MAINTENANCE NOTES….360
4.2.1 NOTES REGARDING THE ENGINE….360
4.2.1.1 ENGINE OIL….360
4.2.1.2 COOLANT….360
4.2.1.3 FUEL….361
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM….361
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM….362
4.2.4 NOTES REGARDING LUBRICATION….362
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING….363
4.3 FUEL, COOLANT AND LUBRICANTS….364
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS….368
4.4 NUT AND BOLT TIGHTENING TORQUES….369
4.4.1 STANDARD TIGHTENING TORQUES….369
4.4.2 SPECIFIC TIGHTENING TORQUES….369
4.5 LUBRICATION….370
4.5.1 LUBRICATION DIAGRAM….370
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY….371
4.6.1 CRITICAL PARTS FOR SAFETY….372
4.7 MAINTENANCE PLAN….375
4.7.1 WHEN REQUIRED….378
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE….378
4.7.1 b CHECKING AND CLEANING THE CAB AIR FILTER….379
4.7.1.c WASHING THE COOLING CIRCUIT….380
4.7.1 d CLEANING THE WATER SEPARATOR….381
4.7.1.e CHECKING THE STEEL TRACK TENSION….382
4.7.1.f CHECKING THE SHOE FASTENING….384
4.7.1.g CHECKING THE RUBBER TRACKS….385
4.7.1.h CHECKING THE RUBBER TRACK TENSION….387
4.7.1.j CHANGING THE RUBBER TRACK….389
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER….391
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER….391
4.7.2.b CHANGING THE HYDRAULIC OIL….391
4.7.3 CHECKS BEFORE STARTING….392
4.7.3.a VARIOUS CHECKS….392
4.7.3.b CHECKING THE COOLANT LEVEL….392
4.7.3.c CHECKING THE FUEL LEVEL….393
4.7.3.d CHECKING THE ENGINE OIL LEVEL….393
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT….394
4.7.3.f DRAINING THE WATER SEPARATOR….395
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION….396
4.7.4.a LUBRICATING THE JOINTS….396
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES….399
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION….399
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL….399
4.7.6.b LUBRICATING THE SWING JOINT….399
4.7.6.c CHECKING THE ELECTRICAL SYSTEM….400
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION….401
4.7.7.a LUBRICATING THE BALL-BEARING RING….401
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION….402
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION….402
4.7.9.a ADJUSTING THE FAN BELT TENSION….402
4.7.9.b CHECKING THE BATTERY ELECTROLYTE LEVEL….403
4.7.9.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS….404
4.7.9.d CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR….404
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION….405
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION….405
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER….405
4.7.11.b CHANGING THE SERVO CONTROL FILTER….407
4.7.11.c CHANGING THE ENGINE OIL….408
4.7.11.d CHANGING THE ENGINE OIL FILTER….409
4.7.11.e CHANGING THE FUEL FILTER….410
4.7.11.f DRAINING THE FUEL TANK….411
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS….411
4.7.11.h CHECKING THE BALL-BEARING RING PINION LUBIRCANT LEVEL….412
4.7.11.j DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES IS USED)….412
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION….414
4.7.12.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS….414
4.7.12.b CHANGING THE OIL IN THE SWING REDUCTION GEAR….415
4.7.12.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE….415
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION….416
4.7.13.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER….416
4.7.13.b CHANGING THE COOLANT….419
4.7.13.c CHANGING THE BALL-BEARING RING PINION LUBRICANT….420
4.7.13.d CHECKING THE ALTERNATOR AND THE STARTER….420
TECHNICAL SPECIFICATIONS….421
5.1 TECHNICAL DATA….422
5.1.1 STANDARD OVERALL DIMENSIONS….422
5.1.2 TECHNICAL CHARACTERISTICS….423
5.1.3 LIFTING CHARACTERISTICS….424
5.1.3.1 LIFTING CAPACITY TABLE….424
5.1.3.2 LIFTING CAPACITY WITH RAISED BLADE….425
5.1.3.3 LIFTING CAPACITY WITH LOWERED BLADE….426
AUTHORIZED OPTIONAL EQUIPMENT….427
6.1 AUTHORIZED OPTIONAL EQUIPMENT….428
6.1.1 PRECAUTIONS REGARDING SAFETY….428
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT….429
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT….430
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER….431
6.2.1 DESCRIPTION AND OPERATION….431
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED….431
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER….435
6.2.3.1 INSTALLING THE HAMMER….435
6.2.3.2 REMOVING THE HAMMER….436
6.2.4 MAINTENANCE….436
6.3 CLAMSHELL BUCKET….437
6.3.1 DESRIPTION AND OPERATION….437
6.3.2 INSTALLING THE CLAMSHELL BUCKET….438
6.3.3 MAINTENANCE….440
WEAM003900 – Hydraulic Excavator PC75R-2 Operation & Maintenance Manual….441
COVER….441
1.1 FOREWORD….443
1.2 INFORMATION ON SAFETY….444
1.3 INTRODUCTION….446
1.3.1 INTENDED USES….446
1.3.2 IMPROPER OR UNAUTHORIZED USE….446
1.3.3 MAIN CHARACTERISTICS….447
1.3.4 RUNNING-IN….447
1.4 PRODUCT IDENTIFICATION….448
1.4.1 MACHINE SERIAL NUMBER….448
1.4.2 MACHINE IDENTIFICATION PLATE….448
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL….449
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER….449
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER….450
1.4.6 CAB SERIAL NUMBER….450
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS….451
CONTENTS….452
SAFETY AND ACCIDENT PREVENTION….459
2.1 SAFETY PLATES….460
2.1.1 POSITION OF THE SAFETY PLATES….460
2.1.2 POSITION OF THE PICTOGRAMS….476
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS….477
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED….479
2.2 GENERAL PRECAUTIONS….480
2.2.1 GENERAL SAFETY RULES….480
2.2.2 SAFETY DEVICES AND GUARDS….480
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS….480
2.2.4 UNAUTHORIZED MODIFICATIONS….481
2.2.5 LEAVING THE OPERATOR’S SEAT….481
2.2.6 GETTING ON AND OFF THE MACHINE….482
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL….482
2.2.8 PREVENTING BURNS….483
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER….483
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….484
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT….484
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE….484
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT….484
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….485
2.3.1 SAFETY ON THE WORK SITE….485
2.3.2 FIRE PREVENTION….485
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB….485
2.3.4 ROOM VENTILATION….486
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS….486
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS – CHECKING THE WINDSHIELD WIPER BLADES….486
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING….487
2.4.1 STARTING THE ENGINE….487
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE….487
2.4.3 CHECKS FOR TRAVELLING IN REVERSE….487
2.4.4 MOVING THE MACHINE….488
2.4.5 MOVING ON SLOPES….489
2.4.6 WORKING ON SLOPES….490
2.4.7 UNAUTHORIZED OPERATIONS….490
2.4.8 PREVENTING ELECTROCUTION….491
2.4.9 VISIBILITY….492
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES….492
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT….492
2.4.12 WORKING ON LOOSE GROUND….492
2.4.13 PARKING THE MACHINE….493
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES….494
2.5.1 LOADING AND UNLOADING THE MACHINE….494
2.5.2 SHIPPING….494
2.6 BATTERY….495
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES….495
2.6.2 STARTING WITH BOOSTER CABLES….495
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY….496
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE….497
2.8.1 WARNING PLATES….497
2.8.2 TOOLS….497
2.8.3 PERSONNEL….498
2.8.4 EQUIPMENT….498
2.8.5 WORKING UNDER THE MACHINE….498
2.8.6 KEEPING THE MACHINE CLEAN….498
2.8.7 USE OF THE ENGINE DURING MAINTENANCE….499
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY….499
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION….499
2.8.10 RULES FOR REFUELLING AND ADDING OIL….500
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR….500
2.8.12 USING LAMPS….500
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR….501
2.8.14 PRECAUTIONS CONCERNING THE STARTER….501
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES….502
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS….502
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES….502
2.8.18 COOLING FAN AND FAN BELT….503
2.8.19 WASTE MATERIALS….503
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES….503
THE MACHINE AND ITS OPERATIONS….505
3.1 SAFETY LOCKS….506
3.1.1 MACHINE LOCKS….506
3.2 GENERAL VIEWS….507
3.2.1 FRONT GENERAL VIEW (MONOBOOM)….507
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)….508
3.2.3 CAB INSIDE GENERAL VIEW….509
3.3 INSTRUMENTS AND CONTROLS….511
3.3.1 INSTRUMENTS….511
3.3.2 WARNING LIGHTS….513
3.3.3 SWITCHES AND PUSH BUTTONS….515
3.3.4 ELECTRICAL ACCESSORIES….523
3.3.5 MACHINE CONTROLS….525
3.4 FUSES AND RELAYS….536
3.4.1 CENTRAL UNIT FUSES AND RELAYS….536
3.4.1.1 CENTRAL UNIT FUSES….537
3.4.1.2 CENTRAL UNIT RELAYS….538
3.4.2 ENGINE LINE FUSES AND RELAYS….539
3.4.2.1 ENGINE LINE FUSES….539
3.4.2.2 ENGINE LINE RELAYS….540
3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provided)….541
3.5 GUARDS AND DRIVER’S SEAT….543
3.5.1 ENGINE HOOD….543
3.5.2 SIDE COVER….543
3.5.3 CAB….544
3.5.4 VENTILATION AND HEATING….548
3.5.5 AIR CONDITIONER (if provided)….549
3.5.6 SEAT….551
3.5.7 SAFETY BELT….552
3.5.8 EMERGENCY EXIT….552
3.5.9 TECHNICAL DOCUMENTATION CASE….553
3.5.10 FIRE EXTINGUISHER….553
3.5.11 FIRST AID KIT….553
3.6 USE OF THE MACHINE….555
3.6.1 CHECKS BEFORE STARTING THE ENGINE….555
3.6.1.1 VISUAL CHECKS….555
3.6.1.2 DAILY CHECKS….555
3.6.1.3 OPERATIONAL CHECKS….556
3.6.2 STARTING THE ENGINE….557
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES….557
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES….558
3.6.3 WARMING THE ENGINE….559
3.6.4 HEATING THE HYDRAULIC OIL….559
3.6.5 HOW TO MOVE THE MACHINE….559
3.6.5.1 STEERING (CHANGING DIRECTION)….561
3.6.5.2 MOVING ON SLOPES….562
3.6.5.3 MAXIMUM IMMERSION DEPTH….563
3.7 PARKING THE MACHINE….564
3.7.1 PARKING ON LEVEL GROUND….564
3.7.2 PARKING ON SLOPES….565
3.8 STOPPING THE ENGINE….566
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES….567
3.9.1 LOADING AND UNLOADING THE MACHINE….567
3.9.2 TRANSPORT….568
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON….569
3.10.1 FUEL AND LUBRICANTS….569
3.10.2 COOLANT….569
3.10.3 BATTERY….570
3.10.4 OTHER PRECAUTIONS….570
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK….570
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON….571
3.12 USING THE WORK EQUIPMENT….572
3.12.1 ORGANIZING THE WORK AREA….572
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT….572
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS….573
3.12.4 DIGGING METHOD….574
3.12.5 CHANGING THE BUCKET….575
3.13 LONG PERIODS OF INACTIVITY….576
3.13.1 BEFORE THE PERIOD OF INACTIVITY….576
3.13.2 DURING THE PERIOD OF INACTIVITY….577
3.13.3 AFTER THE PERIOD OF INACTIVITY….577
3.14 TROUBLESHOOTING….578
3.14.1 HOW TO REMOVE THE MACHINE….578
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED….578
3.14.3 IF THE BATTERY IS DEPLETED….579
3.14.3.1 STARTING WITH BOOSTER CABLES….580
3.14.4 OTHER TROUBLES….581
3.14.4.1 ELECTRICAL CIRCUIT….581
3.14.4.2 HYDRAULIC SYSTEM….582
3.14.4.3 ENGINE….583
MAINTENANCE….585
4.1 GUIDE TO MAINTENANCE….586
4.2 MAINTENANCE NOTES….588
4.2.1 NOTES REGARDING THE ENGINE….588
4.2.1.1 ENGINE OIL….588
4.2.1.2 COOLANT….588
4.2.1.3 FUEL….589
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM….589
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM….590
4.2.4 NOTES REGARDING LUBRICATION….590
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING….591
4.3 FUEL, COOLANT AND LUBRICANTS….592
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS….596
4.4 NUT AND BOLT TIGHTENING TORQUES….597
4.4.1 STANDARD TIGHTENING TORQUES….597
4.4.2 SPECIFIC TIGHTENING TORQUES….597
4.5 LUBRICATION….598
4.5.1 LUBRICATION DIAGRAM….598
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY….599
4.6.1 CRITICAL PARTS FOR SAFETY….600
4.7 MAINTENANCE PLAN….603
4.7.1 WHEN REQUIRED….607
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE….607
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER….609
4.7.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines equipped with air c….610
4.7.1.d CLEANING THE WATER SEPARATOR….611
4.7.1.e CHECKING THE STEEL TRACK TENSION….612
4.7.1.f CHECKING THE SHOE FASTENING….614
4.7.1.g CHECKING THE RUBBER TRACKS….615
4.7.1.h CHECKING THE RUBBER TRACK TENSION….617
4.7.1.j CHANGING THE RUBBER TRACK….619
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER….621
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER….621
4.7.2.b CHANGING THE HYDRAULIC OIL….621
4.7.3 CHECKS BEFORE STARTING….622
4.7.3.a VARIOUS CHECKS….622
4.7.3.b CHECKING THE COOLANT LEVEL….622
4.7.3.c CHECKING THE FUEL LEVEL….623
4.7.3.d CHECKING THE ENGINE OIL LEVEL….623
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT….624
4.7.3.f DRAINING THE WATER SEPARATOR….625
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION….626
4.7.4.a LUBRICATING THE JOINTS….626
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic….629
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION….629
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL….629
4.7.6.b LUBRICATING THE SWING JOINT….629
4.7.6.c CHECKING THE ELECTRICAL SYSTEM….630
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION….631
4.7.7.a LUBRICATING THE BALL-BEARING RING….631
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION….632
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION….632
4.7.9.a ADJUSTING THE FAN BELT TENSION….632
4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT (only for machines equipped with air con….633
4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL….634
4.7.9.d CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS….635
4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR….635
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthet….636
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION….636
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER….636
4.7.11.b CHANGING THE SERVO CONTROL FILTER….638
4.7.11.c CHANGING THE ENGINE OIL….639
4.7.11.d CHANGING THE ENGINE OIL FILTER….640
4.7.11.e CHANGING THE FUEL FILTER….641
4.7.11.f DRAINING THE FUEL TANK….642
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS….642
4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines equipped with air conditioner)….643
4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL….644
4.7.11.k DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable ….644
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION….646
4.7.12.a CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE….646
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION….647
4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS….647
4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR….648
4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER….649
4.7.13.d CHANGING THE COOLANT….652
4.7.13.e CHANGING THE BALL-BEARING RING PINION LUBRICANT….653
4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER….653
4.7.13.g CHECKING THE A/C COOLING GAS QUANTITY (only for machines equipped with air conditioner)….654
4.7.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION….655
4.7.14.a CHANGING THE A/C DEHYDRATOR FILTER (only for machines equipped with air conditioner)….655
4.7.14.b CHECKING THE CORRECT OPERATION OF THE A/C COMPRESSOR (only for machines equipped with ai….655
TECHNICAL SPECIFICATIONS….657
5.1 TECHNICAL DATA….658
5.1.1 STANDARD OVERALL DIMENSIONS….658
5.1.2 TECHNICAL CHARACTERISTICS….659
5.1.3 LIFTING CAPACITIES….660
5.1.3.1 LIFTING CAPACITY TABLE….660
5.1.3.2 LIFTING CAPACITY WITH RAISED BLADE….661
5.1.3.3 LIFTING CAPACITY WITH LOWERED BLADE….662
AUTHORIZED OPTIONAL EQUIPMENT….663
6.1 AUTHORIZED OPTIONAL EQUIPMENT….664
6.1.1 PRECAUTIONS REGARDING SAFETY….664
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT….665
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT….666
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER….667
6.2.1 DESCRIPTION AND OPERATION….667
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED….667
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER….671
6.2.3.1 INSTALLING THE HAMMER….671
6.2.3.2 REMOVING THE HAMMER….672
6.2.4 MAINTENANCE….672
6.3 CLAMSHELL BUCKET….673
6.3.1 DESCRIPTION AND OPERATION….673
6.3.2 INSTALLING THE CLAMSHELL BUCKET….674
6.3.3 MAINTENANCE….676
WEBM004000 – Hydraulic Excavator PC75R-2 Shop Manual….677
COVER….677
CONTENTS….679
LIST OF REVISED PAGES….681
SAFETY….683
FOREWORD….685
HOW TO READ THE SHOP MANUAL….686
HOISTING INSTRUCTIONS….687
STANDARD TIGHTENING TORQUE….688
COATING MATERIALS….690
ELECTRIC WIRE CODE….691
WEIGHT TABLE….692
TABLE OF OIL COOLANT QUANTITIES….693
10. STRUCTURE AND FUNCTION….697
P.T.O….698
POWER TRAIN….699
TRACK FRAME….701
IDLER AND RECOIL SPRING….702
CARRIER ROLLER….703
TRACK ROLLER….703
TRACK SHOE….704
SWING CIRCLE….705
SWING MACHINERY….706
HYDRAULIC CIRCUIT DIAGRAM (STANDARD)….707
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM)….709
HYDRAULIC PUMP….710
9-SPOOL CONTROL VALVE (STANDARD)….736
10-SPOOL CONTROL VALVE (STANDARD+2-PIECE BOOM)….738
SWING MOTOR….766
CENTER SWIVEL JOINT….770
TRAVEL MOTOR….772
PARKING BRAKE….774
BRAKE VALVE….775
TRAVEL MOTOR….777
REDUCTION GEAR….779
CYLINDERS….780
SERVOCONTROL FEED UNIT….782
ACCUMULATOR….787
PPC VALVE (WORK EQUIPMENT)….788
PPC VALVE (BLADE, BOOM SWING, 2-PIECE BOOM)….792
TRAVEL PPC VALVE….796
BOOM AND ARM SAFETY VALVE….801
BLADE SAFETY VALVE….802
2-PIECE BOOM SAFETY VALVE….803
OVERLOAD SENSOR SWITCH….804
SOLENOID VALVE….805
ELECTRICAL DIAGRAM (1/3)….807
ELECTRICAL DIAGRAM (2/3)….809
ELECTRICAL DIAGRAM (3/3)….811
20. TESTING AND ADJUSTING….815
NORMAL OR STANDARD TECHNICAL DATA….816
SPECIAL TOOLS….833
MEASURING THE ENGINE SPEED….835
ADJUSTING VALVE CLEARANCE….836
MEASURING COMPRESSION PRESSURE….837
TESTING AND ADJUSTING FUEL INJECTION TIMING….838
TESTING AND ADJUSTING FAN BELT TENSION….840
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER….841
ADJUSTING PPC VALVE CLEARANCE….842
ADJUSTING THE SAFETY MICROSWITCH….843
MEASURING THE SWING CIRCLE AXIAL CLEARANCE….844
TESTING AND ADJUSTING TRACK-SHOE TENSION….845
AIR BLEEDING FROM HYDRAULIC CIRCUITS….846
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS….849
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS….850
TESTING AND SETTING OF MAIN VALVES….851
ADJUSTING PC VALVE….853
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE….854
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL FEED UNIT….856
MEASURING PUMPS DELIVERY AND FLOW CONTROL STARTING POINT PUMP P1….857
MEASURING TRAVEL DEVIATION….859
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS….860
MEASURING INNER OIL LEAKAGE OF TRAVEL MOTOR….861
ADJUSTING BOOM AND ARM SAFETY VALVES….862
ADJUSTING 2nd BOOM SAFETY VALVES….863
MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL OVERLOAD OPERATION….864
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR….865
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT….866
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS….868
30. DISASSEMBLY AND ASSEMBLY….877
HOW TO READ THE MANUAL….879
PRECAUTIONS TO BE TAKEN WHEN WORKING….880
SPECIAL TOOLS….881
STARTER MOTOR….883
REMOVAL AND INSTALLATION….883
ALTERNATOR….884
REMOVAL AND INSTALLATION….884
INJECTION PUMP….885
REMOVAL….885
INSTALLATION….888
NOZZLE HOLDER….889
REMOVAL AND INSTALLATION….889
CYLINDER HEAD….890
REMOVAL….890
INSTALLATION….892
SEAT….893
REMOVAL AND INSTALLATION….893
CABIN….894
REMOVAL AND INSTALLATION….894
ENGINE HOOD….895
REMOVAL AND INSTALLATION….895
FRONT HOOD….896
REMOVAL AND INSTALLATION….896
HEATING FAN….897
REMOVAL AND INSTALLATION….897
RADIATOR….898
REMOVAL….898
INSTALLATION….899
FUEL TANK….900
REMOVAL….900
INSTALLATION….901
HYDRAULIC OIL TANK….902
REMOVAL AND INSTALLATION….902
ENGINE-PUMP GROUP….903
REMOVAL….903
INSTALLATION….906
PUMP GROUP….907
REMOVAL….907
INSTALLATION….908
ENGINE-PUMP COUPLING JOINT….909
REMOVAL AND INSTALLATION….909
MAIN PUMP INPUT SHAFT OIL SEAL….910
REMOVAL AND INSTALLATION….910
GEAR PUMP….911
REMOVAL AND INSTALLATION….911
SWIVEL JOINT….912
REMOVAL AND INSTALLATION….912
SWING MOTOR….913
REMOVAL AND INSTALLATION….913
SWING MACHINERY….914
REMOVAL AND INSTALLATION….914
DISASSEMBLY….915
ASSEMBLY….918
CONTROL VALVE….921
REMOVAL AND INSTALLATION….921
REVOLVING FRAME….922
REMOVAL….922
INSTALLATION….923
COUNTERWEIGHT….924
REMOVAL AND INSTALLATION….924
SWING CIRCLE….925
REMOVAL AND INSTALLATION….925
TRACK SHOES….926
REMOVAL AND INSTALLATION….926
SPROCKET ASSEMBLY….927
REMOVAL AND INSTALLATION….927
TRAVEL GEAR MOTOR….928
REMOVAL AND INSTALLATION….928
DISASSEMBLY….929
ASSEMBLY….944
BALL BEARING PRELOAD….959
ADJUSTING….959
AXIAL CLEARANCE ON TAPERED ROLLER BEARINGS….960
ADJUSTING….960
IDLER AND RECOIL SPRING ASSEMBLY….961
REMOVAL AND INSTALLATION….961
IDLER….962
DISASSEMBLY AND ASSEMBLY….962
RECOIL SPRING GROUP AND CYLINDER….963
DISASSEMBLY AND ASSEMBLY….963
TRACK ROLLER….964
REMOVAL AND INSTALLATION….964
CARRIER ROLLER….965
REMOVAL AND INSTALLATION….965
R.H. PPC VALVE (BOOM-BUCKET)….966
REMOVAL….966
INSTALLATION….967
L.H. PPC VALVE (ARM-SWING)….968
REMOVAL….968
INSTALLATION….969
BLADE PPC VALVE….970
REMOVAL AND INSTALLATION….970
TRAVEL PEDAL CONTROL….971
REMOVAL AND INSTALLATION….971
1st BOOM SWING PEDAL CONTROL….972
REMOVAL AND INSTALLATION….972
BOOM CYLINDER (FOR 1-PIECE BOOM)….973
REMOVAL AND INSTALLATION….973
BOOM CYLINDER (FOR 2-PIECE BOOM)….974
REMOVAL….974
INSTALLATION….975
2nd BOOM CYLINDERS….976
REMOVAL….976
INSTALLATION….977
ARM CYLINDER….978
REMOVAL AND INSTALLATION….978
BUCKET CYLINDER….979
REMOVAL AND INSTALLATION….979
BOOM SWING CYLINDER….980
REMOVAL AND INSTALLATION….980
BLADE CYLINDER….981
REMOVAL AND INSTALLATION….981
WORK EQUIPMENT CYLINDERS….982
DISASSEMBLY….982
ASSEMBLY….983
WORK EQUIPMENT (FOR 1-PIECE BOOM)….987
REMOVAL AND INSTALLATION….987
WORK EQUIPMENT (FOR 2-PIECE BOOM)….988
REMOVAL….988
INSTALLATION….989
BUCKET….990
REMOVAL AND INSTALLATION….990
ARM….991
REMOVAL….991
INSTALLATION….993
2nd BOOM….994
REMOVAL….994
INSTALLATION….995
BOOM (FOR 1-PIECE BOOM)….996
REMOVAL AND INSTALLATION….996
1st BOOM….997
REMOVAL….997
INSTALLATION….998
SWING BRACKET….999
REMOVAL AND INSTALLATION….999
BLADE….1000
REMOVAL AND INSTALLATION….1000
40. MAINTENANCE STANDARD….1003
P.T.O….1004
SWING CIRCLE….1005
TRACK FRAME….1006
IDLER….1007
CARRIER ROLLER….1008
TRACK ROLLER….1009
TRACK SHOE….1010
SPROCKET….1011
SWING MACHINERY….1012
HYDRAULIC PUMP….1013
CONTROL VALVE….1014
SWING MOTOR….1024
SWIVEL JOINT….1025
TRAVEL MOTOR….1026
SERVOCONTROL FEED UNIT….1028
TRAVEL PPC VALVE….1029
PPC VALVE….1030
BLADE SAFETY VALVE….1032
CYLINDERS….1034
WORK EQUIPMENT (1-PIECE BOOM)….1036
WORK EQUIPMENT (2-PIECE BOOM)….1038

Komatsu Hydraulic Excavator PC75R Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC20, PC25, PC30, PC40, PC45, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC20-3, PC20-6, PC25-1, PC30-3, PC30-6, PC30-7, PC40-6, PC40-7, PC45-1 workshop service repair manual includes:
* 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.

SEBM020R0604 – Hydraulic Excavator PC20-6, PC30-6, PC40-6 Shop Manual.pdf
SEBM020S0707 – Hydraulic Excavator PC25-1, PC30-7, PC40-7, PC45-1 Shop Manual.pdf
SEBM0225C01 – Hydraulic Excavator PC20-3, PC30-3 Shop Manual.pdf
SEAM020P0700 – Hydraulic Excavator PC20-7 Operation & Maintenance Manual.pdf
SEAM006600 – Hydraulic Excavator PC25-1, PC30-7, PC40-7, PC45-1 Operation & Maintenance Manual.pdf
SEAM009502T – Hydraulic Excavator PC40-7 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,522 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
SEAM006600 – Hydraulic Excavator PC25-1, PC30-7, PC40-7, PC45-1 Operation & Maintenance Manual…2
  COVER…2
  1. FOREWORD…3
  2. SAFETY INFORMATION…4
  3. INTRODUCTION…5
    3.1 INTENDED USE…5
    3.2 FEATURES…5
    3.3 BREAKING IN THE MACHINE…5
  4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…6
    4.1 MACHINE SERIAL NO. PLATE  POSITION…6
    4.2 ENGINE SERIAL NO. PLATE POSITION…6
    4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…6
  CONTENTS…7
  SAFETY…11
    6. GENERAL PRECAUTIONS…12
    7. PRECAUTIONS DURING OPERATION…17
      7.1 BEFORE STARTING ENGINE…17
      7.2 OPERATING MACHINE…19
      7.3 TRANSPORTATION…24
      7.4 BATTERY…25
      7.5 TOWING…26
      7.6 BUCKET WITH HOOK…27
    8. PRECAUTIONS FOR MAINTENANCE…30
      8.1 BEFORE CARRYING OUT MAINTENANCE…30
      8.2 DURING MAINTENANCE…33
    9. POSITION FOR ATTACHING SAFETY LABELS…37
  OPERATION…41
    10. GENERAL VIEW…42
      10.1 GENERAL VIEW OF MACHINE…42
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…43
    11. EXPLANATION OF COMPONENTS…44
      11.1 MACHINE MONITOR…44
      11.2 SWITCHES…49
      11.3 CONTROL LEVERS AND PEDALS…52
      11.4 ENGINE HOOD…56
      11.5 FRONT WINDOW (MACHINES EQUIPPED WITH CAB)…57
      11.6 DOOR LOCK…59
      11.7 FUSE…60
      11.8 FUSIBLE LINK…60
      11.9 CAP, COVER WITH LOCK…61
      11.10 CANOPY (MACHINES EQUIPPED WITH CANOPY)…62
    12. OPERATION…63
      12.1 CHECK BEFORE STARTING ENGINE…63
      12.2 STARTING ENGINE…71
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…73
      12.4 MOVING MACHINE OFF…75
      12.5 STEERING MACHINE…78
      12.6 STOPPING MACHINE…80
      12.7 SWINGING…81
      12.8 OPERATION OF WORK EQUIPMENT…82
      12.9 PROHIBITIONS FOR OPERATION…83
      12.10 PRECAUTIONS FOR OPERATION…86
      12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…87
      12.12 HOW TO ESCAPE MUD…89
      12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…90
      12.14 REPLACEMENT OF BUCKET…92
      12.15 PARKING MACHINE…95
      12.16 CHECK AFTER FINISHING WORK…96
      12.17 STOPPING ENGINE…96
      12.18 CHECK AFTER STOPPING ENGINE…97
      12.19 LOCKING…97
      12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…98
    13. TRANSPORTATION…103
      13.1 LOADING, UNLOADING WORK…103
      13.2 METHOD OF LIFTING MACHINE…105
      13.3 PRECAUTIONS FOR LOADING…107
      13.4 PRECAUTIONS FOR TRANSPORTATION…108
    14. COLD WEATHER OPERATION…109
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…109
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…111
      14.3 PREPARING THE CAB HEATER (MACHINES EQUIPPED WITH CAB)…111
      14.4 AFTER COLD WEATHER…111
    15. LONG-TERM STORAGE…112
      15.1 BEFORE STORAGE…112
      15.2 DURING STORAGE…113
      15.3 AFTER STORAGE…113
    16. TROUBLESHOOTING…114
      16.1 PHENOMENA THAT ARE NOT FAILURES…114
      16.2 METHOD OF TOWING MACHINE…114
      16.3 PRECAUTIONS ON PARTICULAR JOBSITES…114
      16.4 IF BATTERY IS DISCHARGED…115
      16.5 OTHER TROUBLE…120
  MAINTENANCE…125
    17. GUIDES TO MAINTENANCE…126
    18. OUTLINES OF SERVICE…128
      18.1 OUTLINE OF OIL, FUEL, COOLANT…128
      18.2 OUTLINE OF ELECTRIC SYSTEM…131
      18.3 OUTLINE OF HYDRAULIC SYSTEM…132
    19. WEAR PARTS LIST…133
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…134
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…138
      21.1 INTRODUCTION OF NECESSARY TOOLS…138
      21.2 TORQUE LIST…139
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…140
    23. MAINTENANCE SCHEDULE CHART…142
      23.1 MAINTENANCE SCHEDULE CHART…142
      23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…144
    24. SERVICE PROCEDURE…145
      24.1 INITIAL 250 HOURS SERVICE…145
        CHECK ENGINE VALVE CLEARANCE, ADJUST…192
      24.2 WHEN REQUIRED…146
        24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…146
        24.2.2 CLEAN INSIDE OF COOLING SYSTEM…149
        24.2.3 DRAIN WATER, SEDIMENT FROM FUEL TANK…153
        24.2.4 CLEAN WATER SEPARATOR ELEMENT…153
        24.2.5 CHECK ELECTRIC WIRINGS…154
        24.2.6 CHECK RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…155
        24.2.7 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…157
        24.2.8 REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…159
        24.2.9 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH STEEL SHOES)…162
        24.2.10 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…165
        24.2.11 INSPECTION OF BUCKET PLAY ADJUSTMENT MECHANISM…168
      24.3 CHECK BEFORE STARTING…169
        24.3.1 CHECK COOLANT LEVEL, ADD WATER…169
        24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…169
        24.3.3 CHECK FUEL LEVEL, ADD FUEL…170
        24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…171
        24.3.5 CHECK DUST INDICATOR…172
        24.3.6 CHECK WATER SEPARATOR…172
      24.4 EVERY 100 HOURS SERVICE…173
        24.4.1 LUBRICATING…173
          1. SWING PINION (1POINT)…173
          2. SWING CIRCLE (1POINT)…173
          3. BOOM SWING CYLINDER FOOT PIN (1POINT)…173
          4. BOOM SWING CYLINDER ROD END (1POINT)…173
          5. BOOM CYLINDER FOOT PIN (1POINT)…173
          6. BLADE CYLINDER FOOT PIN (1POINT)…173
          7. BLADE FOOT PIN (2 POINTS)…173
          8. BLADE CYLINDER ROD END (1POINT)…173
          9. BOOM FOOT PIN (2 POINTS)…173
          10. BOOM SWING BRACKET PIN (2 POINTS)…173
          11. ARM CYLINDER FOOT PIN (1POINT)…174
          12. BOOM CYLINDER ROD END (1POINT)…174
          13. BOOM-ARM COUPLING PIN (1POINT)…174
          14. ARM CYLINDER ROD END PIN (1POINT)…174
          15. BUCKET CYLINDER FOOT PIN (1POINT)…174
          16. BUCKET CYLINDER ROD END PIN (1POINT)…174
          17. LINK COUPLING PIN (1POINT)…174
          18. BUCKET-LINK COUPLING PIN (2 POINTS)…174
          19. ARM-BUCKET COUPLING PIN (1POINT)…174
          20. ARM-LINK COUPLING PIN (1POINT)…174
      24.5 EVERY 250 HOURS SERVICE…175
        24.5.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…175
        24.5.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…177
        24.5.3 CHECK LEVEL OF BATTERY ELECTROLYTE…179
        24.5.4 REPLACE HYDRAULIC FILTER ELEMENT…180
        24.5.5 CHECK FAN BELT TENSION, ADJUST…181
      24.6 EVERY 500 HOURS SERVICE…182
        24.6.1 REPLACE FUEL FILTER CARTRIDGE…182
        24.6.2 CLEAN, CHECK RADIATOR FINS…184
      24.7 EVERY 1000 HOURS SERVICE…185
        24.7.1 CHANGE OIL IN SWING MACHINERY CASE…185
        24.7.2 CHANGE OIL IN FINAL DRIVE CASE…186
      24.8 EVERY 2000 HOURS SERVICE…188
        24.8.1 CHANGE OIL IN HYDRAULIC TANK CLEAN STRAINER…188
        24.8.2 CHECK ALTERNATOR, STARTING MOTOR…192
        24.8.3 CHECK ENGINE VALVE CLEARANCE, ADJUST…192
  SPECIFICATIONS…193
    25. SPECIFICATIONS…194
  OPTIONS, ATTACHMENTS…211
    26. GENERAL PRECAUTIONS…212
      26.1 PRECAUTIONS RELATED TO SAFETY…212
      26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…213
    27. HANDLING BUCKET WITH HOOK…214
      27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…214
      27.2 PROHIBITED OPERATIONS…214
      27.3 PRECAUTIONS DURING OPERATIONS…214
SEAM009502T – Hydraulic Excavator PC40-7 Operation & Maintenance Manual…215
  COVER…215
  1. FOREWORD…216
  2. SAFETY INFORMATION…219
  3. INTRODUCTION…220
  4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…221
  5. CONTENTS…222
  SAFETY…225
    6. GENERAL PRECAUTIONS…226
    7. PRECAUTIONS DURING OPERATION…231
      7.1 BEFORE STARTING ENGINE…231
      7.2 OPERATING MACHINE…233
      7.3 TRANSPORTATION…238
      7.4 BATTERY…239
      7.5 TOWING…240
      7.6 BUCKET WITH HOOK…241
    8. PRECAUTIONS FOR MAINTENANCE…244
      8.1 BEFORE CARRYING OUT MAINTENANCE…244
      8.2 DURING MAINTENANCE…247
    9. POSITION FOR ATTACHING SAFETY LABELS…251
  OPERATION…255
    10. GENERAL VIEW…256
      10.1 GENERAL VIEW OF MACHINE…256
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…257
    11. EXPLANATION OF COMPONENTS…258
      11.1 MACHINE MONITOR…258
      11.2 SWITCHES…263
      11.3 CONTROL LEVERS AND PEDALS…265
      11.4 ENGINE HOOD…269
      11.5 FUSE…270
      11.6 FUSIBLE LINK…270
      11.7 CAP, COVER WITH LOCK…271
      11.8 USING SEAT BELT…272
      11.9 STORAGE PLACE FOR OPERATION AND MAINTENANCE MANUAL…273
      11.10 HANDLING ACCUMULATOR…273
    12. OPERATION…275
      12.1 CHECK BEFORE STARTING ENGINE…275
      12.2 STARTING ENGINE…283
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…285
      12.4 MOVING MACHINE OFF…287
      12.5 STEERING MACHINE…290
      12.6 STOPPING MACHINE…292
      12.7 SWINGING…293
      12.8 OPERATION OF WORK EQUIPMENT…294
      12.9 PROHIBITIONS FOR OPERATION…295
      12.10 PRECAUTIONS FOR OPERATION…298
      12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…299
      12.12 HOW TO ESCAPE FROM MUD…301
      12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…302
      12.14 REPLACEMENT OF BUCKET…304
      12.15 PARKING MACHINE…307
      12.16 CHECK AFTER FINISHING WORK…308
      12.17 STOPPING ENGINE…308
      12.18 CHECK AFTER STOPPING ENGINE…309
      12.19 LOCKING…309
      12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…310
    13. TRANSPORTATION…315
      13.1 LOADING, UNLOADING WORK…315
      13.2 METHOD OF LIFTING MACHINE…317
      13.3 PRECAUTIONS FOR LOADING…319
      13.4 PRECAUTIONS FOR TRANSPORTATION…320
    14. COLD WEATHER OPERATION…321
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…321
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…323
      14.3 PREPARING THE CAB HEATER (MACHINES EQUIPPED WITH CAB)…323
      14.4 AFTER COLD WEATHER…323
    15. LONG-TERM STORAGE…324
      15.1 BEFORE STORAGE…324
      15.2 DURING STORAGE…325
      15.3 AFTER STORAGE…325
    16. TROUBLESHOOTING…326
      16.1 PHENOMENA THAT ARE NOT FAILURES…326
      16.2 METHOD OF TOWING MACHINE…326
      16.3 PRECAUTIONS ON PARTICULAR JOBSITES…326
      16.4 IF BATTERY IS DISCHARGED…327
      16.5 OTHER TROUBLE…332
  MAINTENANCE…336
    17. GUIDES TO MAINTENANCE…337
    18. OUTLINES OF SERVICE…339
      18.1 OUTLINE OF OIL,FUEL,COOLANT…339
      18.2 OUTLINE OF ELECTRIC SYSTEM…342
      18.3 OUTLINE OF HYDRAULIC SYSTEM…343
    19. WEAR PARTS LIST…344
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…345
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…349
      21.1 INTRODUCTION OF NECESSARY TOOLS…349
      21.2 TORQUE LIST…350
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…351
    23. MAINTENANCE SCHEDULE CHART…353
      23.1 MAINTENANCE SCHEDULE CHART…353
      23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…355
    24. SERVICE PROCEDURE…356
      24.1 INITIAL 250 HOURS SERVICE…356
      24.2 WHEN REQUIRED…357
      24.3 CHECK BEFORE STARTING…380
      24.4 EVERY 100 HOURS SERVICE…384
      24.5 EVERY 250 HOURS SERVICE…386
      24.6 EVERY 500 HOURS SERVICE…392
      24.7 EVERY 1000 HOURS SERVICE…395
      24.8 EVERY 2000 HOURS SERVICE…397
  SPECIFICATIONS…402
    25. SPECIFICATIONS…403
SEAM020P0700 – Hydraulic Excavator PC20-7 Operation & Maintenance Manual…407
  COVER…407
  FOREWORD…408
  BREAKING IN YOUR NEW MACHINE…409
  CONTENTS…410
  GENERAL LOCATIONS AND SPECIFICATIONS…411
  INSTRUMENTS AND CONTROLS…413
  CHECK BEFORE STARTING…439
  OPERATING YOUR MACHINE…445
  REPLACEMENT OF BUCKET…465
  SELECTION OF TRACK SHOES (STEEL SHOES ONLY)…467
  HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…468
  COLD WEATHER OPERATION…475
  PERIODIC MAINTENANCE…480
    PERIODICAL REPLACEMENT OF SAFETY PARTS…481
    MAINTENANCE TABLE…484
    OIL FILLER AND LEVEL GAUGE POSITIONS…487
    CHECK BEFORE STARTING…489
    EVERY 100 HOURS SERVICE…489
    EVERY 250 HOURS SERVICE…491
    EVERY 500 HOURS SERVICE…497
    EVERY 1000 HOURS SERVICE…499
    EVERY 2000 HOURS SERVICE…501
    WHEN REQUIRED…503
  SERVICE METER…521
  MACHINE AND ENGINE SERIAL NUMBERS…523
  FUEL,COOLANT AND LUBRICANTS…525
  SAFETY AND OPERATION…527
    CONTENTS…528
    SAFETY HINTS…529
    OPERATING RADIO…545
    LOCKING CAP…549
    HANDLING OF BATTERY…551
    METHOD OF RAISING THE MACHINE…554
    TRANSPORTATION…556
    PRECAUTIONS FOR MAINTENANCE…557
    STORAGE…563
    COOLANT AND LUBRICANTS…564
SEBM020R0604 – Hydraulic Excavator PC20-6, PC30-6, PC40-6 Shop Manual…565
  COVER…565
  CONTENTS…566
  10 STRUCTURE AND FUNCTION…581
    POWER TRAIN…582
    SWING CIRCLE…583
    SWING MACHINERY…584
    SPROCKET…586
    TRACK FRAME AND RECOIL SPRING…587
    IDLER…588
    TRACK ROLLER…588
    TRACK SHOE…589
    HYDRAULIC PIPING…591
    HYDRAULIC CIRCUIT SCHEMATICS…593
    HYDRAULIC CIRCUIT DIAGRAM…596
    HYDRAULIC TANK…603
    HYDRAULIC TRIPLE GEAR PUMP…605
    6-SPOOL CONTROL VALVE…607
    2-SPOOL CONTROL VALVE…609
    3-SPOOL CONTROL VALVE…610
    CENTER SWIVEL JOINT…613
    SWING MOTOR…615
    TRAVEL MOTOR (WITH REDUCTION GEAR)…616
    VALVE CONTROL…621
    WORK EQUIPMENT…622
    ELECTRICAL CIRCUIT DIAGRAM…623
  20 TESTING AND ADJUSTING…627
    TABLE OF JUDGEMENT STANDARD VALVE…628
    TESTING AND ADJUSTING TOOL LIST…638
    ADJUSTING VALVE CLEARANCE (PC20,30-6)…639
    ADJUSTING VALVE CLEARANCE (PC40-6)…640
    MEASURING COMPRESSION PRESSURE…641
    TESTING AND ADJUSTING FUEL INJECTION TIMING (PC20,30-6)…642
    TESTING AND ADJUSTING FUEL INJECTION TIMING (PC40-6)…643
    BLEEDING AIR FROM HYDRAULIC CYLINDERS…644
    MEASURING AND ADJUSTING HYDRAULIC PRESSURE…645
    MEASURING HYDRAULIC PRESSURE OF ACCELERATION CIRCUIT (PC30,40-6)…648
    MEASURING DISCHARGE AMOUNT OF PUMP…649
    MEASURING OIL LEAKAGE FROM SWING, TRAVEL MOTORS…650
    TESTING FOR LEAKAGE OF OIL FROM CENTER SWIVEL JOINT (PC20-6)…651
    TESTING FOR LEAKAGE OF OIL FROM CENTER SWIVEL JOINT (PC30-6)…652
    TESTING FOR LEAKAGE OF OIL FROM CENTER SWIVEL JOINT (PC40-6)…653
    MEASURING LEAKAGE FROM HYDRAULIC CYLINDERS…654
    TROUBLESHOOTING…655
      PREPARATION OF TROUBLESHOOTING…656
      HOW TO USE DIAGNOSTIC TABLE…658
      PREVENTING RECURRENCE OF THE SAME TROUBLE…660
        1.WORK EQUIPMENT, SWING, AND TRAVEL DO NOT MOVE, OR SPEED IS EXTREMELY SLOW…661
        2.ARM IN (OUT) LACKS POWER (INCLUDING LACK OF SPEED)…662
        3.BUCKET CURL (DUMP), BOOM RAISE (PUSHING UP CHASSIS), AND BOOM SWING LACK POWER (INCLUDING LACK OF SPEED)…663
        4.ARM IN (OUT) OPERATION IS IMPOSSIBLE…664
        5.BUCKET CURL (DUMP), BOOM RAISE (LOWER), BOOM SWING OPERATION IS IMPOSSIBLE…665
        6.EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT (BOOM, ARM, BUCKET, BLADE, BOOM SWING)…666
        7.BLADE LACKS POWER (INCLUDING LACK OF SPEED)…667
        8.BLADE OPERATION IS IMPOSSIBLE…668
        9.LEFT (RIGHT) BOOM SWING LACKS POWER (INCLUDING LACK OF SPEED)…669
        10.SWING OPERATION IS IMPOSSIBLE TO LEFT (OR RIGHT)…670
        11.EXCESSIVE OVERRUN OF SWING ON SLOPES (HYDRAULIC DRIFT OF SWING)…671
        12.EXCESSIVE OVERRUN WHEN SWING IS STOPPED…672
        13.MACHINE NATURALLY DEVIATES TO ONE SIDE WHEN TRAVELING…673
        14.MACHINE DOES NOT TRAVEL FORWARD (IN REVERSE)…674
        15.TRAVEL SPEED DOES NOT CHANGE (PC30.40-6)…675
  30 DISASSEMBLY AND ASSEMBLY…676
    METHOD OF READING MANUAL…678
    TABLE OF SPECIAL TOOLS…680
    STARTING MOTOR…682
      REMOVAL…682
      INSTALLATION…682
    ALTERNATOR…682
      REMOVAL…682
      INSTALLATION…682
    WATER PUMP…684
      REMOVAL…684
      INSTALLATION…684
    FUEL INJECTION PUMP…686
      REMOVAL…686
      INSTALLATION…686
    NOZZLE HOLDER…688
      REMOVAL…688
      INSTALLATION…688
    CYLINDER HEAD…690
      REMOVAL (PC20.30-6)…690
      INSTALLATION (PC20.30-6)…690
      REMOVAL (PC40-6)…692
      INSTALLATION (PC40-6)…692
    HYDRAULIC OIL COOLER …694
      REMOVAL…694
      INSTALLATION…694
    RADIATOR…694
      REMOVAL …694
      INSTALLATION…694
    ENGINE…696
      REMOVAL (PC20,30-6)…696
      INSTALLATION (PC20,30-6)…696
      REMOVAL (PC40-6)…698
      INSTALLATION (PC40-6)…698
    SWING CIRCLE…700
      REMOVAL…700
      INSTALLATION…700
    SWING MACHINERY…702
      REMOVAL…702
      INSTALLATION …702
      DISASSEMBLY (PC20.30-6)…704
      ASSEMBLY (PC20.30-6)…706
      DISASSEMBLY (PC40-6)…708
      ASSEMBLY (PC40-6)…710
    REVOLVING FRAME…712
      REMOVAL…712
      INSTALLATION…712
    TRACK SHOE…714
      REMOVAL…714
      INSTALLATION…714
    TRACK ROLLER…716
      REMOVAL…716
      INSTALLATION…716
    IDLER, RECOIL SPRING…716
      REMOVAL…716
      INSTALLATION…716
    RECOIL SPRING…718
      DISASSEMBLY…718
      ASSEMBLY…718
    SPROCKET…720
      REMOVAL…720
      INSTALLATION…720
    HYDRAULIC PUMP…720
      REMOVAL…720
      INSTALLATION…720
    6-SPOOL CONTROL VALVE…722
      REMOVAL…722
      INSTALLATION…722
    3-SPOOL CONTROL VALVE…722
      REMOVAL…722
      INSTALLATION…722
    2-SPOOL CONTROL VALVE…722
      REMOVAL…722
      INSTALLATION…722
    6-SPOOL CONTROL VALVE…724
      DISASSEMBLY…724
      ASSEMBLY…724
    3-SPOOL CONTROL VALVE…726
      DISASSEMBLY…726
      ASSEMBLY…726
    SWING MOTOR…728
      REMOVAL…728
      INSTALLATION…728
      DISASSEMBLY…730
      ASSEMBLY…732
    CENTER SWIVEL JOINT…734
      REMOVAL…734
      INSTALLATION…734
      DISASSEMBLY (PC20,30-6)…736
      ASSEMBLY (PC20,30-6)…736
      DISASSEMBLY (PC40-6)…738
      ASSEMBLY (PC40-6)…738
    TRAVEL MOTOR…740
      REMOVAL…740
      INSTALLATION…740
      DISASSEMBLY (PC20-6)…742
      ASSEMBLY (PC20-6)…754
      DISASSEMBLY (PC30,40-6)…772
      ASSEMBLY (PC30,40-6)…786
      DISASSEMBLY (PC20-6)…804
      ASSEMBLY (PC20-6)…812
      DISASSEMBLY (PC30-6)…822
      ASSEMBLY (PC30-6)…830
      DISASSEMBLY (PC40-6)…842
      ASSEMBLY (PC40-6)…850
    BOOM CYLINDER …860
      REMOVAL…860
      INSTALLATION…860
    ARM CYLINDER …862
      REMOVAL…862
      INSTALLATION…862
    BUCKET CYLINDER…862
      REMOVAL…862
      INSTALLATION…862
    BLADE CYLINDER…864
      REMOVAL…864
      INSTALLATION…864
    BOOM SWING CYLINDER…864
      REMOVAL…864
      INSTALLATION…864
    HYDRAULIC CYLINDER…866
      DISASSEMBLY…866
      ASSEMBLY…868
    REPLACING HYDRAULIC CYLINDER PISTON RING…870
    WORK EQUIPMENT…872
      REMOVAL…872
      INSTALLATION…872
    BLADE  …872
      REMOVAL…872
      INSTALLATION…872
    BUCKET…874
      REMOVAL…874
      INSTALLATION…874
    ARM  …874
      REMOVAL…874
      INSTALLATION…874
    ARM, BUCKET…876
      REMOVAL…876
      INSTALLATION…876
    BOOM…876
      REMOVL…876
      INSTALLATION…876
    FLOOR FRAME…878
      REMOVAL…878
      INSTALLATION…878
  40 MAINTENANCE STANDARD…880
    SWING CIRCLE…881
    SWING MACHINERY…882
    SPROCKET…884
    TRACK FRAME AND RECOIL SPRING…885
    IDLER…886
    TRACK ROLLER…887
    TRACK SHOE…888
    TRIPLE GEAR PUMP…890
    CENTER SWIVEL JOINT…892
    SWING MOTOR…894
    TRAVEL MOTOR BRAKE VALVE…895
    6-SPOOL CONTROL VALVE…897
    2-SPOOL CONTROL VALVE…898
    3-SPOOL CONTROL VALVE…899
    HYDRAULIC CYLINDER…900
    WORK EQUIPMENT…906
SEBM020S0707 – Hydraulic Excavator PC25-1, PC30-7, PC40-7, PC45-1 Shop Manual…910
  COVER…910
  CONTENTS…911
  SAFETY…914
    SAFETY NOTICE…914
  FOREWARD…916
    GENERAL…916
    HOW TO READ THE SHOP MANUAL…917
    HOISTING INSTRUCTIONS…918
    COATING MATERIALS…919
    STANDARD TIGHTENING TORQUE…920
    ELECTRIC WIRE CODE…922
    CONVERSION TABLE…923
    WEIGHT TABLE…930
    WEIGHT TABLE…931
    LIST OF LUBRICANT AND WATER…934
  10 STRUCTURE AND FUNCTION…937
    POWER TRAIN…938
    SWING CIRCLE…939
    SWING MACHINERY…940
    TRACK FRAME AND RECOIL SPRING…942
    HYDRAULIC PIPING…945
    HYDRAULIC CIRCUIT DIAGRAM…946
    HYDRAULIC TANK AND FUEL TANK…950
    HYDRAULIC PUMP…951
    CONTROL PUMP…959
    7 – SPOOL CONTROL VALVE…960
    2 – SPOOL CONTROL VALVE…964
    SWING MOTOR…968
    CENTER SWIVEL JOINT…971
    TRAVEL MOTOR…972
    HYDRAULIC CYLINDER…977
    VALVE CONTROL…981
    PPC VALVE…982
    SOLENOID VALVE…988
    WORK EQUIPMENT…990
    HYDRAULIC BREAKER…991
    ELECTRICAL CIRCUIT DIAGRAM…994
    MONITOR SYSTEM…997
  20 TESTING AND ADJUSTING…1006
    TABLE OF JUDGEMENT STANDARD VALUE…1007
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…1025
    TOOL FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…1027
    ADJUSTING VALVE CLEARANCE…1028
    MEASURING COMPRESSION PRESSURE…1030
    ADJUSTING FUEL INJECTION TIMING…1031
    MEASURING ENGINE OIL PRESSURE…1032
    ADJUSTING FUEL CONTROL LEVER…1034
    TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…1035
    TESTING CONTROL CIRCUIT PRESSURE…1038
    MEASURING OUTPUT PRESSURE OF PPC VALVE…1039
    ADJUSTING PPC VALVE…1040
    ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…1041
    MEASURING SOLENOID VALVE OUTLET PORT PRESSURE…1043
    ADJUSTING BLADE CONTROL LEVER…1044
    TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…1045
    BLEEDING AIR FROM HYDRAULIC CIRCUIT…1046
    RELEASING REMAINING FROM HYDRAULIC CIRCUIT…1048
    TESTING HYDRAULIC BREAKER GAS PRESSURE…1049
    TROUBLESHOOTING…1051
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…1052
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…1053
      CHECKS BEFORE TROUBLESHOOTING…1060
      ELECTRICAL CIRCUIT DIAGRAM…1061
      POSITION OF CONNECTORS FOR TROUBLESHOOTING…1064
      CONNECTION TABLE FOR CONNECTOR…1068
      METHOD OF USING TROUBLESHOOTING CHARTS…1075
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…1077
        E-1 THE ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF…1078
        E-2 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELEASED…1081
        E-3 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED…1082
        E-4 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS DEPRESSED…1083
        E-5 TRAVEL SPEED INCREASES EVEN WHEN TRAVEL SPEED ACCELERATION PEDAL IS NOT DEPRESSED…1084
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…1085
        H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW…1086
        H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…1087
        H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW…1088
          a) NONE OF WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS SLOW…1088
          b) ONLY TRAVEL IS NORMAL, OR DROP IN SPEED IS COMPARATIVELY SMALL…1089
        H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER…1089
        H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…1089
        H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW…1090
        H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER…1091
        H-8 EXCESSIVE HYDRAULIC DRIFT…1091
        H-9 EXCESSIVE TIME LAG…1091
        H-10 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE…1092
          a) DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND REVERSE…1092
          b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE…1096
        H-11 EXCESSIVE DEVIATION WHEN STARTING (PC30, 40)…1097
        H-12 TRAVEL LACKS POWER (OR SPEED IS SLOW)…1098
        H-13 TRAVEL SPEED DOES NOT SWITCH…1099
        H-14 MACHINE DOES NOT MOVE (ONE SIDE ONLY)…1099
        H-15 TRAVEL LEVER IS HEAVY…1100
        H-16 DOES NOT SWING…1100
        H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR…1102
        H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING…1102
        H-19 EXCESSIVE SHOCK WHEN STOPPING SWING…1103
        H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1103
        H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING…1104
        H-22 EXCESSIVE HYDRAULIC DRIFT OF BOOM SWING…1105
        TABLE OF FAILURE MODES AND CAUSES…1106
      TROUBLESHOOTING OF MONITOR SYSTEM (M  MODE)…1107
        M-1 MONITOR PANEL DOES NOT WORK…1108
        M-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON, OR ALL LAMPS STAY…1109
        M-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)…1110
        M-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)…1110
        M-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING…1111
        M-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)…1111
        M-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)…1112
        M-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING…1112
        M-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY…1113
          a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE…1113
          b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY. ENTERS RED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING…1113
        M-10 ABNORMALITY IN FUEL GAUGE DISPLAY…1114
          a) ALL SEGMENTS OF FUEL GAUGE GO OUT…1114
          b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN…1114
          c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED…1115
        M-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND…1115
        M-12 ABNORMALITY IN SERVICE METER DISPLAY…1116
          a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING…1116
          b) SERVICE METER PILOT LAMP DOES NOT FLASH…1116
        M-13 NIGHT LIGHTING DOES NOT LIGHT UP…1117
          a) WHEN LAMP SWITCH IS AT POSITION 1 OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP…1117
          b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP IS NOT BLOWN BEFORE STARTING TROUBLESHOOTING…1117
        M-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)…1118
      TROUBLESHOOTING OF HYDRAULIC BREAKER…1119
  30 DISASSEMBLY AND ASSEMBLY…1122
    METHOD OF USING MANUAL…1123
    PRECAUTIONS WHEN CARRYING OUT OPERATION…1124
    SPECIAL TOOL LIST…1126
    WEIGHT TABLE…1131
    TIGHTENING TORQUES AND STANDARD VALUES TABLE…1132
    LUBRICANT AND COOLANT TABLE…1133
    ENGINE, HYDRAULIC PUMP ASSEMBLY…1135
      REMOVAL…1135
      INSTALLATION…1138
    HYDRAULIC PUMP ASSEMBLY…1139
      HYDRAULIC PUMP ASSEMBLY (PC30-7)…1139
        DISASSEMBLY…1139
        ASSEMBLY…1141
      HYDRAULIC PUMP ASSEMBLY (PC45-1)…1147
        DISASSEMBLY…1147
        ASSEMBLY…1151
    GEAR PUMP ASSEMBLY…1158
      DISASSEMBLY AND ASSEMBLY…1158
    CENTER SWIVEL JOINT ASSEMBLY…1159
      REMOVAL AND INSTALLATION…1159
      DISASSEMBLY AND ASSEMBLY…1160
    TRAVEL MOTOR ASSEMBLY …1161
      TRAVEL MOTOR ASSEMBLY (PC25-1, PC30-7, PC40-7)…1161
        DISASSEMBLY…1161
        ASSEMBLY…1167
      TRAVEL MOTOR ASSEMBLY (PC45-1)…1173
        DISASSEMBLY…1173
        ASSEMBLY…1182
    SWING MOTOR ASSEMBLY…1193
      DISASSEMBLY…1193
      ASSEMBLY…1195
    SWING MACHINERY ASSEMBLY…1199
      DISASSEMBLY…1199
      ASSEMBLY…1201
    REVOLVING FRAME ASSEMBLY…1203
      REMOVAL AND INSTALLATION…1203
    RECOIL SPRING ASSEMBLY…1204
      DISASSEMBLY…1204
      ASSEMBLY…1206
    2 SPOOL CONTROL VALVE ASSEMBLY…1209
      DISASSEMBLY…1209
      ASSEMBLY…1210
    7 SPOOL CONTROL VALVE ASSEMBLY…1211
      DISASSEMBLY…1211
      ASSEMBLY…1213
    PPC VALVE ASSEMBLY…1215
      DISASSEMBLY…1215
      ASSEMBLY…1216
    HYDRAULIC CYLINDER ASSEMBLY…1217
      DISASSEMBLY…1217
      ASSEMBLY…1219
    WORK EQUIPMENT ASSEMBLY…1221
      REMOVAL AND INSTALLATION…1221
    BUCKET ASSEMBLY…1222
      REMOVAL AND INSTALLATION…1222
    HYDRAULIC BREAKER ASSEMBLY…1223
      REMOVAL AND INSTALLATION…1223
      DISASSEMBLY…1224
      ASSEMBLY…1227
    HYDRAULIC BREAKER BUSHING…1231
      REMOVAL…1231
    CHISEL…1232
      REMOVAL AND INSTALLATION…1232
  40 MAINTENANCE STANDARD…1235
    SWING CIRCLE…1236
    SWING MACHINERY…1237
    SPROCKET…1239
    TRACK FRAME AND RECOIL FRAME…1242
    IDLER…1246
    TRACK ROLLER…1252
    CARRIER ROLLER…1258
    TRACK SHOE…1260
    HYDRAULIC PUMP…1264
    7 SPOOL CONTROL VALVE…1266
    2 SPOOL CONTROL VALVE…1268
    SWING MOTOR…1269
    CENTER SWIVEL JOINT…1270
    PPC VALVE…1271
    HYDRAULIC CYLINDER…1274
    WORK EQUIPMENT…1278
    HYDRAULIC BREAKER…1282
    PISTON, CHISEL…1284
SEBM0225C01 – Hydraulic Excavator PC20-3, PC30-3 Shop Manual…1297

Komatsu Hydraulic Excavator PC20, PC25, PC30, PC40, PC45 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC50UU, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC50UU-1, PC50UU-2 workshop service repair manual includes:
* 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.

SEBM020U0104 – Hydraulic Excavator PC50UU-1 Shop Manual.pdf
SEBM000906 – Hydraulic Excavator PC50UU-2 Shop Manual.pdf
SEAM020U0100 – Hydraulic Excavator PC50UU-1 Operation & Maintenance Manual.pdf
SEAM020U0101 – Hydraulic Excavator PC50UU-1 Operation & Maintenance Manual.pdf
SEAM005500 – Hydraulic Excavator PC50UU-2 Operation & Maintenance Manual.pdf
SEAM005503T – Hydraulic Excavator PC50UU-2 Operation & Maintenance Manual.pdf
SEAM034800 – Hydraulic Excavator PC28UU-2 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,895 pages
File Format: PDF
Language: English

SEAM005500 – Hydraulic Excavator PC50UU-2 Operation & Maintenance Manual…2
COVER…2
1. FOREWORD…3
2. SAFETY INFORMATION…4
3. INTRODUCTION…5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…6
CONTENTS…7
SAFETY…12
6. General Precautions…13
7. Precautions During Operation…18
7.1 Before Starting Engine…18
7.2 Operating Machine…20
7.3 Transportation…25
7.4 Battery…26
7.5 Towing…27
8. Precautions for Maintenance…28
8.1 Before Carrying Out Maintenance…28
8.2 During Maintenance…31
9. Position for Attaching Safety Labels…35
OPERATION…40
10. General View…41
10.1 General View of Machine…41
10.2 General View of Controls and Gauges…42
11. Explanation of Components…43
11.1 Machine Monitor…44
11.2 Switches…50
11.3 Control Levers and Pedals…53
11.4 Engine Hood…57
11.5 Front Window…58
11.6 Sliding Door…60
11.7 Fuse Box…61
11.8 Fusible Link…61
11.9 Cap with Lock, Cover…62
11.10 Tool Box…63
11.11 Grease Gun Holder…63
12. Operation…64
12.1 Check Before Starting Engine…64
12.2 Starting Engine…72
12.3 Operations and Checks After Starting Engine…74
12.4 Moving Machine Off…77
12.5 Steering Machine…79
12.6 Stopping Machine…81
12.7 Swinging…82
12.8 Prohibitions for Operation…83
12.9 Precautions for Operation…85
12.10 Precautions when Traveling Up or Down Hills…86
12.11 Work Possible Using Hydraulic Excavator…88
12.12 Parking Machine…90
12.13 Check After Finishing Work…91
12.14 Stopping Engine…91
12.15 Check After Stopping Engine…92
12.16 Locking…92
12.17 How to Excape From Mud…93
12.18 Replacement of Bucket…94
12.19 Handling 4-System…96
12.20 Handling Rubber Shoes (Rubber Shoes Only)…106
13. Transportation…111
13.1 Loading, Unloading Work…111
13.2 Method for Lifting Chassis…113
13.3 Precautions for Loading…115
13.4 Precautions for Transportation…116
14. Cold Weather Operation…117
14.1 Precautions for Low Temperature…117
14.2 Cautions After Completion of Work…119
14.3 Preparing the Cab Heater…120
14.4 After Cold Weather…120
15. Long-term Storage…121
15.1 Before Storage…121
15.2 During Storage…122
15.3 After Storage…122
16. Troubleshooting…123
16.1 Phenomena That Are Not Failures…123
16.2 Method of Towing Machine…125
16.3 Precautions on Particular Jobsites…125
16.4 If Battery is Discharged…126
16.5 Other Trouble…130
MAINTENANCE…136
17. Guides to Maintenance…137
18. Outlines of Service…140
18.1 Outline of Oil, Fuel, Coolant…140
18.2 Relating to Electric System…143
19. Wear Parts List…144
20. Use of Fuel, Coolant and Lubricants According to Ambient Temperature…145
21. Standard Tightening Torbues for Bolts and Nuts…149
21.1 Introduction of Necessary Tools…149
21.2 Torque List…150
22. Periodic Replacement of Safety Critical Parts…151
23. Maintenance Schedule Chart…153
23.1 Maintenance Schedule Chart…153
24. Service Procedure…156
24.1 Initial 250 Hours Service (only after the first 250 hours)…156
Engine Valve Clearance, Check and Adjust…156
24.2 When Required…157
Check, Clean and Replace Air Cleaner Element…157
Clean Inside of Cooling System…160
Drain Water, Sediment from Fuel Tank…164
Check Level of Battery Electrolyte…165
Clean Water Separator Element…166
Check Electric Wirings…167
Check Rubber Shoes (machine equipped with rubber shoes)…168
Check and Adjust Track Tension (machine equipped with rubber shoes)…170
Replace Rubber Shoes (machine equipped with rubber shoes)…173
Check and Adjust Track Tension (machine equipped with steel shoes)…176
Replace Bucket Teeth…179
Adjust Bucket Clearance…180
24.3 Check Before Starting…181
Check and Refill Coolant…181
Check Oil Level in Engine Oil Pan, Add Oil…181
Check Fuel Level…182
Check Oil Level in Hydraulic Tank, Add Oil…183
Check Dust Indicator…184
Check Water Separator…184
24.4 Every 100 Hours Service…185
Lubricating…185
Swing Circle (1 point)…185
Swing Pinion (1 point)…185
Blade Cylinder Foot Pin ( 1 point)…185
Blade Cylinder Rod End ( 1 point)…185
Blade Foot Pin ( 2 points)…185
First Boom Foot Pin ( 2 points)…185
Boom Cylinder Foot Pin ( 1 point)…185
Boom Cylinder Rod End ( 1 point)…185
First Boom – Second Boom Coupling Pin ( 2 points)…185
Offset Cylinder Foot Pin ( 1 point)…186
Offset Cylinder Rod End Pin ( 1 point)…186
Sub-link Coupling Pin ( 2 points)…186
Second Boom – Third Bracket Coupling Pin ( 2 points )…186
Arm Cylinder Foot Pin ( 2 points )…186
Arm Cylinder Rod End Pin ( 1 point)…186
Third Bracket – Arm Coupling Pin ( 2 points )…186
Bucket Cylinder Foot Pin ( 1 point )…186
Bucket Cylinder Rod End Pin ( 1 point )…186
Arm-Link Coupling Pin ( 1 point )…186
Link Coupling Pin ( 1 point )…186
Bucket-Link Coupling Pin ( 1 point )…186
Arm-Bucket Coupling Pin ( 1 point )…186
24.5 Every 250 Hours Service…187
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge…187
Check Oil Level in Final Drive Case, Add Oil…189
Replace Hydraulic Filter Element…190
Check Fan Belt Tension, Adjust…192
24.6 Every 500 Hours Serv ice…193
Replace Fuel Filter Cartridge…193
Clean, Check Radiator Fins…195
24.7 Every 1000 Hours Service…196
Change Oil in Swing Machinery Case…196
Change Oil in Final Drive Case…197
24.8 Every 2000 Hours Service…198
Change Oil in Hydraulic Tank, Clean Strainer…198
Check Alternator, Starting Motor…200
Check Engine Valve Clearance, Adjust…200
SPECIFICATIONS…202
25. Specifications…203
OPTION, ATTACHMENT…206
26. Using Car Radio…207
26.1 Explanation of Parts…207
26.2 Method of Use…209
26.3 Precautions for Use…210
26.4 Specifications…211
27. Using Car Cooler…212
27.1 Control Panel…212
27.2 Precautions When Using…212
27.3 Inspection and Maintenance of Car Cooler…213
28. Handling Window Washer…215
28.1 Operation of Window Washer…215
28.2 Check Window Washer Fluid, Add Fluid…215
29. General Precautions…216
29.1 Precautions Related to Safety…216
30. Introduction of Attachments…217
30.1 Specification, Use…217
30.2 Precautions When installing Attachments…218
30.3 Replacing Bucket Teeth ( bucket with vertical pin type tooth )…219
30.4 Precautions When Using Hydraulic Breaker…222
31. Machines Able to Install Attachments…225
31.1 Explanation of Equipment…225
31.2 Hydraulic Circuit…227
31.3 Operation…228
31.4 Long-term Storage…229
31.5 Specifications…229
SEAM005503T – Hydraulic Excavator PC50UU-2 Operation & Maintenance Manual…230
COVER…230
1. FOREWORD…231
2. SAFETY INFORMATION…234
3. INTRODUCTION…235
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…236
5. CONTENTS…237
SAFETY…241
6. GENERAL PRECAUTIONS…242
7. PRECAUTIONS DURING OPERATION…247
7.1 BEFORE STARTING ENGINE…247
7.2 OPERATING MACHINE…249
7.3 TRANSPORTATION…254
7.4 BATTERY…255
7.5 TOWING…256
8. PRECAUTIONS FOR MAINTENANCE…257
8.1 BEFORE CARRYING OUT MAINTENANCE…257
8.2 DURING MAINTENANCE…260
9. POSITION FOR ATTACHING SAFETY LABELS…264
OPERATION…268
10. GENERAL VIEW…269
10.1 GENERAL VIEW OF MACHINE…269
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…270
11. EXPLANATION OF COMPONENTS…271
11.1 MACHINE MONITOR…272
11.2 SWITCHES…278
11.3 CONTROL LEVERS AND PEDALS…281
11.4 ENGINE HOOD…285
11.5 FRONT WINDOW…286
11.6 SLIDING DOOR…288
11.7 FUSE BOX…289
11.8 FUSIBLE LINK…289
11.9 CAP WITH LOCK,COVER…290
11.10 TOOL BOX…291
11.11 GREASE GUN HOLDER…291
12. OPERATION…292
12.1 CHECK BEFORE STARTING ENGINE…292
12.2 STARTING ENGINE…300
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…302
12.4 MOVING MACHINE OFF…305
12.5 STEERING MACHINE…307
12.6 STOPPING MACHINE…309
12.7 SWINGING…310
12.8 PROHIBITIONS FOR OPERATION…311
12.9 PRECAUTIONS FOR OPERATION…313
12.10 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…314
12.11 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…316
12.12 PARKING MACHINE…318
12.13 CHECK AFTER FINISHING WORK…319
12.14 STOPPING ENGINE…319
12.15 CHECK AFTER STOPPING ENGINE…320
12.16 LOCKING…320
12.17 HOW TO ESCAPE FROM MUD…321
12.18 REPLACEMENT OF BUCKET…322
12.19 HANDLING 4-SYSTEM…324
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…334
13. TRANSPORTATION…339
13.1 LOADING, UNLOADING WORK…339
13.2 METHOD OF LIFTING CHASSIS…341
13.3 PRECAUTIONS FOR LOADING…343
13.4 PRECAUTIONS FOR TRANSPORTATION…344
14. COLD WEATHER OPERATION…345
14.1 PRECAUTIONS FOR LOW TEMPERATURE…345
14.2 COUTIONS AFTER COMPLETION OF WORK…347
14.3 PREPARING THE CAB HEATER…348
14.4 AFTER COLD WEATHER…348
15. LONG-TERM STORAGE…349
15.1 BEFORE STORAGE…349
15.2 DURING STORAGE…350
15.3 AFTER STORAGE…350
16. TROUBLESHOOTING…351
16.1 PHENOMENA THAT ARE NOT FAILURES…351
16.2 METHOD OF TOWING MACHINE…353
16.3 PRECAUTIONS ON PARTICULAR JOBSITES…353
16.4 IF BATTERY IS DISCHARGED…354
16.5 OTHER TROUBLE…358
MAINTENANCE…363
17. GUIDES TO MAINTENANCE…364
18. OUTLINES OF SERVICE…367
18.1 OUTLINE OF OIL,FUEL,COOLANT…367
18.2 RELATING TO ELECTRIC SYSTEM…370
19. WEAR PARTS LIST…371
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…372
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…376
21.1 INTRODUCTION OF NECESSARY TOOLS…376
21.2 TORQUE LIST…377
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…378
23. MAINTENANCE SCHEDULE CHART…380
24. SERVICE PROCEDURE…383
24.1 INITIAL 250 HOURS SERVICE…383
24.2 WHEN REQUIRED…384
24.3 CHECK BEFORE STARTING…408
24.4 EVERY 100 HOURS SERVICE…412
24.5 EVERY 250 HOURS SERVICE…413
24.6 EVERY 500 HOURS SERVICE…419
24.7 EVERY 1000 HOURS SERVICE…424
24.8 EVERY 2000 HOURS SERVICE…425
24.9 EVERY 4000 HOURS SERVICE…426
SPECIFICATIONS…429
25. SPECIFICATIONS…430
OPTIONS,ATTACHMENTS…433
26. USING CAR RADIO…434
26.1 EXPLANATION OF PARTS…434
26.2 METHOD OF USE…436
26.3 PRECAUTIONS FOR USE…437
26.4 SPECIFICATIONS…438
27. USING CAR COOLER…439
27.1 CONTROL PANEL…439
27.2 PRECAUTIONS WHEN USING…439
27.3 INSPECTION AND MAINTENANCE OF CAR COOLER…440
28. HANDLING WINDOW WASHER…442
28.1 OPERATION OF WINDOW WASHER…442
28.2 CHECK WINDOW WASHER FLUID,ADD FLUID…442
29. GENERAL PRECAUTIONS…443
29.1 PRECAUTIONS RELATED TO SAFETY…443
30. INTRODUCTION OF ATTACHMENTS…444
30.1 SPECIFICATION,USE…444
30.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…445
30.3 REPLACING BUCKET TEETH (BUCKET WITH VERTICAL PIN TYPE TOOTH)…446
30.4 PRECAUTIONS WHEN USING HYDRAULIC BREAKER…449
31. MACHINES ABLE TO INSTALL ATTACHMENTS…452
31.1 EXPLANATION OF EQUIPMENT…452
31.2 HYDRAULIC CIRCUIT…454
31.3 OPERATION…455
31.4 LONG-TERM STORAGE…456
31.5 SPECIFICATIONS…456
SEAM020U0100 – Hydraulic Excavator PC50UU-1 Operation & Maintenance Manual…458
COVER…458
FOREWORD…459
BREAKING IN YOUR NEW MACHINE…460
CONTENTS…461
GENERAL LOCATIONS AND SPECIFICATIONS…462
INSTRUMENTS AND CONTROLS…463
CHECK BEFORE STARTING…475
OPERATING YOUR MACHINE…479
REPLACEMENT OF BUCKET…493
COLD WEATHER OPERATION…494
PERIODIC MAINTENANCE…498
MAINTENANCE TABLE…499
OIL FILLER AND LEVEL GAUGE POSITIONS…502
EVERY 50 HOURS SERVICE…503
EVERY 100 HOURS SERVICE…504
INITIAL 250 HOURS SERVICE…507
EVERY 250 HOURS SERVICE…507
EVERY 500 HOURS SERVICE…512
EVERY 1000 HOURS SERVICE…515
EVERY 2000 HOURS SERVICE…517
WHEN REQUIRED…519
TROUBLE SHOOTING GUIDE…525
SERVICE METER…528
MACHINE AND ENGINE SERIAL NUMBERS…529
FUEL,COOLANT AND LUBRICANTS…530
SAFETY AND OPERATION…532
CONTENTS…533
SAFETY HINTS…534
EXCAVATOR'S WORK…543
HANDLING OF BATTERY…544
TRANSPORTATION…547
PRECAUTIONS FOR MAINTENANCE…549
STORAGE…554
COOLANT AND LUBRICANTS…556
SEAM020U0101 – Hydraulic Excavator PC50UU-1 Operation & Maintenance Manual…558
COVER…558
FOREWORD…559
BREAKING IN YOUR NEW MACHINE…560
CONTENTS…561
GENERAL LOCATIONS AND SPECIFICATIONS…562
INSTRUMENTS AND CONTROLS…563
CHECK BEFORE STARTING…576
OPERATING YOUR MACHINE…581
REPLACEMENT OF BUCKET…596
COLD WEATHER OPERATION…597
PERIODIC MAINTENANCE…601
PERIODICAL REPLACEMENT OF SAFETY PARTS…602
MAINTENANCE TABLE…604
OIL FILLER AND LEVEL GAUGE POSITIONS…607
EVERY 50 HOURS SERVICE…608
EVERY 100 HOURS SERVICE…609
INITIAL 250 HOURS SERVICE…612
EVERY 250 HOURS SERVICE…612
EVERY 500 HOURS SERVICE…617
EVERY 1000 HOURS SERVICE…620
EVERY 2000 HOURS SERVICE…622
WHEN REQUIRED…624
HANDLING RUBBER SHOES…630
TROUBLE SHOOTING GUIDE…635
SERVICE METER…638
MACHINE AND ENGINE SERIAL NUMBERS…639
FUEL,COOLANT AND LUBRICANTS…640
SAFETY AND OPERATION…642
CONTENTS…643
SAFETY HINTS…644
EXCAVATOR'S WORK…653
HANDLING OF BATTERY…654
TRANSPORTATION…657
METHOD OF RAISING THE MACHINE…659
PRECAUTIONS FOR MAINTENANCE…660
STORAGE…665
COOLANT AND LUBRICANTS…667
SEAM034800 – Hydraulic Excavator PC28UU-2 Operation & Maintenance Manual…669
COVER…669
1. FOREWORD…670
2. SAFETY INFORMATION…671
3. INTRODUCTION…672
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…673
5. CONTENTS…674
SAFETY…678
6. GENERAL PRECAUTIONS…679
7. PRECAUTION DURING OPERATION…684
7.1 BEFORE STARTING ENGINE…684
7.2 OPERATING MACHINE…686
7.3 TRANSPORTATION…691
7.4 BATTERY…692
7.5 TOWING…693
8. PRECAUTIONS FOR MAINTENANCE…694
8.1 BEFORE CARRYING OUT MAINTENANCE…694
8.2 DURING MAINTENANCE…697
9. POSITION FOR ATTACHING SAFETY LABELS…701
9.1 POSITION FOR ATTACHING SAFETY LABELS…701
OPERATION…704
10. GENERAL VIEW…705
10.1 GENERAL VIEW OF MACHINE…705
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…706
11. EXPLANATION OF COMPONENTS…707
11.1 MACHINE MONITOR…708
11.2 SWITCHES…714
11.3 CONTROL LEVERS AND PEDALS…716
11.4 ENGINE HOOD…720
11.5 FUSE BOX…721
11.6 FUSIBLE LINK…721
11.7 COVER WITH LOCK…722
11.8 TOOL BOX…723
11.9 GREASE GUN HOLDER…723
12. OPERATION…724
12.1 CHECK BEFORE STARTING ENGINE…724
12.2 STARTING ENGINE…731
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…733
12.4 MOVING MACHINE OFF…736
12.5 STEERING MACHINE…738
12.6 STOPPING MACHINE…740
12.7 SWINGING…741
12.8 PROHIBITIONS FOR OPERATION…742
12.9 PRECAUTIONS FOR OPERATION…744
12.10 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…745
12.11 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…747
12.12 PARKING MACHINE…749
12.13 CHECK AFTER FINISHING WORK…750
12.14 STOPPING ENGINE…750
12.15 CHECK AFTER STOPPING ENGINE…751
12.16 LOCKING…751
12.17 HOW TO ESCAPE FROM MUD…752
12.18 REPLACEMENT OF BUCKET…753
12.19 HANDLING 4-SYSTEM…755
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…765
13. TRANSPORTATION…770
13.1 LOADING,UNLOADING WORK…770
13.2 METHOD FOR LIFTING CHASSIS…772
13.3 PRECAUTIONS FOR LOADING…774
13.4 PRECAUTIONS FOR TRANSPORTATION…775
14. COLD WEATHER OPERATION…776
14.1 PRECAUTIONS FOR LOW TEMPERATURE…776
14.2 CAUTIONS AFTER COMPLETION OF WORK…778
14.3 PREPARING THE CAB HEATER (IF EQUIPPED)…779
14.4 AFTER COLD WEATHER…779
15. LONG-TERM STORAGE…780
15.1 BEFORE STORAGE…780
15.2 DURING STORAGE…781
15.3 AFTER STORAGE…781
16. TROUBLESHOOTING…782
16.1 PHENOMENA THAT ARE NOT FAILURES…782
16.2 METHOD OF TOWING MACHINE…784
16.3 PRECAUTIONS ON PARTICULAR JOBSITES…784
16.4 IF BATTERY IS DISCHARGED…785
16.5 OTHER TROUBLE…789
MAINTENANCE…794
17. GUIDES TO MAINTENANCE…795
18. OUTLINES OF SERVICE…798
18.1 OUTLINE OF OIL,FUEL,COOLANT…798
18.2 RELATING TO ELECTRIC SYSTEM…801
19. WEAR PARTS LIST…802
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…803
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…807
21.1 INTRODUCTION OF NECESSARY TOOLS…807
21.2 TORQUE LIST…808
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…809
23. MAINTENANCE SCHEDULE CHART…811
23.1 MAINTENANCE SCHEDULE CHART…811
24. SERVICE PROCEDURE…814
24.1 INITIAL 250 HOURS SERVICE…814
24.2 WHEN REQUIRED…815
24.3 CHECK BEFORE STARTING…838
24.4 EVERY 100 HOURS SERVICE…842
24.5 EVERY 250 HOURS SERVICE…844
24.6 EVERY 500 HOURS SERVICE…849
24.7 EVERY 1000 HOURS SERVICE…852
24.8 EVERY 2000 HOURS SERVICE…854
SPECIFICATIONS…857
25. SPECIFICATIONS…858
OPTIONS,ATTACHMENTS…861
26. GENERAL PRECAUTIONS…862
26.1 PRECAUTIONS RELATED TO SAFETY…862
27. HANDLING BUCKET WITH HOOK…863
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…863
27.2 PROHIBITED OPERATIONS…863
27.3 PRECAUTIONS DURING OPERATIONS…863
28. INTRODUCTION OF ATTACHMENTS…864
28.1 SPECIFICATION,USE…864
28.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…865
28.3 HANDLING POWER TILT,MECHANICAL ANGLE BLADE…866
SEBM020U0104 – Hydraulic Excavator PC50UU-1 Shop Manual…1710
COVER…1710
CONTENTS…1711
10 STRUCTURE AND FUNCTION…1724
POWER TRAIN…1725
SWING MACHINERY…1726
SWING CIRCLE…1727
TRACK FRAME AND RECOIL SPRING…1728
IDLER…1730
TRACK ROLLER…1731
TRACK SHOE…1732
HYDRAULIC PIPING…1733
HYDRAULIC CIRCUIT SCHEMATICS…1734
HYDRAULIC CIRCUIT DIAGRAM…1736
HYDRAULIC TANK AND FUEL TANK…1738
HYDRAULIC PUMP…1739
6-SPOOL CONTROL VALVE…1740
3-SPOOL CONTROL VALVE…1744
SUCTION VALVE…1747
SWING MOTOR…1749
CENTER SWIVEL JOINT…1750
TRAVEL MOTOR WITH REDUCTION GEAR…1751
1. TRAVEL MOTOR AND FINAL DRIVE…1752
2. BRAKE VALVE…1755
HYDRAULIC CYLINDER…1757
WORK EQUIPMENT CONTROL…1760
WORK EQUIPMENT…1761
ELECTRICAL CIRCUIT…1762
20 TESTING AND ADJUSTING…1764
TABLE OF JUDGEMENT STANDARD VALUE…1765
TESTING AND ADJUSTING TOOL LIST…1780
ADJUSTING VALVE CLEARANCE…1781
MEASURING COMPRESSION PRESSURE…1782
ADJUSTING FUEL INJECTION TIMING…1783
TESTING AND ADJUSTING HYDRAULIC PRESSURE…1784
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR…1786
MEASURING OIL LEAKAGE FROM CYLINDER…1787
CHECKING FOR OIL LEAKAGE FROM SWIVEL JOINT…1788
TROUBLESHOOTING…1789
PREPARATION OF TROUBLESHOOTING…1790
HOW TO USE DIAGNOSTIC TABLE…1792
PREVENTING RECURRENCE OF THE SAME TROUBLE…1794
DIAGNOSTIC TABLE…1795
1.BUCKET CURL(DUMP)LACKS POWER OR SPEED…1795
2.ARM(BOOM)LACKS POWER OR SPEED…1796
3.IMPOSSIBLE TO CURL OR DUMP BUCKET…1797
4.IMPOSSIBLE TO MOVE WORK EQUPIMENT(BOOM,ARM)…1798
5.HYDRAULIC DRIFT OF WORK EQUIPMENT IS EXCESSIVE(BOOM,ARM,BUCKET,BLADE)…1799
6.BLADE,BOOM,OFFSET SPEED TOO LOW…1800
7.BLADE,BOOM,OFFSET DO NOT MOVE…1801
8.LEFT(OR RIGHT)SWING LACKS POWER OR SPEED…1802
9.IMPOSSIBLE TO SWING TO LEFT(OR RIGHT)…1803
10.HYDRAULIC DRIFT OF SWING ON SLOPES IS EXCESSIVE…1804
11.SWING BRAKE ANGLE IS EXCESSIVE…1805
12.MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING…1806
13.IMPOSSIBLE TO TRAVEL FORWARD(OR REVERSE)…1807
30 DISASSEMBLY AND ASSEMBLY…1808
METHOD OF READING MANUAL…1810
SPECIAL TOOL LIST…1812
WEIGHT TABLE…1814
TIGHTENING TORQUE TABLE…1815
LIST OF LUBRICANT AND WATER…1817
STARTING MOTOR…1818
REMOVAL…1818
INSTALLATION…1818
ALTERNATOR…1818
REMOVAL…1818
INSTALLATION…1818
NOZZLE HOLDER…1820
REMOVAL…1820
INSTALLATION…1820
RADIATOR…1820
REMOVAL…1820
INSTALLATION…1820
FUEL INJECTION PUMP…1822
REMOVAL…1822
INSTALLATION…1822
CYLINDER HEAD…1824
REMOVAL…1824
INSTALLAION…1824
FAN PULLEY…1826
REMOVAL…1826
INSTALLATION…1826
WATER PUMP…1826
REMOVAL…1826
INSTALLATION…1826
THERMOSTAT…1826
REMOVAL…1826
INSTALLATION…1826
ENGINE…1828
REMOVAL…1828
INSTALLATION…1828
SWING CIRCLE…1830
REMOVAL…1830
INSTALLATION…1830
SWING MACHINERY…1830
REMOVAL…1830
INSTALLATION…1830
DISASSEMBLY…1832
ASSEMBLY…1834
CENTER SWIVEL JOINT…1836
REMOVAL…1836
INSTALLATION…1836
DISASSEMBLY…1836
ASSEMBLY…1836
SWING MOTOR…1838
REMOVAL…1838
INSTALLATION…1838
TRAVEL MOTOR…1838
REMOVAL…1838
INSTALLATION…1838
REVOLVING FRAME…1840
REMOVAL…1840
INSTALLATION…1840
IDLER…1842
REMOVAL…1842
INSTALLATION…1842
RECOIL SPRING…1842
REMOVAL…1842
INSTALLAION…1842
DISASSEMBLY…1842
ASSEMBLY…1842
TRACK ROLLER…1844
REMOVAL…1844
INSTALLATION…1844
TRACK SHOE…1846
REMOVAL…1846
INSTALLAION…1846
HYDRAULIC PUMP…1848
REMOVAL…1848
INSTALLATION…1848
6-SPOOL CONTROL VALVE…1850
REMOVAL…1850
INSTALLATION…1850
3-SPOOL CONTROL VALVE…1850
REMOVAL…1850
INSTALLATION…1850
6-SPOOL CONTROL VALVE…1852
DISASSEMBLY…1852
ASSEMBLY…1852
3-SPOOL CONTROL VALVE…1854
DISASSEMBLY…1854
ASSEMBLY…1854
MAIN RELIEF VALVE…1856
REMOVAL…1856
INSTALLATION…1856
DISASSEMBLY…1856
ASSEMBLY…1856
BOOM CYLINDER…1858
REMOVAL…1858
INSTALLATION…1858
ARM CYLINDER…1858
REMOVAL…1858
INSTALLATION…1858
BUCKET CYLINDER …1860
REMOVAL…1860
INSTALLATION…1860
BLADE CYLINDER…1860
REMOVAL…1860
INSTALLATION…1860
OFFSET CYLINDER…1862
REMOVAL…1862
INSTALLATION…1862
HYDRAULIC CYLINDER…1864
DISASSEMBLY…1864
ASSEMBLY…1866
WORK EQUIPMENT…1868
REMOVAL…1868
INSTALLATION…1868
BLADE…1868
REMOVAL…1868
INSTALLATION…1868
ARM AND BUCKET…1870
REMOVAL…1870
INSTALLATION…1870
BUCKET …1870
REMOVAL…1870
INSTALLATION…1870
ARM…1872
REMOVAL…1872
INSTALLATION…1872
BOOM …1874
REMOVAL…1874
INSTALLATION…1874
SECOND BOOM…1876
REMOVAL…1876
INSTALLATION…1876
THIRD BOOM…1876
REMOVAL…1876
INSTALLATION…1876
SECONG AND THIRD BOOM(WITH ARM CYLINDER ASSEMBLY)…1878
REMOVAL…1878
INSTALLATION…1878
FLOOR FRAME…1878
REMOVAL…1878
INSTALLATION…1878
40 MAINTENANCE STANDARD…1880
SWING MACHINERY…1881
SWING CIRCLE…1882
TRACK FRAME…1883
IDLER…1885
TRACK ROLLER…1887
TRACK SHOE…1889
SPROCKET…1890
HYDRAULIC PUMP…1891
6-SPOOL CONTROL VALVE…1892
3-SPOOL CONTROL VALVE…1894
CENTER SWIVEL JOINT…1895
HYDRAULIC CYLINDER…1896
WORK EQUIPMENT…1897

Komatsu Hydraulic Excavator PC50UU Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC45MR, PC55MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC45MR-3, PC55MR-3 workshop service repair manual includes:
* 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.

SEN04597-06 – Hydraulic Excavator PC45MR-3, PC55MR-3 Shop Manual.pdf
TEN00306-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual.pdf
TEN00390-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual.pdf
TEN00508-01 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,576 pages
File Format: PDF
Language: English

SEN04597-06 – Hydraulic Excavator PC45MR-3, PC55MR-3 Shop Manual…2
COVER…2
00 Index and foreword…0
100 Index…3
Composition of shop manual…4
Table of contents…6
200 Foreword and general information…13
Safety notice…14
How to read the shop manual…20
Explanation of terms for maintenance standard…22
Handling of electric equipment and hydraulic component…24
Handling of connectors newly used for engines…33
How to read electric wire code…36
Precautions when carrying out work…39
Method of disassembling and connecting push-pull type coupler…42
Standard tightening torque table…45
Conversion table…49
01 Specification…0
100 Specification and technical data…55
Specification dimension drawing…56
Working range drawing…57
Specifications…58
Weight table…64
Table of fuel, coolant and lubricants…68
10 Structure, function and maintenance standard…0
100 Engine and cooling system…71
PTO…72
Cooling system…74
200 Power train…77
Power train…78
Swing circle…79
Swing machinery…80
300 Undercarriage and frame…83
Track frame…84
Idler cushion…85
Idler…86
Track roller…88
Carrier roller…89
Sprocket…90
Track shoe…91
410 Hydraulic system, Part 1…95
Hydraulic components layout drawing…96
Hydraulic tank, filter…97
Center swivel joint…99
Travel motor…100
Hydraulic cylinder…108
Solenoid valve…112
Multi-control valve…117
420 Hydraulic system, Part 2…119
Hydraulic pump…120
Control valve…128
Anti-drop valve…142
430 Hydraulic system, Part 3…149
CLSS…150
Operation for each function and valve…154
Swing motor…176
PPC valve…183
500 Work equipment…197
Work equipment…198
Dimensions of each part of work equipment…202
600 Cab and its attachments…207
Floor…208
700 Electrical system…211
Engine control system…212
Electrical control system…216
Auto-deceleration function…222
Attachment proportional switch, breaker operation switch, work mode selection, flow control function…224
KOMTRAX system…232
Component parts of system…235
Monitor system…236
Sensors…239
20 Standard value table…0
100 Standard service value table…243
Standard service value table for engine related parts…244
Standard service value table for chassis related parts…246
30 Testing and adjusting…0
100 Testing and adjusting…263
Tools for testing, adjusting, and troubleshooting…265
Testing engine speed…268
Testing exhaust gas color…269
Testing and adjusting valve clearance…270
Testing compression pressure…272
Testing engine oil pressure…273
Testing and adjusting fuel injection timing…274
Testing and adjusting alternator belt tension…278
Testing and adjusting air conditioner compressor belt tension…279
Adjusting fuel control lever…280
Testing clearance in swing circle bearings…281
Testing and adjusting track shoe tension…282
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits…283
Testing and adjusting LS differential pressure…288
Adjusting PC valve…291
Testing and adjusting control pump circuit oil pressure…292
Testing solenoid valve output pressure…294
Testing PPC valve output pressure…295
Adjusting PPC valve…297
Testing swing holding brake release pressure…298
Testing and adjusting travel deviation…299
Testing oil leakage from work equipment cylinder…301
Bleeding air from each part…303
Releasing residual pressure from hydraulic circuit…305
Releasing residual pressure from hydraulic tank…306
Pressurizing hydraulic tank…306
How to open and close (tilt) floor…307
Inspection procedures for diode…312
Function and flow of operator and service mode…314
How to start operation of KOMTRAX terminal…338
Lamp display of KOMTRAX terminal…342
Removal and installation of KOMTRAX terminal…345
Preparation work for troubleshooting of electrical system…346
40 Troubleshooting…0
100 General information on troubleshooting…349
Points to remember when troubleshooting…350
Sequence of events in troubleshooting…351
Checks before troubleshooting…352
Classification and procedures of troubleshooting…353
Information contained in troubleshooting table…354
Connection table for connector pin numbers…358
T- branch box and T- branch adapter table…394
110 Failure code table and fuse locations…399
User code and failure code list…400
Fuse locations…401
120 General information on troubleshooting…405
Points to remember when troubleshooting…406
Sequence of events in troubleshooting…407
Checks before troubleshooting…408
Classification and procedures of troubleshooting…409
Information contained in troubleshooting table…410
Connection table for connector pin numbers…414
T- branch box and T- branch adapter table…450
130 Troubleshooting by failure code…455
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller…457
Failure code [DBH1KK] Unswitched power supply error…459
Failure code [DBH2KK] Solenoid power supply error…461
Failure code [DBH5KP] 5V sensor power supply output 0 error…463
Failure code [DBH6KP] 5V sensor power supply output 1 error…464
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit)…465
Failure code [DDWLKB] Breaker switch error (Hot short circuit)…466
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)…467
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)…468
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error…469
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault)…470
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit)…472
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)…474
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)…476
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)…478
Failure code [D1E0KB] Motor power supply relay error (Ground fault)…480
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)…482
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)…484
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)…486
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)…488
Failure code [DY10MA] Fuel control motor operation error…490
Failure code [D1E0KA] Fuel control motor power supply relay contactsticking (NC side)…492
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)…494
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection)…496
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)…498
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit)…499
200 Troubleshooting of electrical system (E-mode)…501
Before carrying out troubleshooting of electrical system…502
E-1 Engine does not start…504
E-2 Engine does not stop…512
E-3 When starting switch is turned ON, any item does not operate…514
E-4 When starting switch is turned ON, some items do not operate…516
E-5 Alarm buzzer is abnormal…517
E-6 Engine oil pressure caution is turned ON…519
E-7 Charge level caution is turned ON…520
E-8 Preheating system does not operate or preheater does not become hot…522
E-9 Coolant temperature gauge is abnormal…524
E-10 Fuel level gauge is abnormal…528
E-11 Service meter does not operate while engine is running…532
E-12 2nd travel speed is not selected…535
E-13 Working lamp does not light up…538
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves…540
E-15 Windshield wiper does not operate…542
E-16 Windshield washer does not operate…544
E-17 Defective air conditioner…546
E-18 KOMTRAX system does not operate normally…554
300 Troubleshooting of hydraulic and mechanical system (H-mode)…557
Information contained in troubleshooting table…559
H-1 Speed or power of whole work equipment, travel, swing, and blade is low…560
H-2 Engine speed lowers extremely or engine stalls…564
H-3 Whole work equipment, travel system, swing system, and blade do not work…565
H-4 Abnormal sound comes out from around hydraulic pump…569
H-5 Fine control performance or response is low…569
H-6 Speed or power of boom is low…570
H-7 Speed or power of arm is low…571
H-8 Speed or power of bucket is low…572
H-9 Speed or power of boom swing is low…573
H-10 Work equipment does not move singly…573
H-11 Work equipment hydraulic drift is large…574
H-12 Time lag of work equipment is large…576
H-13 In compound operation of work equipment, speed of part loaded more is low…576
H-14 Machine deviates during travel…577
H-15 Travel speed or travel power is low (while work equipment is normal)…579
H-16 Machine is not steered well or steering power is low…580
H-17 Travel speed does not change…581
H-18 Travel motor does not work…582
H-19 Speed or power of swing is low…584
H-20 Machine does not swing…586
H-21 Swing acceleration performance is low…588
H-22 Machine overruns when it stops swinging…590
H-23 Large shock is made when machine stops swinging…591
H-24 When upper structure stops swinging, it makes large sound…591
H-25 Hydraulic drift of swing is large…592
H-26 Speed or power of blade is low…593
H-27 Blade does not move…594
H-28 Hydraulic drift of blade is large…595
400 Troubleshooting of engine (S-mode)…597
Method of using troubleshooting charts…599
S-1 Starting performance is poor…602
S-2 Engine does not start…603
S-3 Engine does not pick up smoothly…606
S-4 Engine stops during operations…607
S-5 Engine does not rotate smoothly…608
S-6 Engine lacks output (or lacks power)…609
S-7 Exhaust smoke is black (incomplete combustion)…610
S-8 Oil consumption is excessive (or exhaust smoke is blue)…611
S-9 Oil becomes contaminated quickly…612
S-10 Fuel consumption is excessive…613
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…614
S-12 Oil pressure drops…615
S-13 Oil level rises (Entry of coolant/fuel)…616
S-14 Coolant temperature becomes too high (overheating)…617
S-15 Abnormal noise is made…618
S-16 Vibration is excessive…619
50 Disassembly and assembly…0
100 General information on disassembly and assembly…621
How to read this manual…622
Coating materials list…624
Special tool list…627
Sketches of special tools…630
200 Engine and cooling system…633
Removal and installation of fuel injection pump assembly…634
Removal and installation of radiator assembly…636
Removal and installation of hydraulic oil cooler assembly…638
Removal and installation of engine and hydraulic pump assembly…642
300 Power train…649
Removal and installation of swing motor and swing machinery assembly…650
Disassembly and assembly of swing motor and swing machinery assembly…651
Removal and installation of swing circle assembly…656
400 Undercarriage and frame…659
Removal and installation of track shoe assembly…660
Disassembly and assembly of idler assembly…661
Disassembly and assembly of recoil spring assembly…663
Disassembly and assembly of track roller assembly…666
Disassembly and assembly of carrier roller assembly…667
Removal and installation of revolving frame assembly…668
500 Hydraulic system…671
Removal and installation of center swivel joint assembly…672
Disassembly and assembly of center swivel joint assembly…674
Removal and installation of work equipment pump assembly…678
Disassembly and assembly of control valve assembly…680
Disassembly and assembly of hydraulic cylinder assembly…681
600 Work equipment…687
Removal and installation of work equipment assembly…688
700 Cab and its attachments…691
Removal and installation of operator’s cab glass (stuck glass)…692
Removal and installation of front window assembly…701
Removal and installation of floor frame assembly (Canopy specification)…702
Removal and installation of operator cab and floor frame assembly (Operator cab specification)…705
800 Electrical system…709
Removal and installation of air conditioner unit assembly (If equipped)…710
Removal and installation of KOMTRAX terminal…713
90 Diagrams and Drawings…0
100 Hydraulic diagrams and drawings…715
Hydraulic circuit diagram…717
200 Electrical diagrams and drawings…0
Electrical circuit diagram (1/3)…724
Electrical circuit diagram (2/3)…725
Electrical circuit diagram (3/3)…726
Connector list and stereogram…727
Related circuit diagram of proportional swithch…728
TEN00306-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual…732
COVER…732
FOREWORD…733
FOREWORD…734
SAFETY INFORMATION…735
INTRODUCTION…737
DIRECTIONS OF MACHINE…737
PRODUCT INFORMATION…738
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…738
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…738
EPA NAMEPLATE…739
SERVICE METER LOCATION…739
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…740
CONTENTS…741
SAFETY…745
SAFETY…746
SAFETY LABELS…748
LOCATION OF SAFETY LABELS…748
SAFETY LABELS…749
GENERAL PRECAUTIONS…754
SAFETY MACHINE OPERATION…763
STARTING ENGINE…763
OPERATION…766
TRANSPORTATION…772
BATTERY…773
TOWING…775
LIFTING OBJECTS WITH BUCKET…776
SAFETY MAINTENANCE INFORMATION…777
OPERATION…785
MACHINE VIEW ILLUSTRATIONS…786
OVERALL MACHINE VIEW…786
CONTROLS AND GAUGES…787
DETAILED CONTROLS AND GAUGES…788
MONITORING SYSTEM…788
SWITCHES…794
CONTROL LEVERS AND PEDALS…798
WINDSHIELD…804
SLIDING DOOR…808
SLIDING WINDOW…808
EMERGENCY ESCAPE HAMMER…809
COVER WITH LOCK…810
ENGINE REAR COVER…811
COOLING COVER…811
MUD COVER…812
METHOD OF OPENING (TILTING) FLOOR…813
AUXILIARY ELECTRIC POWER…819
FUSE…819
BLOCK FUSE…820
OPERATION MANUAL STORAGE…821
TOOL BOX…821
ASHTRAY…821
HANDLING MACHINES EQUIPPED WITH KOMTRAX…822
MACHINE OPERATIONS AND CONTROLS…823
BEFORE STARTING ENGINE…823
STARTING ENGINE…841
AFTER STARTING ENGINE…845
STOPPING THE ENGINE…848
MACHINE OPERATION…849
STEERING THE MACHINE…854
SWINGING…856
WORK EQUIPMENT CONTROLS AND OPERATIONS…857
PROHIBITED OPERATIONS…859
GENERAL OPERATION INFORMATION…861
TRAVELING ON SLOPES…863
ESCAPE FROM MUD…865
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…866
BUCKET REPLACEMENT…868
PARKING MACHINE…869
MACHINE INSPECTION AFTER DAILY WORK…870
LOCKING…871
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…872
TRANSPORTATION…877
TRANSPORTATION PROCEDURE…877
LOADING AND UNLOADING WITH TRAILER…878
LIFTING MACHINE…884
COLD WEATHER OPERATION…887
COLD WEATHER OPERATION INFORMATION…887
CAB HEATER IN COLD WEATHER…888
AFTER DAILY WORK COMPLETION…889
AFTER COLD WEATHER SEASON…889
LONG TERM STORAGE…890
BEFORE STORAGE…890
DURING STORAGE…890
AFTER STORAGE…890
TROUBLES AND ACTIONS…892
RUNNING OUT OF FUEL…892
PHENOMENA THAT ARE NOT FAILURES…892
TOWING THE MACHINE…893
SEVERE JOB CONDITION…893
DISCHARGED BATTERY…894
OTHER TROUBLE…898
MAINTENANCE…901
MAINTENANCE INFORMATION…902
OUTLINE OF SERVICE…904
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…904
ELECTRIC SYSTEM MAINTENANCE…908
HANDLING HYDRAULIC SYSTEM…908
WEAR PARTS…909
WEAR PARTS LIST…909
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…910
TIGHTENING TORQUE SPECIFICATIONS…913
TIGHTENING TORQUE LIST…913
SAFETY CRITICAL PARTS…914
SAFETY CRITICAL PARTS LIST…914
MAINTENANCE SCHEDULE…915
MAINTENANCE SCHEDULE CHART…915
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…916
MAINTENANCE PROCEDURE…917
WHEN REQUIRED…917
CHECK BEFORE STARTING…950
EVERY 500 HOURS MAINTENANCE…951
EVERY 1000 HOURS MAINTENANCE…959
EVERY 1500 HOURS MAINTENANCE…962
EVERY 2000 HOURS MAINTENANCE…963
SPECIFICATIONS…969
SPECIFICATIONS…970
ATTACHMENTS, OPTIONS…973
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…974
SAFETY FIRST…974
ATTACHMENT INSTALLATION…975
BUCKET WITH HOOK…976
HOOK CONDITION…976
PROHIBITED OPERATIONS…976
AIR CONDITIONER…977
CONTROL PANEL AND COMPONENTS…977
AIR CONDITIONER CONTROLS…978
PHENOMENA THAT ARE NOT FAILURES…979
AIR CONDITIONER MAINTENANCE…980
WINDSHIELD WASHER…985
WINDSHIELD WASHER OPERATION…985
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…985
MACHINE READY FOR ATTACHMENT…986
LOCATIONS…986
HYDRAULIC CIRCUIT…989
ATTACHMENT OPERATIONS…992
LONG TERM STORAGE…993
SPECIFICATIONS…994
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…995
CONTROL PATTERN CHANGE PROCEDURE…995
MACHINE CONTROL PATTERNS…996
ATTACHMENT GUIDE…997
ATTACHMENT COMBINATIONS…997
RECOMMENDED ATTACHMENT OPERATIONS…998
HYDRAULIC BREAKER…998
INDEX…1003
TEN00390-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual…1007
COVER…1007
FOREWORD…1008
FOREWORD…1009
SAFETY INFORMATION…1010
INTRODUCTION…1012
DIRECTIONS OF MACHINE…1012
PRODUCT INFORMATION…1013
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1013
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1013
EPA NAMEPLATE…1014
SERVICE METER LOCATION…1014
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1015
CONTENTS…1016
SAFETY…1020
SAFETY…1021
SAFETY LABELS…1023
LOCATION OF SAFETY LABELS…1023
SAFETY LABELS…1024
GENERAL PRECAUTIONS…1029
SAFETY MACHINE OPERATION…1038
OPERATION…1041
TRANSPORTATION…1047
BATTERY…1048
TOWING…1050
LIFTING OBJECTS WITH BUCKET…1051
SAFETY MAINTENANCE INFORMATION…1052
OPERATION…1060
MACHINE VIEW ILLUSTRATIONS…1061
OVERALL MACHINE VIEW…1061
CONTROLS AND GAUGES…1062
DETAILED CONTROLS AND GAUGES…1063
MONITORING SYSTEM…1063
SWITCHES…1069
CONTROL LEVERS AND PEDALS…1073
WINDSHIELD…1079
SLIDING DOOR…1082
SLIDING WINDOW…1082
EMERGENCY ESCAPE HAMMER…1083
COVER WITH LOCK…1084
ENGINE REAR COVER…1085
COOLING COVER…1085
MUD COVER…1086
METHOD OF OPENING (TILTING) FLOOR…1087
AUXILIARY ELECTRIC POWER…1093
FUSE…1093
BLOCK FUSE…1094
OPERATION MANUAL STORAGE…1095
TOOL BOX…1095
ASHTRAY…1095
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1096
MACHINE OPERATIONS AND CONTROLS…1097
BEFORE STARTING ENGINE…1097
STARTING ENGINE…1115
AFTER STARTING ENGINE…1119
STOPPING THE ENGINE…1122
MACHINE OPERATION…1123
STEERING THE MACHINE…1128
SWINGING…1130
WORK EQUIPMENT CONTROLS AND OPERATIONS…1131
PROHIBITED OPERATIONS…1133
GENERAL OPERATION INFORMATION…1135
TRAVELING ON SLOPES…1137
ESCAPE FROM MUD…1139
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1140
BUCKET REPLACEMENT…1142
PARKING MACHINE…1143
MACHINE INSPECTION AFTER DAILY WORK…1144
LOCKING…1145
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1146
TRANSPORTATION…1151
TRANSPORTATION PROCEDURE…1151
LOADING AND UNLOADING WITH TRAILER…1152
LIFTING MACHINE…1158
COLD WEATHER OPERATION…1161
COLD WEATHER OPERATION INFORMATION…1161
CAB HEATER IN COLD WEATHER…1162
AFTER DAILY WORK COMPLETION…1163
AFTER COLD WEATHER SEASON…1163
LONG TERM STORAGE…1164
BEFORE STORAGE…1164
DURING STORAGE…1164
AFTER STORAGE…1164
TROUBLES AND ACTIONS…1166
RUNNING OUT OF FUEL…1166
PHENOMENA THAT ARE NOT FAILURES…1166
TOWING THE MACHINE…1167
SEVERE JOB CONDITION…1167
DISCHARGED BATTERY…1168
OTHER TROUBLE…1172
MAINTENANCE…1176
MAINTENANCE INFORMATION…1177
OUTLINE OF SERVICE…1179
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1179
ELECTRIC SYSTEM MAINTENANCE…1183
HANDLING HYDRAULIC SYSTEM…1183
WEAR PARTS…1184
WEAR PARTS LIST…1184
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1185
TIGHTENING TORQUE SPECIFICATIONS…1188
TIGHTENING TORQUE LIST…1188
SAFETY CRITICAL PARTS…1189
SAFETY CRITICAL PARTS LIST…1189
MAINTENANCE SCHEDULE…1190
MAINTENANCE SCHEDULE CHART…1190
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1191
MAINTENANCE PROCEDURE…1192
WHEN REQUIRED…1192
CHECK BEFORE STARTING…1225
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1225
EVERY 500 HOURS MAINTENANCE…1226
EVERY 1000 HOURS MAINTENANCE…1234
EVERY 1500 HOURS MAINTENANCE…1237
EVERY 2000 HOURS MAINTENANCE…1238
SPECIFICATIONS…1244
SPECIFICATIONS…1245
ATTACHMENTS, OPTIONS…1248
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1249
SAFETY FIRST…1249
ATTACHMENT INSTALLATION…1250
BUCKET WITH HOOK…1251
HOOK CONDITION…1251
PROHIBITED OPERATIONS…1251
AIR CONDITIONER…1252
CONTROL PANEL AND COMPONENTS…1252
AIR CONDITIONER CONTROLS…1253
PHENOMENA THAT ARE NOT FAILURES…1254
AIR CONDITIONER MAINTENANCE…1255
WINDSHIELD WASHER…1260
WINDSHIELD WASHER OPERATION…1260
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1260
MACHINE READY FOR ATTACHMENT…1261
LOCATIONS…1261
HYDRAULIC CIRCUIT…1267
ATTACHMENT OPERATIONS…1269
LONG TERM STORAGE…1274
SPECIFICATIONS…1274
OTHER TROUBLE…1275
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1277
CONTROL PATTERN CHANGE PROCEDURE…1277
MACHINE CONTROL PATTERNS…1278
ATTACHMENT GUIDE…1279
ATTACHMENT COMBINATIONS…1279
RECOMMENDED ATTACHMENT OPERATIONS…1280
HYDRAULIC BREAKER…1280
INDEX…1286
TEN00508-01 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual…1290
COVER…1290
FOREWORD…1291
FOREWORD…1292
SAFETY INFORMATION…1293
INTRODUCTION…1295
DIRECTIONS OF MACHINE…1295
PROTECTIVE STRUCTURE…1295
PRODUCT INFORMATION…1296
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1296
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1296
EPA NAMEPLATE…1297
SERVICE METER LOCATION…1297
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1298
CONTENTS…1299
SAFETY…1303
SAFETY…1304
SAFETY LABELS…1306
LOCATION OF SAFETY LABELS…1306
SAFETY LABELS…1307
GENERAL PRECAUTIONS…1313
SAFETY MACHINE OPERATION…1322
STARTING ENGINE…1322
OPERATION…1325
TRANSPORTATION…1331
BATTERY…1332
TOWING…1334
LIFTING OBJECTS WITH BUCKET…1335
SAFETY MAINTENANCE INFORMATION…1336
OPERATION…1345
MACHINE VIEW ILLUSTRATIONS…1346
OVERALL MACHINE VIEW…1346
CONTROLS AND GAUGES…1347
DETAILED CONTROLS AND GAUGES…1348
MONITORING SYSTEM…1348
SWITCHES…1354
CONTROL LEVERS AND PEDALS…1358
WINDSHIELD…1364
SLIDING DOOR…1367
SLIDING WINDOW…1367
EMERGENCY ESCAPE HAMMER…1368
COVER WITH LOCK…1369
ENGINE REAR COVER…1371
COOLING COVER…1371
MUD COVER…1372
METHOD OF OPENING (TILTING) FLOOR…1373
AUXILIARY ELECTRIC POWER…1379
FUSE…1379
BLOCK FUSE…1380
OPERATION MANUAL STORAGE…1381
TOOL BOX…1381
ASHTRAY…1381
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1382
MACHINE OPERATIONS AND CONTROLS…1383
BEFORE STARTING ENGINE…1383
STARTING ENGINE…1401
AFTER STARTING ENGINE…1405
STOPPING THE ENGINE…1408
MACHINE OPERATION…1409
STEERING THE MACHINE…1414
SWINGING…1416
WORK EQUIPMENT CONTROLS AND OPERATIONS…1417
PROHIBITED OPERATIONS…1419
GENERAL OPERATION INFORMATION…1421
TRAVELING ON SLOPES…1423
ESCAPE FROM MUD…1425
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1426
BUCKET REPLACEMENT…1428
PARKING MACHINE…1429
MACHINE INSPECTION AFTER DAILY WORK…1430
LOCKING…1431
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1432
TRANSPORTATION…1437
TRANSPORTATION PROCEDURE…1437
LOADING AND UNLOADING WITH TRAILER…1438
LIFTING MACHINE…1444
COLD WEATHER OPERATION…1447
COLD WEATHER OPERATION INFORMATION…1447
CAB HEATER IN COLD WEATHER…1448
AFTER DAILY WORK COMPLETION…1449
AFTER COLD WEATHER SEASON…1449
LONG TERM STORAGE…1450
BEFORE STORAGE…1450
DURING STORAGE…1450
AFTER STORAGE…1450
TROUBLES AND ACTIONS…1452
RUNNING OUT OF FUEL…1452
PHENOMENA THAT ARE NOT FAILURES…1452
TOWING THE MACHINE…1453
SEVERE JOB CONDITION…1453
DISCHARGED BATTERY…1454
OTHER TROUBLE…1458
MAINTENANCE…1461
MAINTENANCE INFORMATION…1462
OUTLINE OF SERVICE…1464
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1464
ELECTRIC SYSTEM MAINTENANCE…1468
HANDLING HYDRAULIC SYSTEM…1468
WEAR PARTS…1469
WEAR PARTS LIST…1469
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1470
TIGHTENING TORQUE SPECIFICATIONS…1473
TIGHTENING TORQUE LIST…1473
SAFETY CRITICAL PARTS…1474
SAFETY CRITICAL PARTS LIST…1474
MAINTENANCE SCHEDULE…1475
MAINTENANCE SCHEDULE CHART…1475
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1477
MAINTENANCE PROCEDURE…1478
WHEN REQUIRED…1478
CHECK BEFORE STARTING…1510
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1510
EVERY 100 HOURS MAINTENANCE…1511
EVERY 500 HOURS MAINTENANCE…1512
EVERY 1000 HOURS MAINTENANCE…1520
EVERY 1500 HOURS MAINTENANCE…1523
EVERY 2000 HOURS MAINTENANCE…1524
SPECIFICATIONS…1531
SPECIFICATIONS…1532
ATTACHMENTS, OPTIONS…1535
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1536
SAFETY FIRST…1536
ATTACHMENT INSTALLATION…1537
BUCKET WITH HOOK…1538
HOOK CONDITION…1538
PROHIBITED OPERATIONS…1538
AIR CONDITIONER…1539
CONTROL PANEL AND COMPONENTS…1539
AIR CONDITIONER CONTROLS…1540
PHENOMENA THAT ARE NOT FAILURES…1541
AIR CONDITIONER MAINTENANCE…1542
WINDSHIELD WASHER…1547
WINDSHIELD WASHER OPERATION…1547
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1547
MACHINE READY FOR ATTACHMENT…1548
LOCATIONS…1548
HYDRAULIC CIRCUIT…1554
ATTACHMENT OPERATIONS…1556
LONG TERM STORAGE…1561
SPECIFICATIONS…1561
OTHER TROUBLE…1562
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1564
CONTROL PATTERN CHANGE PROCEDURE…1564
MACHINE CONTROL PATTERNS…1565
ATTACHMENT GUIDE…1566
ATTACHMENT COMBINATIONS…1566
RECOMMENDED ATTACHMENT OPERATIONS…1567
HYDRAULIC BREAKER…1567
INDEX…1573

Komatsu Hydraulic Excavator PC45MR, PC55MR Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC30R, PC35R, PC40R, PC45R, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 (Deluxe) workshop service repair manual includes:
* 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.

WEBM003000 – Hydraulic Excavator PC35R-8, PC45R-8 Shop Manual.pdf
WEBM003900 – Hydraulic Excavator PC35R-8, PC45R-8 Deluxe Shop Manual.pdf
SEBM012603 – Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 Shop Manual.pdf
SEBM012604 – Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 Shop Manual.pdf
SEAM015301 – Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 Operation & Maintenance Manual.pdf
SEAM015304T – Hydraulic Excavator PC35R-8, PC45R-8 Operation & Maintenance Manual.pdf
WEAM003200 – Hydraulic Excavator PC35R-8, PC45R-8 Operation & Maintenance Manual.pdf
WEAM003202 – Hydraulic Excavator PC35R-8, PC45R-8 Deluxe Operation & Maintenance Manual.pdf

Total Pages: 2,413 pages
File Format: PDF
Language: English

SEAM015301 – Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 Operation & Maintenance Manual…2
  COVER…2
  1.  FOREWORD…3
  2.  SAFETY INFORMATION…4
  3.  INTRODUCTION…5
  4.  LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…6
  5.  CONTENTS…7
  SAFETY…11
    6.  GENERAL PRECAUTIONS…12
    7.  PRECAUTIONS DURING OPERATION…17
      7.1  BEFORE STARTING ENGINE…17
      7.2  AFTER STARTING ENGINE…19
      7.3  TRANSPORTATION…26
      7.4  BATTERY…27
      7.5  TOWING…29
      7.6  LIFTING OPERATIONS…29
      7.7  WINDOW WASHER FLUID…29
    8.  PRECAUTIONS FOR MAINTENANCE…30
      8.1  BEFORE CARRYING OUT MAINTENANCE…30
      8.2  DURING MAINTENANCE…34
    9.  POSITION FOR ATTACHING SAFETY LABELS…39
      9.1  POSITION FOR ATTACHING SAFETY LABELS…39
  OPERATION…43
    10.  GENERAL VIEW…44
      10.1  GENERAL VIEW OF MACHINE…44
      10.2  GENERAL VIEW OF CONTROLS AND GAUGES…45
    11.  EXPLANATION OF COMPONENTS…46
      11.1  MACHINE MONITOR…46
      11.2  SWITCHES…51
      11.3  CONTROL LEVERS AND PEDALS…54
      11.4  ENGINE HOOD…57
      11.5  FRONT WINDOW (MACHINES EQUIPPED WITH CAB)…59
      11.6  SLIDING DOOR (MAHCINES EQUIPPED WITH CAB)…61
      11.7  HAMMER FOR EMERGENCY ESCAPE (MACHINES EQUIPPED WITH CAB)…62
      11.8  FUSES…62
      11.9  FUSIBLE LINK…63
      11.10  CAP, COVER WITH LOCK…63
      11.11  MANUAL POCKET…64
      11.12  TOOL BOX…64
      11.13  DUST INDICATOR…64
    12.  OPERATION…65
      12.1  CHECK BEFORE STARTING ENGINE…65
      12.2  STARTING ENGINE…74
      12.3  OPERATIONS AND CHECKS AFTER STARTING ENGINE…76
      12.4  MOVING MACHINE OFF…78
      12.5  STEERING MACHINE…81
      12.6  STOPPING MACHINE…83
      12.7  SWINGING…84
      12.8  OPERATION OF WORK EQUIPMENT…85
      12.9  PROHIBITIONS FOR OPERATION…86
      12.10  PRECAUTIONS FOR OPERATION…89
      12.11  PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…90
      12.12  HOW TO ESCAPE FROM MUD…92
      12.13  WORK POSSIBLE USING HYDRAULIC EXCAVATOR…93
      12.14  REPLACEMENT OF BUCKET…95
      12.15  PARKING MACHINE…98
      12.16  CHECK AFTER FINISHING WORK…99
      12.17  STOPPING ENGINE…99
      12.18  CHECK AFTER STOPPING ENGINE…100
      12.19  LOCKING…100
      12.20  HANDLING OF RUBBER SHOE AND ROAD LINER (PC40R, 45R) (MACHINES WITH RUBBER SHOES OR ROAD LINERS)…101
    13.  TRANSPORTATION…106
      13.1  LOADING, UNLOADING WORK…106
      13.2  METHOD OF LIFTING MACHINE…108
      13.3  PRECAUTIONS FOR LOADING AND SECURING MACHINE…110
      13.4  PRECAUTIONS FOR TRANSPORTATION…111
    14.  COLD WEATHER OPERATION…112
      14.1  PRECAUTIONS FOR LOW TEMPERATURE…112
      14.2  PRECAUTIONS AFTER COMPLETION OF WORK…114
      14.3  PREPARING THE CAB HEATER (MACHINES EQUIPPED WITH CAB)…114
      14.4  AFTER COLD WEATHER…114
    15.  LONG-TERM STORAGE…115
      15.1  BEFORE STORAGE…115
      15.2  DURING STORAGE…116
      15.3  AFTER STORAGE…116
    16.  TROUBLESHOOTING…117
      16.1  PHENOMENA THAT ARE NOT FAILURES…117
      16.2  METHOD OF TOWING MACHINE…117
      16.3  PRECAUTIONS ON PARTICULAR JOBSITES…117
      16.4  IF BATTERY IS DISCHARGED…118
      16.5  OTHER TROUBLE…122
  MAINTENANCE…127
    17.  GUIDES TO MAINTENANCE…128
    18.  OUTLINES OF SERVICE…130
      18.1  OUTLINE OF OIL, FUEL, COOLANT…130
      18.2  OUTLINE OF ELECTRIC SYSTEM…133
      18.3  OUTLINE OF HYDRAULIC SYSTEM…134
    19.  WEAR PARTS LIST…135
    20.  USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…136
    21.  STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…140
      21.1  INTRODUCTION OF NECESSARY TOOLS…140
      21.2  TORQUE LIST…141
    22.  PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…142
    23.  MAINTENANCE SCHEDULE CHART…145
      23.1  MAINTENANCE SCHEDULE CHART…145
      23.2  MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…147
    24.  SERVICE PROCEDURE…148
      24.1  INITIAL 250 HOURS SERVICE…148
      24.2  WHEN REQUIRED…149
      24.3  CHECK BEFORE STARTING…171
      24.4  EVERY 100 HOURS SERVICE…175
      24.5  EVERY 250 HOURS SERVICE…176
      24.6  EVERY 500 HOURS SERVICE…178
      24.7  EVERY 1000 HOURS SERVICE…189
      24.8  EVERY 2000 HOURS SERVICE…191
      24.9  EVERY 4000 HOURS SERVICE…192
  SPECIFICATIONS…197
    25.  SPECIFICATIONS…198
  OPTIONS, ATTACHMENTS…215
    26  GENERAL PRECAUTIONS…216
      26.1  PRECAUTIONS RELATED TO SAFETY…216
      26.2  PRECAUTIONS WHEN INSTALLING ATTACHMENTS…217
    27.  HANDLING BUCKET WITH HOOK…218
      27.1  CHECKING FOR DAMAGE TO BUCKET WITH HOOK…218
      27.2  PROHIBITED OPERATIONS…218
      27.3  PRECAUTIONS DURING OPERATIONS…218
    28.  USING SEAT BELT…219
      28.1  SEAT BELT…219
    29.  OPERATION OF CAR RADIO (MACHINE EQUIPPED WITH CAB)…221
      29.1  EXPLANATION OF CONTROLS…221
      29.2  OPERATION METHOD…223
      29.3  PRECAUTIONS FOR USE…225
      29.4  SPECIFICATIONS…226
    30.  OPERATION OF WINDOW WASHER (MACHINE EQUIPPED WITH CAB)…227
      30.1  OPERATION OF WINDOW WASHER…227
      30.2  CHECK AND REFILLING OF WINDOW WASHER FLUID…227
    31.  INTRODUCTION OF ATTACHMENTS…228
      31.1  SPECIFICATIONS AND USES…228
      31.2  COMBINATIONS TABLE OF ATTACHEMENTS…229
      31.3  SELECTION OF TRACK SHOES (RUBBER SHOE, ROAD LINER)…231
      31.4  CONSUMABLE PARTS OF BUCKET…232
      31.5  HANDLING OF POWER ANGLE/POWER TILT BLADE…233
      31.6  PRECAUTIONS FOR OPERATING WITH HYDRAULIC BREAKER…236
      31.7  OPERATION OF MACHINE WHICH CAN BE EQUIPPED WITH ATTACHMENTS…239
SEAM015304T – Hydraulic Excavator PC35R-8, PC45R-8 Operation & Maintenance Manual…247
  COVER…247
  1.FOREWORD…248
  2.SAFETY INFORMATION…251
  3.INTRODUCTION…252
  4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…253
  5.CONTENTS…254
  SAFETY…258
    6.GENERAL PRECAUTIONS…259
    7.PRECAUTIONS DURING OPERATION…264
      7.1 BEFORE STARTING ENGINE…264
      7.2 AFTER STARTING ENGINE…266
      7.3 TRANSPORTATION…273
      7.4 BATTERY…274
      7.5 TOWING…276
    8.PRECAUTIONS FOR MAINTENANCE…277
      8.1 BEFORE CARRYING OUT MAINTENANCE…277
      8.2 DURING MAINTENANCE…281
    9.POSITION FOR ATTACHING SAFETY LABELS…286
  OPERATION…290
    10.GENERAL VIEW…291
      10.1 GENERAL VIEW OF MACHINE…291
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES…292
    11.EXPLANATION OF COMPONENTS…293
      11.1 MACHINE MONITOR…293
      11.2 SWITCHES…298
      11.3 CONTROL LEVERS AND PEDALS…301
      11.4 ENGINE HOOD …304
      11.5 FRONT WINDOW(MACHINES EQUIPPED WITH CAB)…306
      11.6 SLIDING DOOR(MACHINES EQUIPPED WITH CAB)…308
      11.7 HAMMER FOR EMERGENCY ESCAPE(MACHINES EQUIPPED WITH CAB)…309
      11.8 FUSES…309
      119. FUSIBLE LINK…310
      11.10 CAP,COVER WITH LOCK…310
      11.11 MANUAL POCKET…311
      11.12 TOOL BOX…311
      11.13 DUST INDICATOR…311
    12.OPERATION…312
      12.1 CHECK BEFORE STARTING ENGINE…312
      12.2 STARTING ENGINE…321
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…323
      12.4 MOVING MACHINE OFF…325
      12.5 STEERING MACHINE…328
      12.6 STOPPING MACHINE…330
      12.7 SWINGING…331
      12.8 OPERATION OF WORK EQUIPMENT…332
      12.9 PROHIBITIONS FOR OPERATION…333
      12.10 PRECAUTIONS FOR OPERATION…336
      12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…337
      12.12 HOW TO ESCAPE FROM MUD…339
      12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…340
      12.14 REPLACEMENT OF BUCKET…342
      12.15 PARKING MACHINE…345
      12.16 CHECK AFTER FINISHING WORK…346
      12.17 STOPPING ENGINE…346
      12.18 CHECK AFTER STOPPING ENGINE…347
      12.19 LOCKING…347
      12.20 HANDLING OF RUBBER SHOE AND ROAD LINER (PC45R)(MACHINES WITH RUBBER SHOES OR ROAD LINER)…348
    13.TRANSPORTATION…353
      13.1 LOADING,UNLOADING WORK…353
      13.2 METHOD FOR LIFTING MACHINE…355
      13.3 PRECAUTIONS FOR LOADING AND SECURING MACHINE…357
      13.4 PRECAUTIONS FOR TRANSPORTATION…358
    14.COLD WEATHER OPERATION…359
      14.1 PRECAUTIONS FOR LOW TEMPERATURE…359
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK…361
      14.3 PREPARING THE CAB HEATER(MACHINES EQUIPPED WITH CAB)…361
      14.4 AFTER COLD WEATHER…361
    15.LONG-TERM STORAGE…362
      15.1 BEFORE STORAGE…362
      15.2 DURING STORAGE…363
      15.3 AFTER STORAGE…363
    16.TROUBLESHOOTING…364
      16.1 PHENOMENA THAT ARE NOT FAILURES…364
      16.2 METHOD OF TOWING MACHINE…364
      16.3 PRECAUTIONS ON PARTICULAR JOBSITES…364
      16.4 IF BATTERY IS DISCHARGED…365
      16.5 OTHER TROUBLE…369
  MAINTENANCE …373
    17.GUIDES TO MAINTENANCE…374
    18.OUTLINES OF SERVICE…376
      18.1 OUTLINE OF OIL,FUEL,COOLANT…376
      18.2 OUTLINE OF ELECTRIC SYSTEM…379
      18.3 OUTLINE OF HYDRAULIC SYSTEM…380
    19.WEAR PARTS LIST…381
    20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…382
    21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…386
      21.1 INTRODUCTION OF NECESSARY TOOLS…386
      21.2 TORQUE LIST…387
    22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…388
    23.MAINTENANCE SCHEDULE CHART…391
      23.1 MAINTENANCE SCHEDULE CHART…391
      23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…393
    24.SERVICE PROCEDURE…394
      24.1 INITIAL 250 HOURS SERVICE…394
      24.2 WHEN REQUIRED…395
      24.3 CHECK BEFORE STARTING…417
      24.4 EVERY 100 HOURS SERVICE…421
      24.5 EVERY 250 HOURS SERVICE…422
      24.6 EVERY 500 HOURS SERVICE…424
      24.7 EVERY 1000 HOURS SERVICE…435
      24.8 EVERY 2000 HOURS SERVICE…437
      24.9 EVERY 4000 HOURS SERVICE…438
  SPECIFICATIONS…442
    25.SPECIFICATIONS…443
  OPTIONS,ATTACHMENTS…451
    26.GENERAL PRECAUTIONS…452
      26.1 PRECAUTIONS RELATED TO SAFETY…452
      26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…453
    27.HANDLING BUCKET WITH HOOK…454
      27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…454
      27.2 PROHIBITED OPERATIONS…454
      27.3 PRECAUTIONS DURING OPERATIONS…454
    28.USING SEAT BELT…455
      28.1 SEAT BELT…455
    29.OPERATION OF CAR RADIO(MACHINE EQUIPPED WITH CAB)…457
      29.1 EXPLANATION OF CONTROLS…457
      29.2 OPERATION METHOD…459
      29.3 PRECAUTIONS FOR USE…461
      29.4 SPECIFICATIONS…462
    30.OPERATION OF WINDOW WASHER(MACHINE EQUIPPED WITH CAB)…463
      30.1 OPERATION OF WINDOW WASHER…463
      30.2 CHECK AND REFILING OF WINDOW WASHER FLUID…463
    31.INTRODUCTION OF ATTACHMENTS…464
      31.1 SPECIFICATIONS AND USES…464
      31.2 COMBINATIONS TABLE OF ATTACHMENTS…465
      31.3 SELECTION OF TRACK SHOES(RUBBER SHOE,ROAD LINER)…466
      31.4 CONSUMABLE PARTS OF BUCKET…467
      31.5 HANDLING OF POWER ANGLE/POWER TILT BLADE…468
      31.6 PRECAUTIONS FOR OPERATING WITH HYDRAULIC BREAKER…471
      31.7 OPERATION OF MACHINE WHICH CAN BE EQUIPPED WITH ATTACHMENTS…474
SEBM012603 – Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 Shop Manual…481
  COVER…481
  CONTENTS…482
  01 GENERAL…502
    GENERAL ASSEMBLY DRAWING…503
    SPECIFICATIONS…511
    WEIGHT TABLE…519
    LIST OF LUBRICANT AND WATER…523
  10 STRUCTURE AND FUNCTION…525
    PTO(COUPLING)…526
    RADIATOR,OIL COOLER…527
    ENGINE CONTROL…528
    POWER TRAIN…529
    SWING CIRCLE…530
    SWING MACHINERY…531
    TRACK FRAME,RECOIL SPRING…532
    HYDRAULIC PIPING DRAWING…533
    HYDRAULIC CIRCUIT DIAGRAM…534
    HYDRAULIC PUMP…542
    CENTER SWIVEL JOINT…549
    SWING MOTOR…550
    TRAVEL MOTOR…555
    9-SPOOL CONTROL VALVE…566
    CLSS…574
    MULTI-CONTROL VALVE…598
    ELECTRICAL WIRING DIAGRAM…599
    VALVE CONTROL…600
    WORK EQUIPMENT,SWING PPC VALVE…601
    SOLENOID VALVE…605
    WORK EQUIPMENT…607
    MACHINE MONITOR SYSTEM…608
    ELECTRICAL CIRCUIT DIAGRAM…612
    HYDRAULIC CYLINDER…613
  20 TESTING AND ADJUSTING…614
    STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…615
    STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…617
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS…633
    TESTING AND ADJUSTING…635
      TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING…636
      MEASURING ENGINE SPEED…637
      MEASURING EXHAUST COLOR…638
      ADJUSTING VALVE CLEARANCE…639
      MEASURING COMPRESSION PRESSURE…640
      TESTING AND ADJUSTING FUEL INJECTION TIMING…641
      MEASURING ENGINE OIL PRESSURE…642
      TESTING AND ADJUSTING FAN BELT TENSION…643
      ADJUSTING CONTROL LEVERS AND PEDALS…644
      MEASURING SPROCKET WEAR…647
      TESTING AND ADJUSTING TRACK SHOE TENSION…648
      TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT…649
      TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE…652
      ADJUSTING PC VALVE…654
      TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…655
      TESTING OUTPUT PRESSURE OF SOLENOID VALVE…657
      TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE(PC20R)…658
      ADJUSTING WORK EQUIPMENT,SWING PPC VALVE…660
      TESTING AND ADJUSTING TRAVEL DEVIATION…661
      TESTING OIL LEAKAGE…662
      RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…663
      RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK…663
      PRESSURIZING HYDRAULIC TANK…663
      BLEEDING AIR…664
    TROUBLESHOOTING…666
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…667
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…668
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…669
      CHECKS BEFORE TROUBLESHOOTING…677
      CONNECTOR TYPES AND MOUNTING LOCATIONS…678
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…681
      METHOD OF USING TROUBLESHOOTING CHARTS…691
      TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)…693
        E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…694
        E-1 ENGINE DOES NOT START…696
          a) WHEN STARTING MOTOR DOES NOT TURN(STARTING SYSTEM)…696
          b) WHEN STARTING MOTOR TURNS(ENGINE STOP SOLENOID SYSTEM)…699
        E-2 ENGINE DOES NOT STOP…701
        E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED…702
        E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED…703
        E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED…704
        E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED…705
      TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE)…706
        TABLE OF FAILURE MODES AND CAUSES…707
        H- 1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER…709
        H- 2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS…710
        H- 3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE…711
        H- 4 ABNORMAL NOISE GENERATED(FROM AROUND PUMP)…711
        H- 5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…712
        H- 6 BOOM IS SLOW OR LACKS POWER…713
        H- 7 ARM IS SLOW OR LACKS POWER…713
        H- 8 BUCKET IS SLOW OR LACKS POWER…714
        H- 9 BOOM SWING IS SLOW OR LACKS POWER…714
        H-10 BLADE IS SLOW OR LACKS POWER…715
        H-11 BOOM,ARM,BUCKET DO NOT MOVE(BOOM SWING,BLADE,TRAVEL AND SWING ARE NORMAL)…715
        H-12 EXCESSIVE HYDRAULIC DRIFT(BOOM,ARM,BUCKET,BOOM SWING,BLADE)…716
          a) BOOM…716
          b) ARM,BUCKET,BOOM SWING…716
          c) BLADE…716
        H-13 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING)…717
        H-14 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW…717
        H-15 TRAVEL DEVIATION…718
          a) DEVIATION IN NORMAL TRAVEL…718
          b) DEVIATION WHEN STARTING…718
        H-16 TRAVEL SPEED IS SLOW OR LACKS POWER…719
        H-17 STEERING DOES NOT TURN EASILY…719
        H-18 TRAVEL SPEED DOES NOT SWITCH…720
        H-19 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)…720
        H-20 SWING SPEED IS SLOW OR LACKS POWER…721
          a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS…721
          b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY(LEFT OR RIGHT)…721
        H-21 DOES NOT SWING…722
          a) DOES NOT SWING IN EITHER DIRECTION…722
          b) DOES NOT SWING IN ONE DIRECTION(LEFT OR RIGHT)…722
        H-22 SWING ACCELERATION IS POOR…723
          a) ACCELERATION IS POOR IN BOTH DIRECTIONS…723
          b) ACCELERATION IS POOR IN ONE DIRECTION ONLY(LEFT OR RIGHT)…723
        H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…724
          a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS…724
          b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY(LEFT OR RIGHT)…724
        H-24 EXCESSIVE SHOCK WHEN STOPPING SWING(IN ONE DIRECTION ONLY)…725
        H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…725
        H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…725
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)…726
        ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS…727
        M- 1 WHEN STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN…728
        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…728
        M- 3 WHEN STARTING SWITCH IS TURNED ON,SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS…729
          a) NO GAUGE LAMPS LIGHT UP(FUEL,COOLANT TEMPERATURE)…729
          b) CAUTION LAMPS(ENGINE OIL PRESSURE,BATTERY CHARGE),PILOT LAMP(PREHEATING) DO NOT LIGHT UP…729
        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…729
        M- 5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…730
        M- 6 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP…730
        M- 7 WHEN STARTING SWITCH IS TURNED TO HEAT,PREHEATING PILOT LAMP DOES NOT LIGHT UP…731
        M- 8 WHEN ENGINE IS RUNNING,ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP…731
        M- 9 WHEN ENGINE IS RUNNING,CHARGE CAUTION LAMP LIGHTS UP…732
        M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE…733
          a) LEVEL DOES NOT RISE FROM SEGMENT C…733
          b) LEVEL DOES NOT GO DOWN FROM SEGMENT H,OR ALL SEGMENTS GO OUT…733
          c) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY…734
        M-11 ABNORMALITY IN FUEL GAUGE…735
          a) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT…735
          b) LEVEL DOES NOT GO DOWN FROM SEGMENT F…735
          c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY…736
        M-12 DEFECTIVE OPERATION OF ALARM BUZZER…737
          a) BUZZER DOES NOT SOUND…737
          b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…737
        M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE…738
          a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP…738
          b) WHEN CHARGE CAUTION LAMP LIGHTS UP…738
          c) PILOT LAMP DOES NOT FLASH(SERVICE METER IS ACTUATED)…738
        M-14 NIGHT LIGHTING DOES NOT LIGHT UP…739
          a) GAUGE LIGHTING DOES NOT LIGHT UP…739
          b) SERVICE METER LIGHTING DOES NOT LIGHT UP…739
  30 DISASSEMBLY AND ASSEMBLY…740
    METHOD OF USING MANUAL…742
    PRECAUTIONS WHEN CARRYING OUT OPERATION…743
    SPECIAL TOOL LIST…745
    STARTING MOTOR…748
      REMOVAL AND INSTALLATION…748
    ALTERNATOR…749
      REMOVAL AND INSTALLATION…749
    FUEL INJECTION PUMP…750
      REMOVAL(PC30R,35R)…750
      INSTALLATION(PC30R,35R)…751
      REMOVAL(PC40R,45R)…752
      INSTALLATION(PC40R,45R)…753
    NOZZLE HOLDER…754
      REMOVAL AND INSTALLATION…754
    WATER PUMP…755
      REMOVAL…755
      INSTALLATION…756
    THERMOSTAT…757
      REMOVAL AND INSTALLATION…757
    ENGINE FRONT SEAL…758
      REMOVAL AND INSTALLATION…758
    ENGINE REAR SEAL…759
      REMOVAL…759
      INSTALLATION…760
    CYLINDER HEAD…761
      REMOVAL(PC30R,35R)…761
      INSTALLATION(PC30R,35R)…763
      REMOVAL(PC40R,45R)…764
      INSTALLATION(PC40R,45R)…766
    RADIATOR,HYDRAULIC COOLER…767
      REMOVAL…767
      INSTALLATION…768
    ENGINE,HYDRAULID PUMP…769
      REMOVAL…769
      INSTALLATION…773
    FUEL TANK…774
      REMOVAL AND INSTALLATION…774
    DAMPER…775
      REMOVAL AND INSTALLATION…775
    CENTER SWIVEL JOINT…776
      REMOVAL AND INSTALLATION…776
    CENTER SWIVEL JOINT…777
      DISASSEMBLY AND ASSEMBLY…777
    TRAVEL MOTOR…778
      REMOVAL AND INSTALLATION…778
    SPROCKET…779
      REMOVAL AND INSTALLATION…779
    SWING MOTOR,SWING MACHINERY…780
      REMOVAL…780
      INSTALLATION…781
      DISASSEMBLY…782
      ASSEMBLY…785
    REVOLVING FRAME…788
      REMOVAL…788
      INSTALLATION…790
    SWING CIRCLE…791
      REMOVAL AND INSTALLATION…791
    IDLER…792
      REMOVAL AND INSTALLATION…792
      DISASSEMBLY…793
      ASSEMBLY…794
    RECOIL SPRING…795
      REMOVAL AND INSTALLATION…795
      DISASSEMBLY…796
      ASSEMBLY…798
    TRACK ROLLER…800
      REMOVAL AND INSTALLATION…800
      DISASSEMBLY…801
      ASSEMBLY…802
    CARRIER ROLLER…803
      REMOVAL AND INSTALLATION…803
      DISASSEMBLY AND ASSEMBLY…804
    RUBBER SHOE…805
      REMOVAL AND INSTALLATION…805
    STEEL SHOE…806
      REMOVAL AND INSTALLATION(PC30R,35R)…806
      REMOVAL AND INSTALLATION(PC40R,45R)…807
    HYDRAULIC TANK…808
      REMOVAL AND INSTALLATION…808
    HYDRAULIC COOLER…809
      REMOVAL AND INSTALLATION…809
    HYDRAULIC PUMP…810
      REMOVAL AND INSTALLATION…810
    CONTROL VALVE…811
      REMOVAL…811
      INSTALLATION…812
      DISASSEMBLY…813
      ASSEMBLY…820
    2-SPOOL SOLENOID VALVE…827
      REMOVAL AND INSTALLATION…827
    LEFT PPC VALVE…828
      REMOVAL AND INSTALLATION…828
    RIGHT PPC VALVE…829
      REMOVAL AND INSTALLATION…829
    PPC VALVE…830
      DISASSEMBLY…830
      ASSEMBLY…831
    BOOM CYLINDER…832
      REMOVAL…832
      INSTALLATION…833
    ARM CYLINDER…834
      REMOVAL…834
      INSTALLATION…835
    BUCKET CYLINDER…836
      REMOVAL…836
      INSTALLATION…837
    BOOM SWING CYLINDER…838
      REMOVAL…838
      INSTALLATION…839
    BLADE CYLINDER…840
      REMOVAL…840
      INSTALLATION…841
    HYDRAULIC CYLNDER…842
      DISASSEMBLY…842
      ASSEMBLY…845
    WORK EQUIPMENT…848
      REMOVAL…848
      INSTALLATION…849
    BUCKET…850
      REMOVAL AND INSTALLATION…850
    ARM…851
      REMOVAL…851
      INSTALLATION…852
    BUCKET,ARM…853
      REMOVAL…853
      INSTALLATION…854
    BOOM…855
      REMOVAL…855
      INSTALLATION…856
    BOOM SWING BRACKET…857
      REMOVAL…857
      INSTALLATION…858
    BLADE…859
      REMOVAL…859
      INSTALLATION…860
    OPERATOR'S CAB…861
      REMOVAL AND INSTALLATION…861
    CANOPY…861
      REMOVAL AND INSTALLATION…861
    FLOOR FRAME…862
      REMOVAL…862
      INSTALLATION…864
  40 MAINTENANCE STANDARD…865
    SWING CIRCLE…866
    SWING MACHINERY…867
    SPROCKET…869
    TRACK FRAME,RECOIL SPRING…871
    IDLER…873
    TRACK ROLLER…874
    CARRIER ROLLER…875
    TRACK SHOE…876
    CENTER SWIVEL JOINT…881
    HYDRAULIC PUMP…882
    WORK EQUIPMENT,SWING PPC VALVE…883
    SWING MOTOR…884
    9-SPOOL CONTROL VALVE…885
    HYDRAULIC CYLINDER…891
    WORK EQUIPMENT…895
  90 OTHER…899
    HYDRAULIC CIRCUIT DIAGRAM(PC30R-8)…900
    HYDRAULIC CIRCUIT DIAGRAM(PC35R-8)…901
    HYDRAULIC CIRCUIT DIAGRAM(PC40R-8)…902
    HYDRAULIC CIRCUIT DIAGRAM(PC45R-8)…903
    ELECTRICAL CIRCUIT DIAGRAM…904
    HYDRAULIC PIPING DRAWING…905
    SYSTEM DIAGRAM DRAWING…906
SEBM012604 – Hydraulic Excavator PC30R-8, PC35R-8, PC40R-8, PC45R-8 Shop Manual…907
  COVER…907
  CONTENTS…908
  00 FOREWARD…912
    SAFETY…912
    FOREWARD…914
    HOW TO READ THE SHOP MANUAL…915
    HOISTING INSTRUCTIONS…916
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…917
    COATING MATERIALS…919
    STANDARD TIGHTENING TORQUE…921
    ELECTRIC WIRE CODE…924
    CONVERSION TABLE…925
    UNITS…931
  01  GENERAL…932
    GENERAL ASSEMBLY DRAWING…933
    SPECIFICATIONS…941
    WEIGHT TABLE…949
    LIST OF LUBRICANT AND WATER…953
  10  STRUCTURE AND FUNCTION…955
    PTO (COUPLING)…956
    RADIATOR, OIL COOLER…957
    ENGINE CONTROL…958
    POWER TRAIN…959
    SWING CIRCLE…960
    SWING MACHINERY…961
    TRACK FRAME, RECOIL SPRING…962
    HYDRAULIC PIPING…963
    HYDRAULIC CIRCUIT DIAGRAM…964
    HYDRAULIC PUMP…972
    CENTER SWIVEL JOINT…979
    SWING MOTOR…980
    TRAVEL MOTOR…985
    9-SPOOL CONTROL VALVE…996
    CLSS…1004
    MULTI-CONTROL VALVE…1028
    ELECTRICAL WIRING DIAGRAM…1029
    VALVE CONTROL…1031
    WORK EQUIPMENT, SWING PPC VALVE…1032
    SOLENOID VALVE…1036
    WORK EQUIPMENT…1038
    MACHINE MONITOR SYSTEM…1039
    ELECTRICAL CIRCUIT DIAGRAM…1043
    HYDRAULIC CYLINDER…1044
  20  TESTING AND ADJUSTING…1045
    STANDARD VALUE TABLE…1046
      STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…1046
      STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…1048
      STANDARD VALUE TABLE FOR ELECTRICAL PARTS…1064
    TESTING AND ADJUSTING…1067
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…1068
      MEASURING ENGINE SPEED…1069
      MEASURING EXHAUST COLOR…1070
      ADJUSTING VALVE CLEARANCE…1071
      MEASURING COMPRESSION PRESSURE…1072
      TESTING AND ADJUSTING FUEL INJECTION TIMING…1073
      MEASURING ENGINE OIL PRESSURE…1074
      TESTING AND ADJUSTING FAN BELT TENSION…1075
      ADJUSTING CONTROL LEVERS AND PEDALS…1076
      MEASURING SPROCKET WEAR…1079
      TESTING AND ADJUSTING TRACK SHOE TENSION…1080
      TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…1081
      TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE…1084
      ADJUSTING PC VALVE…1086
      TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…1087
      TESTING OUTPUT PRESSURE OF SOLENOID VALVE…1090
      TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE (PC20R)…1091
      ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…1093
      TESTING AND ADJUSTING TRAVEL DEVIATION…1094
      TESTING OIL LEAKAGE…1095
      RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…1096
      RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK…1096
      PRESSURIZING HYDRAULIC TANK…1096
      BLEEDING AIR…1097
    TROUBLESHOOTING…1099
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…1100
      SEQUENCE OF EVENTS IN TROUBLESHOOTING…1101
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…1102
      CHECKS BEFORE TROUBLESHOOTING…1110
      CONNECTOR TYPES AND MOUNTING LOCATIONS…1111
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1114
      METHOD OF USING TROUBLESHOOTING CHARTS…1124
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…1127
        E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1128
        E-1  ENGINE DOES NOT START…1130
          A)  WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)…1130
          B)  WHEN STARTING MOTOR TURNS (ENGINE STOPE SOLENOID SYSTEM)…1133
        E-2  ENGINE DOES NOT STOP…1135
        E-3  WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED…1136
        E-4  WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED…1137
        E-5  TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED…1138
        E-6  TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED…1139
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…1141
        TABLE OF FAILURE MODES AND CAUSES…1142
        H-1  SPEEDS OF ALL WORK EQUIPMENT, SWING TRAVEL ARE SLOW OR LACK POWER…1144
        H-2  THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…1145
        H-3  NO WORK EQUIPMENT, TRAVEL, SWING MOVE…1146
        H-4  ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…1146
        H-5  FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…1147
        H-6  BOOM IS SLOW OR LACKS POWER…1148
        H-7  ARM IS SLOW OR LACKS POWER…1148
        H-8  BUCKET IS SLOW OR LACKS POWER…1149
        H-9  BOOM SWING IS SLOW OR LACKS POWER…1149
        H-10  BLADE IS SLOW OR LACKS POWER…1150
        H-11  BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL)…1150
        H-12  EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE)…1151
          A)  BOOM…1151
          B)  ARM, BUCKET, BOOM SWING…1151
          C)  BLADE…1151
        H-13  EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…1152
        H-14  IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…1152
        H-15  TRAVEL DEVIATION…1153
          A)  DEVIATION IN NORMAL TRAVEL…1153
          B)  DEVEIATION WHEN STARTING…1153
        H-16  TRAVEL SPEED IS SLOW OR LACKS POWER…1154
        H-17  STEERING DOES NOT TURN EASILY…1154
        H-18  TRAVEL SPEED DOES NOT SWITCH…1155
        H-19  TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…1155
        H-20  SWING SPEED IS SLOW OR LACKS POWER…1156
          A)  SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS…1156
          B)  SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY (LEFT OR RIGHT)…1156
        H-21  DOES NOT SWING…1157
          A)  DOES NOT SWING IN EITHER DIRECTION…1157
          B)  DOES NOT SWING N ONE DIRECTION (LEFT OR RIGHT)…1157
        H-22  SWING ACCELERATION IS POOR…1158
          A)  ACCELERATION IS POOR IN BOTH DIRECTIONS…1158
          B)  ACCELERATION IS POOR IN ONE DIRECTION ONLY (LEFT OR RIGHT)…1158
        H-23  EXCESSIVE OVERRUN WHEN STOPPING SWING…1159
          A)  OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS…1159
          B)  OVERRUN WHEN STOPPING IS EXCESSIVE IN  ONE DIRECTION ONLY (LEFT OR RIGHT)…1159
        H-24  EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY)…1160
        H-25  EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1160
        H-26  EXCESSIVE HYDRAULIC DRIFT OF SWING…1160
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…1161
        ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS…1162
        M-1  WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN…1163
        M-2  WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 ECONDS), LAMPS DO NOT GO …1163
        M-3  WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS…1164
          A)  NO GAUGE LAMPS LIGHT UP (FUEL, COOLANT TEMPERATURE)…1164
          B)  CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE), PILOT LAMP (PREHEATING) DO NOT LIGHT UP…1164
        M-4  DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS), EVEN IF STARTING SWITCH IS TURNED TO START, SELF CHECK IS NOT COMP…1164
        M-5  WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES OT LIGHT UP…1165
        M-6  WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHARGE CAUTION LAMP DOES NOT LIGHT UP…1165
        M-7  WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP…1166
        M-8  WHEN ENGINE IS RUNNING , ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP…1166
        M-9  WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP…1167
        M-10  ABNORMALITY IN COOLANT TEMPERATURE GAUGE…1168
          A)  LEVEL DOES NOT RISE FROM SEGMENT C…1168
          B)  LEVEL DOES NOT GO DOWN FROM SEGMENT H, OR ALL SEGMENTS GO OUT…1168
          C)  COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY…1169
        M-11  ABNORMALITY IN FUEL GAUGE…1170
          A)  LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT…1170
          B)  LEVEL DOES NOT GO DOWN FROM SEGMENT F…1170
          C)  FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY…1171
        M-12  DEFECTIVE OPERATION OF ALARM BUZZER…1172
          A)  BUZZER DOES NOT SOUND…1172
          B)  BUZZER CONTINUES TO SOUND AND DOES NOT STOP…1172
        M-13  WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE…1173
          A)  WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP…1173
          B)  WHEN CHARGE CAUTION LAMP LIGHTS UP…1173
          C)  PILOT LAMP DOES NOT FLASH (SERVICE METER IS ACTUATED)…1173
        M-14  NIGHT LIGHTING DOES NOT LIGHT UP…1174
          A)  GAUGE LIGHTING DOES NOT LIGHT UP…1174
          B)  SERVICE METER LIGHTING DOES NOT LIGHT UP…1174
  30  DISASSEMBLY AND ASSEMBLY…1175
    METHOD OF USING MANUAL…1177
    PRECAUTIONS WHEN CARRYING OUT OPERATION…1178
    SPECIAL TOOL LIST…1180
    SKETCHES OF SPECIAL TOOLS…1185
    STARTING MOTOR (REMOVAL, INSTALLATION)…1191
    ALTERNATOR (REMOVAL, INSTALLATION)…1192
    FUEL INJECTION PUMP (REMOVAL)…1193
    FUEL INJECTION PUMP (INSTALLATION)…1194
    NOZZEL HOLDER (REMOVAL, INSTALLATION)…1197
    WATER PUMP (REMOVAL)…1198
    WATER PUMP (INSTALLATION)…1199
    THERMOSTAT (REMOVAL, INSTALLATION)…1200
    ENGINE FRONT SEAL (REMOVAL, INSTALLATION)…1201
    ENGINE REAR SEAL (REMOVAL)…1202
    ENGINE REAR SEAL (INSTALLATION)…1203
    CYLINDER HEAD (REMOVAL)…1204
    CYLINDER HEAD (INSTALLATION)…1206
    RADIATOR, HYDRAULIC COOLER (REMOVAL…1210
    RADIATOR, HYDRAULIC COOLER (INSTALLATION)…1211
    ENGINE, HYDRAULIC PUMP (REMOVAL)…1212
    ENGINE, HYDRAULIC PUMP (INSTALLATION)…1216
    FUEL TANK (REMOVAL, INSTALLATION)…1217
    DAMPER (REMOVAL, INSTALLATION)…1218
    CENTER SWIVEL JOINT (REMOVAL, INSTALLATION)…1219
    CENTER SWIVEL JOINT (DISASSEMBLY, ASSEMBLY)…1220
    TRAVEL MOTOR (REMOVAL, INSTALLATION)…1221
    PHV-300 (FOR PC30R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR …1222
    PHV-350 (FOR PC35R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR…1237
    PHV-500 (FOR PC40R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR…1252
    GM06VL (FOR PC45R-8) DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR…1267
      SAFETY…1268
      SECTIONAL DRAWING OF ASSEMBLY…1269
      PARTS LIST…1271
      TOOLS…1272
      TIGHTENING TORQUE…1279
      DISASSEMBLY…1280
      MAINTENANCE STANDARDS TABLE …1302
      ASSEMBLY…1304
      DIMENSIONS TABLE OF CLEARANCE ADJUSTMENT PARTS…1330
      PERFORMANCE CONFIRMATION TEST…1331
    SPROCKET (REMOVAL, INSTALLATION)…1332
    SWING MOTOR, SWING MACHINERY (REMOVAL)…1333
    SWING MOTOR, SWING MACHINERY (INSTALLATION)…1334
    SWING MOTOR, SWING MACHINERY (DISASSEMBLY)…1335
    SWING MOTOR, SWING MACHINERY (ASSEMBLY)…1338
    DISASSEMBLY SWING MOTOR ASSEMBLY LMF 16AB…1341
    ASSEMBLY SWING MOTOR ASSEMBLY LMF 16AB…1346
    REVOLVING FRAME (REMOVAL)…1354
    REVOLVING FRAME (INSTALLATION)…1356
    SWING CIRCLE (REMOVAL, INSTALLATION)…1357
    IDLER (REMOVAL, INSTALLATION)…1358
    IDLER (DISASSEMBLY)…1359
    IDLER (ASSEMBLY)…1360
    RECOIL SPRING (REMOVAL, INSTALLATION)…1361
    RECOIL SPRING (DISASSEMBLY)…1362
    RECOIL SPRING (ASSEMBLY)…1364
    TRACK ROLLER (REMOVAL, INSTALLATION)…1366
    TRACK ROLLER (DISASSEMBLY)…1367
    TRACK ROLLER (ASSEMBLY)…1368
    CARRIER ROLLER (REMOVAL, INSTALLATON)…1369
    CARRIER ROLLER (DISASSEMBLY, ASSEMBLY)…1370
    RUBBER SHOE (REMOVAL, INSTALLATION)…1371
    STEEL SHOE (REMOVAL, INSTALLATION)…1372
    HYDRAULIC TANK (REMOVAL, INSTALLATION)…1374
    HYDRAULIC COOLER (REMOVAL, INSTALLATION)…1375
    HYDRAULIC PUMP (REMOVAL, INSTALLATION)…1376
    DISASSEMBLY OF MAIN PUMP ASSEMBLY (LPV 45)…1377
    ASSEMBLY OF MAIN PUMP ASSEMBLY (LPV 45)…1385
    CONTROL VALVE (REMOVAL)…1396
    CONTROL VALVE (INSTALLATION)…1397
    CONTROL VALVE (DISASSEMBLY)…1398
    CONTROL VALVE (ASSEMBLY)…1406
    2-SPOOL SOLENOID VALVE (REMOVAL, INSTALLATION)…1413
    LEFT PPC VALVE (REMOVAL, INSTALLATION)…1414
    RIGHT PPC VALVE (REMOVAL, INSTALLATION)…1415
    PPC VALVE (DISASSEMBLY)…1416
    PPC VALVE (ASSEMBLY)…1417
    BOOM CYLINDER (REMOVAL)…1418
    BOOM CYLINDER (INSTALLATION)…1419
    ARM CYLINDER (REMOVAL)…1420
    ARM CYLINDER (INSTALLATION)…1421
    BUCKET CYLINDER (REMOVAL)…1422
    BUCKET CYLINDER (INSTALLATION)…1423
    BOOM SWING CYLINDER (REMOVAL)…1424
    BOOM SWING CYLINDER (INSTALLATION)…1425
    BLADE CYLINDER (REMOVAL)…1426
    BLADE CYLINDER (INSTALLATION)…1427
    HYDRAULIC CYLINDER (DISASSEMBLY)…1428
    HYDRAULIC CYLINDER (ASSEMBLY)…1431
    WORK EQUIPMENT (REMOVAL)…1434
    WORK EQUIPMENT (INSTALLATION)…1435
    BUCKET (REMOVAL, INSTALLATION)…1436
    ARM (REMOVAL)…1437
    ARM (INSTALLATION)…1438
    BUCKET, ARM (REMOVAL)…1439
    BUCKET, ARM (INSTALLATION)…1440
    BOOM (REMOVAL)…1441
    BOOM (INSTALLATION)…1442
    BOOM SWING BRACKET (REMOVAL)…1443
    BOOM SWING BRACKET (INSTALLATION)…1444
    BLADE  (REMOVAL)…1445
    BLADE (INSTALLATION)…1446
    OPERATOR'S CAB (REMOVAL, INSTALLATION)…1447
    CANOPY (REMOVAL, INSTALLATION)…1447
    FLOOR FRAME (REMOVAL, INSTALLATION)…1448
  40  MAINTENANCE STANDARD…1451
    SWING CIRCLE…1452
    SWING MACHINERY…1454
    SPROCKET…1456
    TRACK FRAME, RECOIL SPRING…1458
    IDLER…1460
    TRACK ROLLER…1461
    CARRIER ROLLER…1462
    TRACK SHOE…1463
    CENTER SWIVEL JOINT…1468
    HYDRAULIC PUMP…1469
    WORK EQUIPMENT, SWING PPC VALVE…1470
    SWING MOTOR…1471
    9-SPOOL CONTROL VALVE…1472
    HYDRAULIC CYLINDER…1478
    WORK EQUIPMENT…1482
  90  OTHER…1486
    HYDRAULIC CIRCUIT DIAGRAM PC30R-8…1487
    HYDRAULIC CIRCUIT DIAGRAM PC35R-8…1489
    HYDRAULIC CIRCUIT DIAGRAM PC40R-8…1490
    HYDRAULIC CIRCUIT DIAGRAM PC45R-8…1491
    ELECTRICAL CIRCUIT DIAGRAM…1492
    HYDRAULIC PIPING DRAWING…1493
    SYSTEM DIAGRAM DRAWING…1494
WEAM003200 – Hydraulic Excavator PC35R-8, PC45R-8 Operation & Maintenance Manual…1495
  COVER…1495
  1.1 FOREWORD…1496
  1.2 INFORMATION ON SAFETY…1497
  1.3 INTRODUCTION…1499
    1.3.1 INTENDED USES…1499
    1.3.2 IMPROPER OR UNAUTHORIZED USES…1499
    1.3.3 MAIN CHARACTERISTICS…1500
    1.3.4 RUNNING-IN…1500
  1.4 PRODUCT INDENTIFICATION…1501
    1.4.1 MACHINE SERIAL NUMBER…1501
    1.4.2 MACHINE IDENTIFICATION PLATE…1501
    1.4.3 ENGINE SERIAL NUMBER…1502
    1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…1502
    1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…1503
    1.4.6 CAB SERIAL NUMBER…1503
    1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS…1504
  TABLE OF CONTENTS…1505
  SAFETY AND ACCIDENT PREVENTION…1512
    2.1 SAFETY PLATES…1513
      2.1.1 POSITION OF THE SAFETY PLATES…1513
      2.1.2 POSITION OF THE PICTOGRAMS…1529
      2.1.3 PICTOGRAMS AND REVELANT MEANINGS…1531
      2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…1532
    2.2 GENERAL PRECAUTIONS…1533
      2.2.1 GENERAL SAFETY RULES…1533
      2.2.2 SAFETY DEVICES AND GUARDS…1533
      2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…1533
      2.2.4 UNAUTHORIZED MODIFICATIONS…1534
      2.2.5 LEAVING THE OPERATOR'S SEAT…1534
      2.2.6 GETTING ON AND OFF THE MACHINE…1535
      2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL…1535
      2.2.8 PRVENTING BURNS…1536
      2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWER…1536
      2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…1536
      2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT…1537
      2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE…1537
      2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT…1537
    2.3 PRECAUTIONS TO BE TAKE BEFORE STARTING THE ENGINE…1538
      2.3.1 SAFETY ON THE WORK SITE…1538
      2.3.2 FIRE PREVENTION…1538
      2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB…1538
      2.3.4 ROOM VENTILATION…1539
      2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS…1539
      2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES…1539
    2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING…1540
      2.4.1 STARTING THE ENGINE…1540
      2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE…1540
      2.4.3 CHECKS FOR TRAVELLING IN REVERSE…1540
      2.4.4 MOVING THE MACHINE…1541
      2.4.5 MOVING TON SLOPES…1542
      2.4.6 WORKING ON SLOPES…1543
      2.4.7 UNAUTHORIZED OPERATIONS…1543
      2.4.8 PREVENTING ELECTROCUTION…1544
      2.4.9 VISIBILITY…1545
      2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES…1545
      2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…1545
      2.4.12 WORKING ON LOOSE GROUND…1545
      2.4.13 PARKING THE MACHINE…1546
    2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES…1547
      2.5.1 LOADING AND UNLOADING…1547
      2.5.2 TRANSPORT…1547
    2.6 BATTERY…1548
      2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…1548
      2.6.2 STARTING WITH BOOSTER CABLES…1548
    2.7 PRECAUTIONS FOR EMERGENCY RECOVERY…1549
    2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE…1550
      2.8.1 WARNING PLATES…1550
      2.8.2 TOOLS…1550
      2.8.3 PERSONNEL…1551
      2.8.4 EQUIPMENT…1551
      2.8.5 WORKING UNDER THE MACHINE…1551
      2.8.6 CLEANING THE MACHINE…1551
      2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS…1552
      2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE  CRITICAL FOR SAFETY…1552
      2.8.9 STOP THE ENGINE BEFORE CARRING OUT ANY MAINTENANCE OPERATION OR INSPECTION…1552
      2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP…1553
      2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR…1553
      2.8.12 USING LAMPS…1553
      2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR…1554
      2.8.14 PRECAUTIONS CONCERNING THE STARTER…1554
      2.8.15 HANDLING HIGH-PRESSURE PIPES …1555
      2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…1555
      2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE…1555
      2.8.18 COOLING FAN AND BELT…1556
      2.8.19 WASTE MATERIALS…1556
  DESCRIPTION AND USE OF THE MACHINE…1558
    3.1 SAFETY LOCKS…1559
      3.1.1 MACHINE LOCKS…1559
    3.2 GENERAL VIEWS…1560
      3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB…1560
      3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY…1561
      3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT…1562
    3.3 INSTRUMENTS AND CONTROLS…1563
      3.3.1 INSTRUMENT, WARNING LIGHTS  AND PUSH BUTTONS…1563
      3.3.2 MACHINE CONTROLS…1569
    3.4 FUSES AND RELAYS…1578
      3.4.1 FUSES…1578
        3.4.1.1 EQUIPMENT FUSES…1578
        3.4.1.2 MAIN FUSE…1579
      3.4.2 RELAYS…1580
    3.5 GUARDS AND DRIVER'S SEAT…1581
      3.5.1 ENGINE HOOD…1581
      3.5.2 CANOPY…1582
      3.5.3 CAB…1582
      3.5.4 VENTILATION AND HEATING…1585
      3.5.5 SEAT…1585
      3.5.6 SAFETY BELT…1586
      3.5.7 EMERGENCY EXIT…1586
      3.5.8 TECHNICAL DOCUMENTATION…1587
      3.5.9 FIRE EXTINGUISHER…1587
      3.5.10 FIRST AID KIT…1587
    3.6 USE OF THE MACHINE…1588
      3.6.1 CHECKS BEFORE STARTING THE ENGINE…1588
        3.6.1.1 VISUAL CHECKS…1588
        3.6.1.2 DAILY CHECKS…1588
        3.6.1.3 OPERATIONAL CHECKS…1589
      3.6.2 STARTING THE ENGINE…1590
        3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES…1590
        3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES…1591
      3.6.3 WARMING THE ENGINE…1592
      3.6.4 HEATING THE HYDRAULIC OIL…1592
      3.6.5 HOW TO MOVE THE MACHINE…1592
        3.6.5.1 STEERING (CHANGING DIRECTION)…1594
        3.6.5.2 MOVING ON SLOPES…1595
        3.6.5.3 MAXIMUM IMMERSION DEPTH…1596
    3.7 PARKING THE MACHINE…1597
      3.7.1 PARKING ON LEVEL GROUND…1597
      3.7.2 PARKING ON SLOPES…1598
    3.8 STOPPING THE ENGINE…1599
    3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES…1600
      3.9.1 LOADING AND UNLOADING THE MACHINE…1600
      3.9.2 TRANSPORT…1601
    3.10 LIFTING THE MACHINE…1602
    3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON…1603
      3.11.1 FUEL AND LUBRICANTS…1603
      3.11.2 COOLANT…1603
      3.11.3 BATTERY…1603
      3.11.4 OTHER PRECAUTIONS…1604
      3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK…1604
    3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON…1605
    3.13 USING THE WORK EQUIPMENT…1606
      3.13.1 ORGANIZING THE WORK AREA…1606
      3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS…1607
      3.13.3 DIGGING METHOD…1608
      3.13.4 CHANGING THE BUCKET…1609
    3.14 LONG PERIODS OF INACTIVITY…1610
      3.14.1 BEFORE THE PERIOD OF INACTIVITY…1610
      3.14.2 DURING THE PERIOD OF INACTIVITY…1611
      3.14.3 AFTER THE PERIOD OF INACTIVITY…1611
    3.15 TROUBLESHOOTING…1612
      3.15.1 OCCURRENCES THAT ARE NOT FAILURES…1612
      3.15.2 HOW TO REMOVE THE MACHINE…1612
      3.15.3 AFTER THE FUEL HAS RUN OUT…1613
      3.15.4 IF THE BATTERY IS DOWN…1613
        3.15.4.1 STARTING WITH BOOSTER CABLES…1614
      3.15.5 OTHER TROUBLES…1615
        3.15.5.1 ELECTRICAL CIRCUIT…1615
        3.15.5.2 HYDRAULIC SYSTEM…1615
        3.15.5.3 ENGINE…1616
  MAINTENANCE…1618
    4.1 GUIDE TO MAINTENANCE…1619
    4.2 MAINTENANCE NOTES…1621
      4.2.1 NOTES REGARDING THE ENGINE…1621
        4.2.1.1 ENGINE OIL…1621
        4.2.1.2 COOLANT…1621
        4.2.1.3 FUEL…1622
      4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM…1622
      4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM…1623
      4.2.4 NOTES REGARDING LUBRICATION…1623
      4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING…1624
    4.3 FUEL, COOLANT AND LUBRICANTS…1625
    4.4 NUT AND BOLT…1629
      4.4.1 STANDARD TIGHTENING TORQUES…1629
      4.4.2 SPECIFIC TIGHTENING TORQUES…1629
    4.5 LUBRICATION …1630
      4.5.1 LUBRICATION DIAGRAM…1630
    4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY…1632
    4.7 MAINTENANCE PLAN…1635
      4.7.1 WHEN REQUIRED…1637
        4.7.1.A  WASHING THE COOLANT CIRCUIT…1637
        4.7.1.B DRAINING THE FUEL TANK…1638
        4.7.1.C CHECKING THE ELECTRICAL SYSTEM…1638
        4.7.1.D CHECKING THE STEEL TRACK TENSION…1639
        4.7.1.E CHECKING THE RUBBER TRACKS…1641
        4.7.1.F CHECKING THE RUBBER TRACK TENSION…1643
        4.7.1.G CHANGING THE RUBBER TRACK…1645
        4.7.1 H CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE…1647
      4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)…1648
        4.7.2.A CHANGING THE HYDRAULIC OIL FILTER…1648
        4.7.2.B CHANGING THE HYDRAULIC OIL…1648
      4.7.3 CHECKS BEFORE STARTING…1649
        4.7.3.A VARIOUS CHECKS…1649
        4.7.3.B CHECKING THE COOLANT…1649
        4.7.3.C CHECKING THE FUEL LEVEL…1650
        4.7.3.D CHECKING THE ENGINE OIL LEVEL…1650
        4.7.3.E CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT…1651
        4.7.3.F CHECKING THE AIR CLEANER CLOGGING INDICATOR…1652
        4.7.3.G CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER…1652
      4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION…1653
        4.7.4.A LUBRICATING THE JOINTS AND THE BALL-BEARING RING…1653
      4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION…1655
      4.7.6 MAINTENANCE EVERY 250 HOURS OF OPERATION…1655
        4.7.6.A ADJUSTING THE FAN BELT TENSION…1655
        4.7.6.B CHECKING THE BATTERY ELECTROLYTE LEVEL…1656
        4.7.6.C CHECKING THE FUEL FILTER…1656
        4.7.6.D CHANGING THE ENGINE OIL…1657
      4.7.7 MAINTENANCE EVERY 500 HOURS OF OPERATION…1658
        4.7.7.A CHANGING THE ENGINE OIL FILTER…1658
        4.7.7.B CHANGING THE FUEL FILTER…1659
        4.7.7.C CHANGING THE FUEL PUMP PRECLEANER…1660
        4.7.7.D CLEANING THE OUTSIDE OF THE RADIATORS…1661
        4.7.7.E CHANGING THE HYDRAULIC SYSTEM OIL FILTER…1662
      4.7.8 MAINTENANCE EVERY 1000 HOURS OF OPERATION…1663
        4.7.8.A CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS…1663
      4.7.9 MAINTENANCE EVERY 2000 HOURS OF OPERATION…1664
        4.7.9.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER…1664
        4.7.9.B CHANGING THE COOLANT…1667
        4.7.9.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE…1667
        4.7.9.D CHECKING THE ALTERNATOR AND THE STARTER…1667
  TECHNICAL DATA…1668
    5.1 TECHNICAL DATA…1669
      5.1.1 STANDARD OVERALL DIMENSIONS (FOR PC35R ONLY)…1669
      5.1.2 TECHNICAL CHARACTERISTICS PC35R…1671
      5.1.3 STANDARD OVERALL DIMENSIONS (FOR PC45R ONLY)…1672
      5.1.4 TECHNICAL CHARACTERISTICS PC45R…1674
      5.1.5 LIFTING CAPACITY WITH CAB (FOR PC35R ONLY)…1675
      5.1.6 LIFTING CAPACITY WITH CANOPY (FOR PC35R ONLY)…1676
      5.1.7 LIFTING CAPACITY WITH CAB (FOR PC45R ONLY)…1677
      5.1.8 LIFTING CAPACITY WITH CANOPY (FOR PC45R ONLY)…1678
  AUTHORIZED OPTIONAL EQUIPMENT…1680
    6.1 AUTHORIZED OPTIONAL EQUIPMENT…1681
      6.1.1 PRECAUTIONS REGARDING SAFETY…1681
      6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT…1682
      6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…1683
    6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)…1684
      6.2.1 DESCRIPTION AND CONTROL…1684
      6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED…1684
      6.2.3  INSTALLING AND REMOVING THE DEMOLITION HAMMER…1688
        6.2.3.1 INSTALLING THE HAMMER…1688
        6.2.3.2 REMOVING THE HAMMER…1689
      6.2.4 MAINTENANCE…1689
    6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT…1690
      6.3.1 SELECTION VALVE (1)…1690
      6.3.2 CONTROL PEDAL (2)…1691
      6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT…1692
      6.3.4 MAINTENANCE…1693
WEAM003202 – Hydraulic Excavator PC35R-8, PC45R-8 Deluxe Operation & Maintenance Manual…1694
  COVER…1694
  1.1 FOREWORD…1695
  1.2 INFORMATION ON SAFETY…1696
  1.3 INTRODUCTION…1698
    1.3.1 INTENDED USES…1698
    1.3.2 IMPROPER OR UNAUTHORIZED USES…1698
    1.3.3 MAIN CHARACTERISTICS…1699
    1.3.4 RUNNING-IN…1699
  1.4 PRODUCT IDENTIFICATION…1700
    1.4.1 MACHINE SERIAL NUMBER…1700
    1.4.2 MACHINE IDENTIFICATION PLATE…1700
    1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL…1701
    1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…1701
    1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…1702
    1.4.6 CAB SERIAL NUMBER…1702
    1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…1703
  TABLE OF CONTENTS…1704
  SAFETY AND ACCIDENT PREVENTION…1711
    2.1 SAFETY PLATES…1712
      2.1.1 POSITION OF THE SAFETY PLATES…1712
      2.1.2 POSITION OF THE PICTOGRAMS…1728
      2.1.3 PICTOGRAMS AND RELEVANT MEANINGS…1730
      2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…1732
    2.2 GENERAL PRECAUTIONS…1733
      2.2.1 GENERAL SAFETY RULES…1733
      2.2.2 SAFETY DEVICES AND GUARDS…1733
      2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…1733
      2.2.4 UNAUTHORIZED MODIFICATIONS…1734
      2.2.5 LEAVING THE OPERATOR’S SEAT…1734
      2.2.6 GETTING ON AND OFF THE MACHINE…1735
      2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL…1735
      2.2.8 PREVENTING BURNS…1736
      2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…1736
      2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…1736
      2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT…1737
      2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE…1737
      2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT…1737
    2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE…1738
      2.3.1 SAFETY ON THE WORK SITE…1738
      2.3.2 FIRE PREVENTION…1738
      2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB…1738
      2.3.4 ROOM VENTILATION…1739
      2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS…1739
      2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES…1739
    2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING…1740
      2.4.1 STARTING THE ENGINE…1740
      2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE…1740
      2.4.3 CHECKS FOR TRAVELLING IN REVERSE…1740
      2.4.4 MOVING THE MACHINE…1741
      2.4.5 MOVING ON SLOPES…1742
      2.4.6 WORKING ON SLOPES…1743
      2.4.7 UNAUTHORIZED OPERATIONS…1743
      2.4.8 PREVENTING ELECTROCUTION…1744
      2.4.9 VISIBILITY…1745
      2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES…1745
      2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…1745
      2.4.12 WORKING ON LOOSE GROUND…1745
      2.4.13 PARKING THE MACHINE…1746
    2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES…1747
      2.5.1 LOADING AND UNLOADING…1747
      2.5.2 TRANSPORT…1747
    2.6 BATTERY…1748
      2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…1748
      2.6.2 STARTING WITH BOOSTER CABLES…1748
    2.7 PRECAUTIONS FOR EMERGENCY RECOVERY…1749
    2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE…1750
      2.8.1 WARNING PLATES…1750
      2.8.2 TOOLS…1750
      2.8.3 PERSONNEL…1751
      2.8.4 EQUIPMENT…1751
      2.8.5 WORKING UNDER THE MACHINE…1751
      2.8.6 CLEANING THE MACHINE…1751
      2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS…1752
      2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…1752
      2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION…1752
      2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP…1753
      2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR…1753
      2.8.12 USING LAMPS…1753
      2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR…1754
      2.8.14 PRECAUTIONS CONCERNING THE STARTER…1754
      2.8.15 HANDLING HIGH-PRESSURE PIPES…1755
      2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…1755
      2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE…1755
      2.8.18 COOLING FAN AND BELT…1756
      2.8.19 WASTE MATERIALS…1756
      2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES…1756
  THE MACHINE AND ITS OPERATIONS…1757
    3.1 SAFETY LOCKS…1758
      3.1.1 MACHINE LOCKS…1758
    3.2 GENERAL VIEWS…1759
      3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB…1759
      3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY…1760
      3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT…1761
    3.3 INSTRUMENTS AND CONTROLS…1762
      3.3.1 INSTRUMENTS…1762
      3.3.2 WARNING LIGHTS…1764
      3.3.3 SWITCHES AND PUSH BUTTONS…1766
      3.3.4 ELECTRICAL ACCESSORIES…1769
      3.3.5 MACHINE CONTROLS…1771
    3.4 FUSES AND RELAYS…1784
      3.4.1 FUSES…1784
        3.4.1.1 EQUIPMENT FUSES…1784
        3.4.1.2 MAIN FUSE…1785
      3.4.2 RELAYS…1786
    3.5 GUARDS AND DRIVER'S SEAT…1787
      3.5.1 ENGINE HOOD…1787
      3.5.2 RIGHT COUNTERWEIGHT…1788
      3.5.3 CANOPY…1788
      3.5.4 CAB…1789
      3.5.5 VENTILATION AND HEATING…1792
      3.5.6 SEAT…1793
      3.5.7 SAFETY BELT…1793
      3.5.8 EMERGENCY EXIT…1794
      3.5.9 TECHNICAL DOCUMENTATION CASE…1794
      3.5.10 FIRE EXTINGUISHER…1795
      3.5.11 FIRST AID KIT…1795
    3.6 USE OF THE MACHINE…1797
      3.6.1 CHECKS BEFORE STARTING THE ENGINE…1797
        3.6.1.1 VISUAL CHECKS…1797
        3.6.1.2 DAILY CHECKS…1797
        3.6.1.3 OPERATIONAL CHECKS…1798
      3.6.2 STARTING THE ENGINE…1799
        3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES…1799
        3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES…1800
      3.6.3 WARMING THE ENGINE…1801
      3.6.4 HEATING THE HYDRAULIC OIL…1801
      3.6.5 HOW TO MOVE THE MACHINE…1801
        3.6.5.1 STEERING (CHANGING DIRECTION)…1803
        3.6.5.2 MOVING ON SLOPES…1804
        3.6.5.3 MAXIMUM IMMERSION DEPTH…1805
    3.7 PARKING THE MACHINE…1806
      3.7.1 PARKING ON LEVEL GROUND…1806
      3.7.2 PARKING ON SLOPES…1807
    3.8 STOPPING THE ENGINE…1808
    3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES…1809
      3.9.1 LOADING AND UNLOADING THE MACHINE…1809
      3.9.2 TRANSPORT…1810
    3.10 LIFTING THE MACHINE…1811
    3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON…1812
      3.11.1 FUEL AND LUBRICANTS…1812
      3.11.2 COOLANT…1812
      3.11.3 BATTERY…1812
      3.11.4 OTHER PRECAUTIONS…1813
      3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK…1813
    3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON…1814
    3.13 USING THE WORK EQUIPMENT…1815
      3.13.1 ORGANIZING THE WORK AREA…1815
      3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS…1816
      3.13.3 DIGGING METHOD…1817
      3.13.4 CHANGING THE BUCKET…1818
    3.14 LONG PERIODS OF INACTIVITY…1819
      3.14.1 BEFORE THE PERIOD OF INACTIVITY…1819
      3.14.2 DURING THE PERIOD OF INACTIVITY…1820
      3.14.3 AFTER THE PERIOD OF INACTIVITY…1820
    3.15 TROUBLESHOOTING…1821
      3.15.1 OCCURRENCES THAT ARE NOT FAILURES…1821
      3.15.2 HOW TO REMOVE THE MACHINE…1821
      3.15.3 AFTER THE FUEL HAS RUN OUT…1822
      3.15.4 IF THE BATTERY IS DOWN…1822
        3.15.4.1 STARTING WITH BOOSTER CABLES…1823
      3.15.5 OTHER TROUBLES…1824
        3.15.5.1 ELECTRICAL CIRCUIT…1824
        3.15.5.2 HYDRAULIC SYSTEM…1824
        3.15.5.3 ENGINE…1825
  MAINTENANCE…1827
    4.1 GUIDE TO MAINTENANCE…1828
    4.2 MAINTENANCE NOTES…1830
      4.2.1 NOTES REGARDING THE ENGINE…1830
        4.2.1.1 ENGINE OIL…1830
        4.2.1.2 COOLANT…1830
        4.2.1.3 FUEL…1831
      4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM…1831
      4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM…1832
      4.2.4 NOTES REGARDING LUBRICATION…1832
      4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING…1833
    4.3 FUEL, COOLANT AND LUBRICANTS…1834
      4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS…1839
    4.4 NUT AND BOLT TIGHTENING TORQUES…1840
      4.41 STANDARD TIGHTENING TORQUES…1840
      4.4.2 SPECIFIC TIGHTENING TORQUES…1840
    4.5 LUBRICATION…1841
      4.5.1 LUBRICATION DIAGRAM…1841
    4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY…1842
      4.6.1 CRITICAL PARTS FOR SAFETY…1843
    4.7 MAINTENANCE PLAN…1846
      4.7.1 WHEN REQUIRED…1849
        4.7.1.a WASHING THE COOLING CIRCUIT…1849
        4.7.1.b DRAINING THE FUEL TANK…1850
        4.7.1.c CHECKING THE ELECTRICAL SYSTEM…1850
        4.7.1.d CHECKING THE STEEL TRACK TENSION…1851
        4.7.1.e CHECKING THE RUBBER TRACKS…1853
        4.7.1.f CHECKING THE RUBBER TRACK TENSION…1855
        4.7.1.g CHANGING THE RUBBER TRACK…1857
        4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE…1859
      4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)…1860
        4.7.2.a CHANGING THE HYDRAULIC OIL FILTER…1860
        4.7.2.b CHANGING THE HYDRAULIC OIL…1860
      4.7.3 CHECKS BEFORE STARTING…1861
        4.7.3.a VARIOUS CHECKS…1861
        4.7.3.b CHECKING THE COOLANT LEVEL…1861
        4.7.3.c CHECKING THE FUEL LEVEL…1862
        4.7.3.d CHECKING THE ENGINE OIL LEVEL…1862
        4.7.3.e CHECKING THE OIL IN THE HYDRAULIC CIRCUIT…1863
        4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR…1864
        4.7.3.g CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER…1864
      4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES…1865
      4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION…1866
        4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING…1866
      4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION…1868
      4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION…1868
        4.7.7.a ADJUSTING THE FAN BELT…1868
        4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL…1869
        4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS…1869
        4.7.7.d CHANGING THE ENGINE OIL…1870
      4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEE…1871
      4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION…1871
        4.7.9.a CHANGING THE ENGINE OIL FILTER…1871
        4.7.9.b CHANGING THE FUEL FILTER…1872
        4.7.9.c CHANGING THE FUEL PUMP PRECLEANER…1873
        4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS…1874
        4.7.9.e CHANGING THE HYDRAULIC SYSTEM OIL FILTER…1875
        4.7.9.f DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES IS USED)…1876
      4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION…1877
        4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS…1877
      4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION…1878
        4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER…1878
        4.7.11.b CHANGING THE COOLANT…1881
        4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE…1882
        4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER…1882
  TECHNICAL SPECIFICATIONS…1883
    5.1 TECHNICAL DATA…1884
      5.1.1 STANDARD OVERALL DIMENSIONS (for PC35R only)…1884
      5.1.2 TECHNICAL CHARACTERISTICS PC35R…1886
      5.1.3 STANDARD OVERALL DIMENSIONS (for PC45R only)…1887
      5.1.4 TECHNICAL CHARACTERISTICS PC45R…1889
      5.1.5 LIFTING CAPACITY WITH CAB (for PC35R only)…1890
      5.1.6 LIFTING CAPACITY WITH CANOPY (for PC35R only)…1891
      5.1.7 LIFTING CAPACITY WITH CAB (for PC45R only)…1892
      5.1.8 LIFTING CAPACITY WITH CANOPY (for PC45R only)…1893
  AUTHORIZED OPTIONAL EQUIPMENT…1895
    6.1 AUTHORIZED OPTIONAL EQUIPMENT…1896
      6.1.1 PRECAUTIONS REGARDING SAFETY…1896
      6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT…1897
      6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…1898
    6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)…1899
      6.2.1 DESCRIPTION AND CONTROL…1899
      6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED…1899
      6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER…1903
        6.2.3.1 INSTALLING THE HAMMER…1903
        6.2.3.1 REMOVING THE HAMMER…1904
      6.2.4 MAINTENANCE…1904
    6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT…1905
      6.3.1 SELECTION VALVE (1)…1905
      6.3.2 CONTROL PEDAL (2)…1906
      6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT…1907
      6.3.4 MAINTENANCE…1908
WEBM003000 – Hydraulic Excavator PC35R-8, PC45R-8 Shop Manual…1909
  COVER…1909
  CONTENTS…1910
  FOREWARD…1914
    FOREWARD…1916
    HOW TO READ THE MANUAL…1917
    HOISTING INSTRUCTIONS…1918
    STANDARD TIGHTENING TORQUE…1919
    COATING MATERIALS…1921
    ELECTRIC WIRE CODE…1922
    WEIGHT TABLE…1923
    TABLE OF OIL AND COOLANT QUANTITIES…1924
  10 STRUCTURE AND FUNCTION…1927
    P.T.O…1928
    POWER TRAIN…1929
    SWING CIRCLE…1930
    SWING MACHINERY…1931
    FINAL DRIVE…1932
    TRACK FRAME…1933
    RECOIL SPRING…1934
    CARRIER ROLLER…1935
    TRACK ROLLER…1935
    STEEL SHOE…1936
    HYDRAULIC CIRCUIT DIAGRAM (PC35R)…1937
    HYDRAULIC CIRCUIT DIAGRAM (PC45R)…1938
    HYDRAULIC PUMP…1939
    CONTROL VALVE…1946
    CLSS…1954
    SWIVEL JOINT…1976
    SWING MOTOR…1977
    TRAVEL MOTOR…1979
    CYLINDERS…1983
    ACCUMULATOR…1986
    PPC VALVES (WORK EQUIPMENT)…1987
    PPC VALVE (HAMMER)…1991
    SOLENOID VALVE…1994
    ELECTRICAL DIAGRAM (1/3)…1995
    ELECTRICAL DIAGRAM (2/3)…1996
    ELECTRICAL DIAGRAM (3/3)…1997
  20 TESTING AND ADJUSTMENTS…1999
    NORMAL OR STANDARD TECHNICAL DATA…2000
    SPECIAL TOOLS…2022
    CHECKING THE ENGINE SPEED…2023
    ADJUSTMENT OF VALVE CLEARANCE…2024
    MEASUREMENT OF THE COMPRESSOR PRESSURE…2025
    CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT…2026
    CONTROL AND ADJUSTMENT OF THE INJECTION TIMING…2027
    CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE …2029
    ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER…2030
    ADJUSTING THE FLEXIBLE CABLES…2031
    CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER…2032
    ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL…2033
    ADJUSTMENT OF THE PPC VALVE CLEARANCES…2034
    ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT…2035
    CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION…2036
    CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUTIS…2037
    CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE…2040
    REGULATION OF THE PC VALVE…2042
    CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY…2043
    ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK…2044
    BLEEDING AIR FROM THE HYDRAULIC CIRCUITS…2045
    CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSES OF A DRIFT…2047
    CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS…2053
    CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR…2054
    METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT…2055
  30 REMOVAL AND INSTALLATION…2058
    HOW TO READ THE MANUAL…2060
    PRECAUTIONS TO BE TAKEN WHILE WORKING…2061
    SPECIAL TOOLS…2062
    STARTER MOTOR…2064
      REMOVAL…2064
      INSTALLATION…2064
    ALTERNATOR…2065
      REMOVAL…2065
      INSTALLATION…2065
    INJECTION PUMP…2066
      REMOVAL…2066
      INSTALLATION…2067
    NOZZLE HOLDER…2068
      REMOVAL…2068
      INSTALLATION…2068
    WATER COOLANT PUMP…2069
      REMOVAL…2069
      INSTALLATION…2070
    CYLINDER HEAD…2071
      REMOVAL…2071
      INSTALLATION…2073
    OIL COOLER…2074
      REMOVAL…2074
      INSTALLATION…2074
    OIL COOLER- RADIATOR…2075
      REMOVAL…2075
      INSTALLATION…2076
    ENGINE HOOD…2077
      REMOVAL…2077
      INSTALLATION…2077
    CANOPY…2078
      REMOVAL…2078
      INSTALLATION…2078
    CAB…2079
      REMOVAL…2079
      INSTALLATION…2079
    HEATING FAN…2080
      REMOVAL…2080
      INSTALLATION…2081
    COUNTERWEIGHT…2082
      REMOVAL…2082
      INSTALLATION…2082
    FUEL TANK…2083
      REMOVAL…2083
      INSTALLATION…2084
    HYDRAULIC TANK…2085
      REMOVAL…2085
      INSTALLATION…2086
    ENGINE-PUMP GROUP…2087
      REMOVAL…2087
      INSTALLATION…2090
    PUMP…2091
      REMOVAL…2091
      INSTALLATION…2091
    ENGINE-PUMP COUPLING…2092
      REMOVAL…2092
      INSTALLATION…2092
    CONTROL VALVE…2093
      REMOVAL…2093
      INSTALLATION…2094
    LEFT-HAND PPC VALVE (ARM-BUCKET)…2095
      REMOVAL…2095
      INSTALLATION…2095
    RIGHT-HAND PPC VALVE(BOOM-BUCKET)…2096
      REMOVAL…2096
      INSTALLATION…2096
    SERVOCONTROL SOLENOID GROUP…2097
      REMOVAL…2097
      INSTALLATION…2097
    PLATFORM…2098
      REMOVAL…2098
      INSTALLATION…2101
    SWIVEL JOINT…2102
      REMOVAL…2102
      INSTALLATION…2103
    SWING MACHINERY…2104
      REMOVAL…2104
      INSTALLATION…2104
    REVOLVING FRAME…2105
      REMOVAL…2105
      INSTALLATION…2106
    SWING CIRCLE…2107
      REMOVAL…2107
      INSTALLATION…2107
    RUBBER TRACK SHOES…2108
      REMOVAL…2108
      INSTALLATION…2108
    STEEL TRACK-SHOES…2109
      REMOVAL…2109
      INSTALLATION…2109
    SPROCKET WHEEL…2110
      REMOVAL…2110
      INSTALLATION…2110
    FINAL DRIVE…2111
      REMOVAL…2111
      INSTALLATION…2111
    IDLER AND RECOIL SPRING ASSEMBLY…2112
      REMOVAL…2112
      INSTALLATION…2112
    SPRING RECOIL AND THRUST CYLINDER GROUPS…2113
      DISASSEMBLY…2113
      ASSEMBLY…2114
    IDLER…2116
      DISASSEMBLY…2116
      ASSEMBLY…2117
    TRACK ROLLERS…2118
      REMOVAL…2118
      INSTALLATION…2118
    BOOM CYLINDER…2119
      REMOVAL…2119
      INSTALLATION…2120
    ARM CYLINDER…2121
      REMOVAL…2121
      INSTALLATION…2121
    BUCKET CYLINDER…2122
      REMOVAL…2122
      INSTALLATION…2122
    BOOM SWING CYLINDER…2123
      REMOVAL…2123
      INSTALLATION…2124
    BLADE CYLINDER…2125
      REMOVAL…2125
      INSTALLATION…2125
    WORKING EQUIPMENT CYLINDERS…2126
      DISASSEMBLY…2126
      ASSEMBLY…2128
    UPPER WORKING EQUIPMENT…2132
      REMOVAL…2132
      INSTALLATION…2133
    BUCKET…2134
      REMOVAL…2134
      INSTALLATION…2134
    ARM…2135
      REMOVAL…2135
      INSTALLATION…2136
    ARM ASSEMBLY…2137
      REMOVAL…2137
      INSTALLATION…2137
    BOOM…2138
      REMOVAL…2138
      INSTALLATION…2139
    BOOM SWING SUPPORT…2140
      REMOVAL…2140
      INSTALLATION…2140
    BLADE…2141
      REMOVAL…2141
      INSTALLATION…2141
  40 STANDARD MAINTENANCE…2143
    SWING CIRCLE…2144
    SWING MACHINERY…2145
    FINAL DRIVE…2146
    SPROCKET…2147
    IDLER…2148
    STEEL SHOE…2149
    CARRIER ROLLER…2151
    TRACK ROLLER…2152
    RUBBER SHOE…2153
    TRACK FRAME…2154
    HYDRAULIC PUMP…2156
    CONTROL VALVE…2157
    SWIVEL JOINT…2163
    SWING MOTOR…2164
    TRAVEL MOTOR…2165
    PPC VALVE…2169
    PPC VALVE (HAMMER)…2170
    CYLINDER…2171
    WORK EQUIPMENT…2175
WEBM003900 – Hydraulic Excavator PC35R-8, PC45R-8 Deluxe Shop Manual…2180
  COVER…2180
  CONTENTS…2182
  SAFETY…2186
  FOREWORD…2188
    HOW TO READ THE SHOP MANUAL…2189
    HOISTING INSTRUCTIONS…2190
    STANDARD TIGHTENING TORQUE…2191
    COATING MATERIALS…2193
    ELECTRIC WIRE CODE…2194
    WEIGHT TABLE…2195
    TABLE OF OIL AND COOLANT QUANTITIES…2196
  10. STRUCTURE AND FUNCTION…2200
    P.T.O…2201
    POWER TRAIN…2202
    SWING CIRCLE…2203
    SWING MACHINERY…2204
    FINAL DRIVE…2205
    TRACK FRAME…2206
    RECOIL SPRING…2207
    CARRIER ROLLER…2208
    TRACK ROLLER…2208
    STEEL SHOE…2209
    HYDRAULIC CIRCUIT DIAGRAM PC35R-8…2210
    HYDRAULIC CIRCUIT DIAGRAM PC45R-8…2212
    HYDRAULIC PUMP…2214
    CONTROL VALVE…2221
    CLSS…2229
    SWIVEL JOINT…2251
    SWING MOTOR…2253
    TRAVEL MOTOR…2255
    CYLINDERS…2260
    ACCUMULATOR…2264
    PPC VALVES (WORK EQUIPMENT)…2265
    PPC VALVE (HAMMER)…2269
    SOLENOID VALVE…2272
    ELECTRICAL DIAGRAM (1/3)…2274
    ELECTRICAL DIAGRAM (2/3)…2276
    ELECTRICAL DIAGRAM (3/3)…2278
  20. TESTING AND ADJUSTMENTS…2282
    NORMAL OR STANDARD TECHNICAL DATA…2283
    SPECIAL TOOLS…2305
    CHECKING THE ENGINE SPEED…2306
    ADJUSTMENT OF VALVE CLEARANCE…2307
    MEASUREMENT OF THE COMPRESSION PRESSURE…2308
    CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT…2309
    CONTROL AND ADJUSTMENT OF THE INJECTION TIMING…2310
    CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE…2312
    ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER…2313
    ADJUSTING THE FLEXIBLE CABLES…2314
    CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER…2315
    ADJUSTMENT OF THE STROKE OF THE BOOM SWING COMMAND PEDAL…2316
    ADJUSTMENT OF THE PPC VALVE CLEARANCES…2317
    ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVOCONTROL ENGAGEMENT…2318
    CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION…2319
    CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS…2320
    CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE…2323
    REGULATION OF THE PC VALVE…2325
    CONTROL AND REGULATION OF THE SERVOCONTROL POWER SUPPLY…2326
    ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK…2327
    BLEEDING AIR FROM THE HYDRAULIC CIRCUITS…2328
    CONTROL OF HYDRAULIC DRIFTS – ANALYSIS OF THE CAUSE OF A DRIFT…2330
    CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS…2336
    CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR…2337
    METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT…2338
  30. REMOVAL AND INSTALLATION…2342
    HOW TO READ THE MANUAL…2344
    PRECAUTIONS TO BE TAKEN WHILE WORKING…2345
    SPECIAL TOOLS…2346
    STARTER MOTOR…2348
      REMOVAL…2348
      INSTALLATION…2348
    ALTERNATOR…2349
      REMOVAL…2349
      INSTALLATION…2349
    INJECTION PUMP…2350
      REMOVAL…2350
      INSTALLATION…2351
    NOZZLE HOLDER…2352
      REMOVAL…2352
      INSTALLATION…2352
    WATER COOLANT PUMP…2353
      REMOVAL…2353
      INSTALLATION…2354
    CYLINDER HEAD…2355
      REMOVAL…2355
      INSTALLATION…2357
    RADIATOR GROUP – OIL COOLER…2358
      REMOVAL…2358
      INSTALLATION…2359
    ENGINE HOOD…2360
      REMOVAL…2360
      INSTALLATION…2360
    CANOPY…2361
      REMOVAL…2361
      INSTALLATION…2361
    CAB…2362
      REMOVAL…2362
      INSTALLATION…2362
    HEATING FAN…2363
      REMOVAL…2363
      INSTALLATION…2364
    COUNTERWEIGHT…2365
      REMOVAL…2365
      INSTALLATION…2365
    FUEL TANK…2366
      REMOVAL…2366
      INSTALLATION…2367
    HYDRAULIC TANK…2368
      REMOVAL…2368
      INSTALLATION…2369
    ENGINE-PUMP GROUP…2370
      REMOVAL…2370
      INSTALLATION…2373
    PUMP…2374
      REMOVAL…2374
      INSTALLATION…2374
    ENGINE-PUMP COUPLING…2375
      REMOVAL…2375
      INSTALLATION…2375
    CONTROL VALVE…2376
      REMOVAL…2376
      INSTALLATION…2377
    LEFT-HAND PPC VALVE (ARM-BUCKET)…2378
      REMOVAL…2378
      INSTALLATION…2378
    RIGHT-HAND PPC VALVE (BOOM-BUCKET)…2379
      REMOVAL…2379
      INSTALLATION…2379
    SERVOCONTROL SOLENOID GROUP…2380
      REMOVAL…2380
      INSTALLATION…2380
    PLATFORM…2381
      REMOVAL…2381
      INSTALLATION…2384
    SWIVEL JOINT…2385
      REMOVAL…2385
      INSTALLATION…2386
    SWING MACHINERY…2387
      REMOVAL…2387
      INSTALLATION…2387
    REVOLVING FRAME…2388
      REMOVAL…2388
      INSTALLATION…2389
    SWING CIRCLE…2390
      REMOVAL…2390
      INSTALLATION…2390
    RUBBER TRACK SHOES…2391
      REMOVAL…2391
      INSTALLATION…2391
    STEEL TRACK SHOES…2392
      REMOVAL…2392
      INSTALLATION…2392
    SPROCKET WHEEL…2393
      REMOVAL…2393
      INSTALLATION…2393
    FINAL DRIVE…2394
      REMOVAL…2394
      INSTALLATION…2394
    IDLER AND RECOIL SPRING…2395
      REMOVAL…2395
      INSTALLATION…2395
    SPRING RECOIL AND THRUST CYLINDER GROUPS…2396
      DISASSEMBLY…2396
      ASSEMBLY…2397
    IDLER…2399
      DISASSEMBLY…2399
      ASSEMBLY…2400
    TRACK ROLLERS…2401
      REMOVAL…2401
      INSTALLATION…2401
    BOOM CYLINDER…2402
      REMOVAL…2402
      INSTALLATION…2403
    ARM CYLINDER…2404
      REMOVAL…2404
      INSTALLATION…2404
    BUCKET CYLINDER…2405
      REMOVAL…2405
      INSTALLATION…2405
    BOOM SWING CYLINDER…2406
      REMOVAL…2406
      INSTALLATION…2407
    BLADE CYLINDER…2408
      REMOVAL…2408
      INSTALLATION…2408
    WORK EQUIPMENT CYLINDERS…2409
      DISASSEMBLY…2409
      ASSEMBLY…2411
    UPPER WORK EQUIPMENT…2415
      REMOVAL…2415
      INSTALLATION…2416
    BUCKET…2417
      REMOVAL…2417
      INSTALLATION…2417
    ARM…2418
      REMOVAL…2418
      INSTALLATION…2419
    ARM ASSEMBLY…2420
      REMOVAL…2420
      INSTALLATION…2420
    BOOM…2421
      REMOVAL…2421
      INSTALLATION…2422
    BOOM SWING SUPPORT…2423
      REMOVAL…2423
      INSTALLATION…2423
    BLADE…2424
      REMOVAL…2424
      INSTALLATION…2424
  40. STANDARD MAINTENANCE…2428
    SWING CIRCLE…2429
    SWING MACHINERY…2430
    FINAL DRIVE…2431
    SPROCKET…2432
    IDLER…2433
    STEEL SHOE…2434
      PC35R…2434
      PC45R…2435
    CARRIER ROLLER…2436
    TRACK ROLLER…2437
    RUBBER SHOE…2438
    TRACK FRAME…2439
    HYDRAULIC PUMP…2441
    CONTROL VALVE…2442
    SWIVEL JOINT…2448
    SWING MOTOR…2449
    TRAVEL MOTOR…2451
      PC35R…2451
      PC45R…2453
    PPC VALVE (FOR BOOM, ARM, BUCKET, SWING)…2455
    PPC VALVE (FOR HAMMER)…2456
    CYLINDERS…2457
      PC35R…2457
      PC45R…2459
    WORK EQUIPMENT …2461
      PC35R-8…2461
      PC45R…2463

Komatsu Hydraulic Excavator PC30R, PC35R, PC40R, PC45R Repair Service Manuals

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