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