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