Komatsu Excavator PC40MR-3 service & repair manual

Description Komatsu Excavator PC40MR-3 service & repair manual

Komatsu Hydraulic Excavator PC40MR-3 pdf workshop service manual

Serial numbers:
15001 and up

Technical data, specifications, maintenance, testing, adjusting, troubleshooting, electrical wiring diagrams, hydraulic schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification dimension drawing
Working range drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
PTO
Cooling system
Power train
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
Hydraulic system
Hydraulic components layout drawing
Hydraulic tank, filter
Center swivel joint
Travel motor
Hydraulic cylinder
Solenoid valve
Multi-control valve (If equipped)
Hydraulic pump
Control valve
CLSS
Operation for each function and valve
Swing motor
PPC valve
Work equipment
Dimensions of each part of work equipment
Cab and its attachments
Floor
Electrical system
Engine control system
Electric control system
KOMTRAX system
Component parts of system
Monitor system
Sensors

Standard value table
Standard service value table
Standard service value table for engine related parts
Standard service value table for chassis related parts

Testing and adjusting
Related information on testing and adjusting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing engine oil pressure
Testing and adjusting fuel injection timing
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting fuel control lever
Power train
Testing clearance in swing circle bearings
Undercarriage and frame
Testing and adjusting track shoe tension
Hydraulic system
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits
Testing and adjusting LS differential pressure
Adjusting PC valve
Testing and adjusting control pump circuit oil pressure
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting PPC valve
Testing swing holding brake release pressure
Testing and adjusting travel deviation
Testing oil leakage from work equipment cylinder
Bleeding air from each part
Releasing residual pressure from hydraulic circuit
Releasing residual pressure from hydraulic tank
Pressurizing hydraulic tank
Cab and its attachments
How to open and close (tilt) floor
Electrical system
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Removal and installation of KOMTRAX terminal
Preparation work for troubleshooting of electrical system
Inspection procedures for diode

Troubleshooting
General information on troubleshooting
Points to remember when performing troubleshooting
How to proceed in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Information contained in troubleshooting table
Connection table of connector by No. of pins
T- branch box and T- branch adapter table
User code and failure code list
Fuse locations
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel injection pump assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of engine and hydraulic pump assembly
Power train
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Removal and installation of track shoe assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of revolving frame assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of work equipment pump assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly (Canopy specification)
Removal and installation of operator cab and floor frame assembly (Operator cab specification)
Electrical system
Removal and installation of air conditioner unit assembly (If equipped)
Removal and installation of KOMTRAX terminal

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Electrical circuit diagram
Connector list and stereogram

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