PDF Shop Manual Komatsu PC30MR-5 PC35MR-5 Compact Hydraulic Excavator - 4 MB
This comprehensive shop manual is the ultimate guide for servicing the Komatsu PC30MR-5 and PC35MR-5 compact hydraulic excavators.
It provides detailed diagnostic, repair, and overhaul procedures for all major systems.
With clear instructions, diagrams, and specifications, this manual enables technicians to perform accurate and efficient repairs.
It's an essential resource for keeping these powerful compact machines in top condition.
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--- Page 1 ---
SEN06591-09
COMPACT PC30MR -5
HYDRAULIC
EXCAVATOR
PC35MR -5
PC30MR- 50001
SERIAL NUMBERS and up
PC35MR- 30001
--- Page 3 ---
ABBREVIATION LIST 00 INDEX AND FOREWORD
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.
00-14 PC30MR-5, PC35MR-5
--- Page 4 ---
00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE
PRECAUTIONS TO PREVENT FIRE
Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.
PC30MR-5, PC35MR-5 00-29
--- Page 5 ---
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.
Water entering the connector by high-pressure jetting
The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.
00-44 PC30MR-5, PC35MR-5
--- Page 6 ---
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH
LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.
Method for connecting connector with lock to pull
Insert the connector securely until it “clicks”.
PC30MR-5, PC35MR-5 00-59
--- Page 7 ---
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD
Thread diam- Width across Tightening torque (Nm {kgfm} )
Nominal No.
eter (mm) flats (mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
Width Tightening torque (Nm {kgfm} ) Taper seal Face seal
Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter(mm)
hose (mm)
(mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5
16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ 20.6
16-16UN
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -
00-74 PC30MR-5, PC35MR-5
--- Page 8 ---
01 SPECIFICATIONS ABBREVIATION LIST
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.
*1: Code for applicable machine model
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
PC30MR-5, PC35MR-5 01-7
--- Page 9 ---
WEIGHT TABLE 01 SPECIFICATIONS
WEIGHT TABLE
WEIGHT TABLE: PC30MR-5
k This weight table is provided for your reference when handling the components or when transport-
ing.
k This weight table shows the dry weight.
Unit: kg
Item PC30MR-5
Engine assembly 206
• Engine 152
• Engine mount 7
• PTO 10
• Main pump 30
Cooling assembly 18
Battery 19
Revolving frame 350
Floor frame assembly 163
Canopy (*1) 87
Handrail (*1) 6
Operator's cab assembly (including floor frame assembly) (*2) 439
Operator's seat 25
Fuel tank 6
Hydraulic tank 30
Control valve 44
Counterweight 265
Swing motor (including brake valve) 14
Swing circle 37
Swing machinery 19
Center swivel joint 15
Track frame assembly (excluding track shoes) 655
• Track frame 365
• Idler and idler cushion assembly 26 x 2
• Idler assembly 14 x 2
• Carrier roller 4x2
• Track roller 24 x 2
• Travel motor (including reduction gear) 36 x 2
• Sprocket 10 x 2
Track shoe assembly
Rubber shoe (300 mm) 122 x 2
Double grouser shoe (300 mm) 170 x 2
Road liner (300 mm) 193 x 2
01-22 PC30MR-5, PC35MR-5
--- Page 10 ---
10 STRUCTURE AND FUNCTION SYSTEM OPERATING LAMP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
SYSTEM OPERATING LAMP SYSTEM DIAGRAM
1: Quick release battery terminal (-) 6: Machine monitor
2: Battery 7: Engine controller
3: Fusible link 8: Machine controller
4: Fuse box 9: KOMTRAX terminal
5: System operating lamp
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM
An abnormal disconnection during the operation can be avoided for the circuit of each controller by not remov-
ing the quick release battery terminal (-) while the system operating lamp shows that any of systems is still in
operation by its being lit.
REMARK
• Check that the system operating lamp is not lit always after turning the starting switch to “OFF” position, then
remove the quick release battery terminal (-) to shut off the battery power supply circuit.
• A controller data loss error may occur if the quick release battery terminal (-) is removed (battery power sup-
ply circuit is shut off) while the system operating lamp is lit. Do not remove the quick release battery terminal
(-) while the system operating lamp is lit.
• The system operating lamp goes out in a maximum of eight seconds after the starting switch is turned to
“OFF” position.
• The system operating lamp may be lit while the starting switch is in “OFF” position, because KOMTRAX ter-
minal may maintain its communication under this condition.
Being lit and not being lit of system operating lamp
• Voltage of 12 V is constantly applied to one side of system operating lamp (light emitting diode).
• Voltage of 12 V is constantly applied to one side of system operating lamp (light emitting diode).
• The controller side outputs a turn-on (0 V), and a current flows through the diode and the system operating
lamp is lit when any of controllers is in operation.
REMARK
The system operating lamp may look slightly luminous in the dark even when it is not lit. It is due to the
minute leakage of current and this is not an abnormal phenomenon.
• KOMTRAX terminal repeats the start and stop to maintain the periodic communication when the starting
switch is in “OFF” position.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication state and the time when the machine is not in operation. The lamp may stay lit approxi-
mately for the maximum of one hour.
PC30MR-5, PC35MR-5 10-11
--- Page 11 ---
OVERHEAT PREVENTION SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF OVERHEAT PREVENTION SYSTEM
This system prevents overheating by reducing the pump load and by lowering the engine speed, and protects
engine and hydraulic components when coolant temperature becomes too high during operation 100 seconds or
more after the engine is started.
Operating condition Operation and remedy Condition to cancel
Coolant temperature: Below
Working mode: Travel (Hi 96 °C
→ Engine speed: Kept as it is →
mode) • When above condition is
Pump discharged volume: Throt-
Coolant temperature: 98 °C satisfied, it is restored to
tled
or above the state before operation
(automatic restoration).
Operating condition Operation and remedy Condition to cancel
Coolant temperature: Below
100 °C
Working mode: All modes → Engine speed: Kept as it is → • When above condition is
Coolant temperature: 105 °C Pump discharged volume: Throt-
satisfied, it is restored to
or above tled
the state before operation
(automatic restoration).
Operating condition Operation and remedy Condition to cancel
Coolant temperature: Below
Engine speed: Kept as it is 107 °C
Working mode: All modes → →
Pump discharged volume: Throt- • When above condition is
Coolant temperature: 107 °C tled satisfied, it is restored to
or above
Warning lamp: Lit the state before operation
(automatic restoration).
Operating condition Operation and remedy Condition to cancel
Coolant temperature: Below
110 °C
Engine speed: Low idle Fuel control dial: Return to Low
Working mode: All modes → → idle (MIN) position.
Coolant temperature: 110 °C Warning lamp: Lit
or above • When above condition is
Alarm buzzer: Sounds
satisfied, it is restored to
the state before operation
(manual restoration).
10-26 PC30MR-5, PC35MR-5
--- Page 12 ---
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM
Catego-
Item Display order (*2)
ry (*1)
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation to display clock and service meter
B Check of maintenance information
Setting and display of user menu
• Operation Record
• Machine Setting
• Maintenance
• Monitor Setting
• User message (including KOMTRAX messages for user)
Caution lamp
C
Action level and failure code
Checking function of LCD (Liquid Crystal Display)
D CHECKING FUNCTION OF SERVICE METER
Function of inducement setting and changing password
*1: The operator mode items are classified as follows.
A: Display which is displayed from the time when the starting switch is turned to “ON” position to the time when
display changes to the standard screen, and display which is displayed after starting switch is turned to “OFF”
position
B: Display when the machine monitor switch is operated
C: Display when conditions are satisfied
D: Display that requires special operations of switches
*2: The sequence of display from the time when the starting switch is turned to “ON” position to the time when
the standard screen appears varies depending on the settings and conditions of the machine as follows:
W: When the engine start lock is enabled.
X: When the engine start lock is disabled.
Y: When any abnormality is detected by the check before starting
Z: When any item is detected as the maintenance due time is over
REMARK
• For how to operate the operator mode functions, see “Operation and Maintenance Manual”.
• For the operating method of the engine start lock function, see“ Password setting and canceling manual”.
SERVICE MODE FUNCTION OF MACHINE MONITOR
These functions are not displayed normally. A technician can display and set them special operation of
switches. These functions are used for special settings, testing, adjusting, or troubleshooting.
Items available in the service mode are as follows:
REMARK
For operating method of the service mode functions, see TESTING AND ADJISTING, “SERVICE MODE”.
Pre-defined Monitoring
PC30MR-5, PC35MR-5 10-41
--- Page 13 ---
CLSS 10 STRUCTURE AND FUNCTION
FUNCTION OF CLSS
Control of pump swash plate angle
CLSS controls the pump swash plate angle (pump discharged
volume) so that LS differential pressure (∆PLS) will be con- $FWXDWRU
stant, which is the differential pressure between pump dis-
charged pressure (PP) and control valve outlet LS pressure
(PLS) (actuator load pressure).
“LS differential pressure (∆PLS) = Pump discharged pressure
(PP) - LS pressure (PLS)”
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• The pump swash plate shifts toward the maximum angle
position when LS differential pressure (∆PLS) is lower than
the set pressure of the LS valve (when the actuator load
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• The pump swash plate shifts toward the minimum angle
position when LS differential pressure is higher than the 0DLQSXPS
set pressure (when the actuator load pressure is low). 33
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