PC40MR-1 Sebm016808

SEBM016808
MACHINE MODEL
PC27MRX-1
PC30MRX-1
PC35MRX-1
PC40MRX-1
PC45MRX-1
SERIAL NUMBER
11574 and up
10001 and up
3930 and up
1001 and up
1001 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC27MRX-1 mount the 3D82AE-3 and PC30, 35MRX-1 mount the 3D84E-3 engine.
For details of the engine, see the 68E-88E Series Engine Shop Manual.
PC40MRX, PC45MRX-1 mount the 4D84E-3 and 4D88E-3 engine.
For details of the engine, see the 68E-88E Series Engine Shop Manual.
In some cases model name is written as PC27MR, PC30MR, PC35MR, PC40MR and PC45MR
in the drawing. These names are same as PC27MRX, PC30MRX, PC35MRX, PC40MRX and
PC45MRX.
2003 1
All Rights Reserved
Printed in Japan 08-03(02)
00-1
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CONTENTS
No. of page
01
GENERAL ............................................................................................................. 01-1
10
STRUCTURE AND FUNCTION
20
TESTING AND ADJUSTING ................................................................. 20-1
30
DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40
MAINTENANCE STANDARD ............................................................... 40-1
90
OTHERS
00-2
1
........................................................... 10-1
............................................................................................................... 90-1
PC27 45MRX-1
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PC27 45MRX-1
TESTING AND ADJUSTING
Item
Engine speed
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model
PC30MRX-1
Engine
3D84E-3EK
Unit
Standard value
for new machine
Service limit
value
High idling
rpm
2,650 50
Low idling
rpm
1,110 50
Rated speed
rpm
2,500
At sudden acceleration
Bosch
index
Max. 3.5
5.5
At high idling
Bosch
index
Max. 1.0
2.0
Intake valve
mm
0.20
Exhaust valve
mm
0.20
MPa
{kg/cm2}
2.94
{30}
2.55
{26}
Pa
{mmH2O}
{}
{}
At high idling
MPa
{kg/cm2}
0.3 3.4
{3.0 3.5}
Min. 0.2
{Min. 2.0}
At low idling (SAE30)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Min. 0.1
{Min. 1.0}
At low idling (SAE10W)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Min. 0.1
{Min. 1.0}
Max. 120
Max. 120
Measurement conditions
Exhaust gas color
Valve clearance
(Normal temperature)
Compression pressure Oil temperature: 40 60C

(SAE30 oil)
(engine speed: 250rpm)
Blow-by pressure
(SAE30 oil)
(Water temperature: Operating range)

At high idling
Oil pressure
(SAE30 oil)
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before compression top dead center
deg.
14 1
Fan belt tension
Deflection when pressed with finger

force of approx. 58.8 N {6 kg}
mm
10 15
PC27 45MRX-1
20-3
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Item
Engine speed
Applicable model
PC35MRX-1
Engine
3D84E-3L
Unit
Standard value
for new machine
Service limit
value
High idling
rpm
2,750 50
Low idling
rpm
1,150 50
Rated speed
rpm
2,500
At sudden acceleration
Bosch
index
Max. 3.0
5.5
At high idling
Bosch
index
Max. 1.5
2.0
Intake valve
mm
0.20
Exhaust valve
mm
0.20
MPa
{kg/cm2}
2.94
{30}
2.55
{26}
Pa
{mmH2O}
{}
{}
At high idling
MPa
{kg/cm2}
0.3 3.4
{3.0 3.5}
Min. 0.2
{Min. 2.0}
At low idling (SAE30)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Min. 0.1
{Min. 1.0}
At low idling (SAE10W)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Min. 0.1
{Min. 1.0}
Max. 120
Max. 120
Exhaust gas color
Valve clearance
(Normal temperature)
Compression pressure Oil temperature: 40 60C

(SAE30 oil)
(engine speed: 250rpm)
Blow-by pressure
(SAE30 oil)

At high idling
Oil pressure
(SAE30 oil)
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before compression top dead center
deg.
14 1
Fan belt tension
Deflection when pressed with finger

force of approx. 58.8 N {6 kg}
mm
56
20-4
(8)
PC27 45MRX-1
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

MACHINE MODEL: PC27MRX-1
Applicable model
Engine speed
Category
Item
At 1-pump relief
At 2-pump relief
Hydraulic oil temperature: 45 55C
Engine oil pressure: Within operating
range
Engine water temperature: Within
operating range
1-pump relief: Bucket relief
2-pump relief: Bucket + swing relief
PC27MRX-1
Unit
Standard value
for new machine
Service limit
value
Min. 2,360
Min. 2,000
Min. 2,000
Min. 2,000
rpm
30
30
20
20
Boom control valve

Arm control valve
Spool stroke
Bucket control valve
See Fig. A
Swing control valve

Breaker control valve
mm
Boom swing control valve

Blade control valve
See Fig. B
L.H. travel control valve
R.H. travel control valve
Boom control lever
Travel of control levers stroke
Arm control lever

Bucket control lever
Center of
N RAISE, LOWER
lever knob
Tip of pedal
Read max.
value to end N CURL, DUMP
of travel
Engine
N CURL, DUMP
stopped
Swing control lever
N Left, right swing
Boom swing control pedal
N Left, right boom swing
95 10
95 10
95 10
95 10
95 10
95 10
95 10
95 10
25 5
25 5
mm
Blade control lever
N RAISE, LOWER
50 5
50 5
Travel control lever
N FORWARD, REVERSE (left, right)
85 10
85 10
Fuel control lever
Min. Max.
110 20
110 20
Work equipment, swing
Max. 5
Max. 5
Travel
Max. 35
Max. 35
Play of control lever
20-6
(8)
PC27 45MRX-1
Applicable model
Category
Item
PC27MRX-1
Standard value
Unit for new machine
Service limit
value
RAISE
2.1 0.6
LOWER
1.9 0.3
1.9 0.6
CURL
3.0 0.3
3.6
DUMP
2.7 0.3
3.3
CURL
Cylinder fully
extended
Engine at full throttle

2.1 0.3
2.3 0.3
2.3 0.6
DUMP
See Fig. I
1.9 0.3
1.9 0.6
RAISE
Bucket teeth in
contact with
ground
1.0 0.3
1.6
LOWER
Boom
1.0 0.3
1.6
6.7 1.5
6.7 3.0
6.6 1.5
6.6 3.0
Arm
Cylinder fully
retracted
See Fig. J
Fully extended
Work equipment
Bucket
Cylinder fully
retracted
Work equipment
speed
See Fig. K
sec.
Fully extended
Blade in contact
with ground
See Fig. L

Blade fully raised

Boom swing
Cylinder fully
retracted
Fully extended
PC27 45MRX-1
See Fig. M

Right swing Left swing
Blade
20-11
(8)
MACHINE MODEL: PC35MRX-1

Applicable model
Engine speed
Category
Item
At 1-pump relief
At 2-pump relief
Engine oil pressure: Within operating
range
Engine water temperature: Within
operating range
1-pump relief: Bucket relief
2-pump relief: Bucket + swing relief
PC35MRX-1
Unit
Standard value
for new machine
Service limit
value
Min. 2,330
Min. 1,800
Min. 1,800
Min. 1,800
rpm
30
30
20
20
Boom control valve

Arm control valve
Spool stroke
Bucket control valve
See Fig. A
Swing control valve

Breaker control valve
mm
Boom swing control valve

Blade control valve
See Fig. B
L.H. travel control valve
R.H. travel control valve
Boom control lever
Travel of control levers stroke
Arm control lever

Bucket control lever
Center of
N RAISE, LOWER
lever knob
Tip of pedal
Read max.
value to end N CURL, DUMP
of travel
Engine
N CURL, DUMP
stopped
Swing control lever
N Left, right swing
Boom swing control pedal
N Left, right boom swing
95 10
95 10
95 10
95 10
95 10
95 10
95 10
95 10
25 5
25 5
mm
Blade control lever
N RAISE, LOWER
50 5
50 5
Travel control lever
N FORWARD, REVERSE (left, right)
75 10
75 10
Fuel control lever
Min. Max.
110 10
110 10
Work equipment, swing
Max. 5
Max. 5
Travel
Max. 35
Max. 35
Play of control lever
20-20
(8)
PC27 45MRX-1
Applicable model
Category
Item
PC35MRX-1
Standard value
Service limit
value
RAISE
3.6
LOWER
3.0 0.3
3.6
CURL
3.0 0.3
3.6
DUMP
3.1 0.3
3.7
CURL
Cylinder fully
extended

3.0 0.3
3.0 0.3
3.6
DUMP
See Fig. I
2.2 0.3
2.8
RAISE
Bucket teeth in
contact with
ground
1.0 0.3
1.6
LOWER
Boom
1.0 0.3
1.6
7 1.5
10
7 1.5
10
Arm
Cylinder fully
retracted
See Fig. J
Fully extended
Work equipment
Bucket
Cylinder fully
retracted
Work equipment
speed
See Fig. K
sec.
Fully extended
Blade in contact
with ground
See Fig. L

Blade fully raised

Boom swing
Cylinder fully
retracted
Fully extended
20-24
(8)
See Fig. M

Right swing Left swing
Blade
PC27 45MRX-1
Applicable model
Category
Item
PC40MRX-1
Standard value
Service limit
value
RAISE
3.6
(3)
LOWER
3.0 0.3
3.6
RAISE
2.8 0.3
(3)
3.4
(3)
LOWER
3.0 0.3
3.3
CURL
3.1 0.3
3.7
DUMP
2.8 0.3
3.4
CURL
Cylinder fully
extended

3.0 0.3
(3)
3.3 0.3
3.9
DUMP
See Fig. I
2.2 0.3
2.8
RAISE
Bucket teeth in
contact with
ground
1.3 0.3
1.9
LOWER
Boom (1)
1.3 0.3
1.9
Boom (2)
Bucket teeth in
contact with
ground
Cylinder fully
extended
See Fig. I
Work equipment
Arm
Cylinder fully
retracted
Work equipment
speed
See Fig. J
sec.
Fully extended
Bucket
Cylinder fully
retracted
See Fig. K

Fully extended
Blade
Blade in contact
with ground
See Fig. L

Blade fully raised

1: Canopy specification
2: Cab, TOPS Canopy, TOPS Cab specification
3: Time until cushion starts operation
20-30
(8)
PC27 45MRX-1
Applicable model
Category
Item
PC45MRX-1
Standard value
Service limit
value
RAISE
3.6
(3)
LOWER
3.0 0.3
3.6
RAISE
2.8 0.3
(3)
3.4
(3)
LOWER
3.0 0.3
3.6
CURL
3.4 0.3
3.7
DUMP
2.8 0.3
3.4
CURL
Cylinder fully
extended

3.0 0.3
(3)
3.3 0.3
3.9
DUMP
See Fig. I
2.2 0.3
2.8
RAISE
Bucket teeth in
contact with
ground
1.2 0.3
1.9
LOWER
Boom (1)
1.2 0.3
1.9
Boom (2)
Bucket teeth in
contact with
ground
Cylinder fully
extended
See Fig. I
Work equipment
Arm
Cylinder fully
retracted
Work equipment
speed
See Fig. J
sec.
Fully extended
Bucket
Cylinder fully
retracted
See Fig. K

Fully extended
Blade
Blade in contact
with ground
See Fig. L

Blade fully raised

1: Canopy specification
2: Cab, TOPS Canopy, TOPS Cab specification
3: Time until cushion starts operation
20-36
(8)
PC27 45MRX-1

PC40MR-1 Sebm016808

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SEBM016808

GENERAL ............................................................................................................. 01-1

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING ................................................................. 20-1

DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

MAINTENANCE STANDARD ............................................................... 40-1

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised or made aditions.

LIST OF REVISED PAGES

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

At low idling (SAE30)

At low idling (SAE10W)

Exhaust gas color

Compression pressure Oil temperature: 40 60C

(engine speed: 250rpm)

(Water temperature: Operating range)

Whole speed range (inside oil pan)

Fuel injection timing

Before compression top dead center

Fan belt tension

Deflection when pressed with finger

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

TESTING AND ADJUSTING

At low idling (SAE30)

At low idling (SAE10W)

Exhaust gas color

Compression pressure Oil temperature: 40 60C

(engine speed: 250rpm)

(Water temperature: Operating range)

Whole speed range (inside oil pan)

Fuel injection timing

Before compression top dead center

Fan belt tension

Deflection when pressed with finger

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Boom control valve

Bucket control valve

Swing control valve

Boom swing control valve

Travel of control levers stroke

Arm control lever

Swing control lever

N Left, right swing

Boom swing control pedal

N Left, right boom swing

Travel control lever

N FORWARD, REVERSE (left, right)

Fuel control lever

Work equipment, swing

Play of control lever

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Engine at full throttle

Engine at full throttle

Blade fully raised

Engine at full throttle

Right swing Left swing

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING