Komatsu HYDRAULIC EXCAVATOR PC45MR-3 Shop Manual WEN00001-00- PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC45MR-3 Shop Manual WEN00001-00- PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC45MR-3 Shop Manual WEN00001-00- PDF DOWNLOAD

Language : English
Pages :500
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC45MR-3 Shop Manual WEN00001-00- PDF DOWNLOAD

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC45MR-3 Shop Manual WEN00001-00- PDF DOWNLOAD

Table of contents 1
00 Index and foreword
100 Index WEN00003-00
Composition of shop manual 2
Table of contents 4
200 Foreword and general information WEN00004-00
Safety notice 2
How to read the shop manual 8
Explanation of terms for maintenance standard 10
Handling of electric equipment and hydraulic component 12
Handling of connectors newly used for engines 21
How to read electric wire code 24
Precautions when carrying out operation 27
Method of disassembling and connecting push-pull type coupler 30
Standard tightening torque table 33
Conversion table 37
01 Specification
100 Specification and technical data WEN00006-00
Specification dimension drawing 2
Working range drawing 3
Specifications 4
Weight table 7
Table of fuel, coolant and lubricants 9
10 Structure, function and maintenance standard
100 Engine and cooling system WEN00008-00
PTO 2
Cooling system 4
200 Power train WEN00009-00
Power train 2
Swing circle 3
Swing machinery 4
420 Hydraulic system, Part 2 WEN00012-00
Hydraulic pump 2
Control valve 10
430 Hydraulic system, Part 3 WEN00013-00
CLSS 2
Operation for each function and valve 6
Swing motor 26
PPC valve 33
600 Cab and its attachments WEN00015-00
Floor 2
700 Electrical system WEN00016-00
Engine control system 2
Electric control system 6
Auto-deceleration function 12
Attachment proportional switch, breaker operation switch, work mode selection, flow control function 14
KOMTRAX system 21
Component parts of system 24
Monitor system 25
Sensors 28
20 Standard value table
100 Standard service value table WEN00018-00
WEN00003-00
PC45MR-3 00-100 5
Table of contents
100 Index
Standard service value table for engine related parts 2
Standard service value table for chassis related parts 3
30 Testing and adjusting
100 Testing and adjusting WEN00020-00
Tools for testing, adjusting, and troubleshooting 3
Testing engine speed 6
Testing exhaust gas color 7
Testing and adjusting valve clearance 8
Testing compression pressure 10
Testing engine oil pressure 11
Testing and adjusting fuel injection timing 12
Testing and adjusting alternator belt tension 16
Testing and adjusting air conditioner compressor belt tension 17
Adjusting fuel control lever 18
Testing clearance in swing circle bearings 19
Testing and adjusting track shoe tension 20
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits 21
Testing and adjusting LS differential pressure 26
Adjusting PC valve 29
Testing and adjusting control pump circuit oil pressure 30
Testing solenoid valve output pressure 32
Testing PPC valve output pressure 33
Adjusting PPC valve 35
Testing swing holding brake release pressure 36
Testing and adjusting travel deviation 37
Testing oil leakage from work equipment cylinder 39
Bleeding air from each part 41
Releasing residual pressure from hydraulic circuit 43
Releasing residual pressure from hydraulic tank 44
Pressurizing hydraulic tank 44
How to open and close (tilt) floor 45
Inspection procedures for diode 50
How to start operation of KOMTRAX terminal 51
Lamp display of KOMTRAX terminal 55
Removal and installation of KOMTRAX terminal 58
Preparation work for troubleshooting of electrical system 59
40 Troubleshooting
100 General information on troubleshooting WEN00022-00
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Checks before troubleshooting 4
Classification and procedures of troubleshooting 5
Information contained in troubleshooting table 6
Connection table for connector pin numbers 10
T- branch box and T- branch adapter table 46
200 Troubleshooting of electrical system (E-mode) WEN00023-00
Before carrying out troubleshooting of electrical system 2
E-1 Engine does not start 4
E-2 Engine does not stop 12
E-3 When starting switch is turned ON, any item does not operate 14
E-4 When starting switch is turned ON, some items do not operate 16
E-5 Alarm buzzer is abnormal 17
E-6 Engine oil pressure caution is turned ON 19
E-7 Charge level caution is turned ON 20
E-8 Preheating system does not operate or preheater does not become hot 22
WEN00003-00
00-100 6 PC45MR-3
Table of contents
100 Index
E-9 Coolant temperature gauge is abnormal 24
E-10 Fuel level gauge is abnormal 28
E-11 Service meter does not operate while engine is running 32
E-12 2nd travel speed is not selected 35
E-13 Working lamp does not light up 38
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK,
work equipment still moves 40
E-15 Windshield wiper does not operate 42
E-16 Windshield washer does not operate 44
E-17 Defective air conditioner 46
E-18 KOMTRAX system does not operate normally 54
300 Troubleshooting of hydraulic and mechanical system (H-mode) WEN00024-00
Information contained in troubleshooting table 3
H-1 Speed or power of whole work equipment, travel, swing, and blade is low 4
H-2 Engine speed lowers extremely or engine stalls 8
H-3 Whole work equipment, travel system, swing system, and blade do not work 9
H-4 Abnormal sound comes out from around hydraulic pump 13
H-5 Fine control performance or response is low 13
H-6 Speed or power of boom is low 14
H-7 Speed or power of arm is low 15
H-8 Speed or power of bucket is low 16
H-9 Speed or power of boom swing is low 17
H-10 Work equipment does not move singly 17
H-11 Work equipment hydraulic drift is large 18
H-12 Time lag of work equipment is large 20
H-13 In compound operation of work equipment, speed of part loaded more is low 20
H-14 Machine deviates during travel 21
H-15 Travel speed or travel power is low (while work equipment is normal) 23
H-16 Machine is not steered well or steering power is low 24
H-17 Travel speed does not change 25
H-18 Travel motor does not work 26
H-19 Speed or power of swing is low 28
H-20 Machine does not swing 30
H-21 Swing acceleration performance is low 32
H-22 Machine overruns when it stops swinging 34
H-23 Large shock is made when machine stops swinging 35
H-24 When upper structure stops swinging, it makes large sound 35
H-25 Hydraulic drift of swing is large 36
H-26 Speed or power of blade is low 37
H-27 Blade does not move 38
H-28 Hydraulic drift of blade is large 39
400 Troubleshooting of engine (S-mode) WEN00025-00
Method of using troubleshooting charts 3
S-1 Starting performance is poor 6
S-2 Engine does not start 7
S-3 Engine does not pick up smoothly 10
S-4 Engine stops during operations 11
S-5 Engine does not rotate smoothly 12
S-6 Engine lacks output (or lacks power) 13
S-7 Exhaust smoke is black (incomplete combustion) 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) 15
S-9 Oil becomes contaminated quickly 16
S-10 Fuel consumption is excessive 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 18
S-12 Oil pressure drops 19
S-13 Oil level rises (Entry of coolant/fuel) 20
S-14 Coolant temperature becomes too high (overheating) 21
S-15 Abnormal noise is made 22
WEN00003-00
PC45MR-3 00-100 7
Table of contents
100 Index
S-16 Vibration is excessive 23
50 Disassembly and assembly
100 General information on disassembly and assembly WEN00027-00
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 10
200 Engine and cooling system WEN00028-00
Removal and installation of fuel injection pump assembly 2
Removal and installation of radiator assembly 4
Removal and installation of hydraulic oil cooler assembly 6
Removal and installation of engine and hydraulic pump assembly 10
300 Power train WEN00029-00
Removal and installation of swing motor and swing machinery assembly 2
Disassembly and assembly of swing motor and swing machinery assembly 3
Removal and installation of swing circle assembly 8
500 Hydraulic system WEN00031-00
Removal and installation of center swivel joint assembly 2
Disassembly and assembly of center swivel joint assembly 4
Removal and installation of work equipment pump assembly 6
Disassembly and assembly of control valve assembly 8
Disassembly and assembly of hydraulic cylinder assembly 9
600 Work equipment WEN00032-00
Removal and installation of work equipment assembly 2
700 Cab and its attachments WEN00033-00
Removal and installation of operator’s cab glass (stuck glass) 2
Removal and installation of front window assembly 11
Removal and installation of floor frame assembly (Canopy specification) 12
Removal and installation of operator cab and floor frame assembly (Operator cab specification) 15
800 Electrical system WEN00034-00
Removal and installation of air conditioner unit assembly (If equipped) 2
Removal and installation of KOMTRAX terminal 5

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24