Komatsu PC45MR-3 and PC55MR-3 Hydraulic Excavator Shop Manual SEN04597-03 – PDF Repair Guide

Description

Komatsu PC45MR-3 and PC55MR-3 Hydraulic Excavator Shop Manual

The Komatsu PC45MR-3 and PC55MR-3 Hydraulic Excavator Shop Manual (Form No. SEN04597-03) is the full workshop reference for these compact Komatsu mini excavators. It is written for the technician who needs real procedures, not vague advice — covering the 4D88E-6 diesel engine and cooling system, power train, undercarriage and frame, hydraulic circuits, work equipment, cab and electrical system. Whether you are servicing a PC45MR-3 (serial 5001 and up) or a PC55MR-3 (serial 15001 and up), this Komatsu shop manual gives you the standard values, tightening torques, test methods, troubleshooting charts and exploded diagrams to carry out the job correctly.

File Details

• Manual type: Shop Manual (Service / Repair Manual)
• Brand: Komatsu
• Models covered: PC45MR-3, PC55MR-3
• Serial numbers: PC45MR-3: 5001 and up · PC55MR-3: 15001 and up
• Language: English
• Page count: Approx. 590 pages
• File format: PDF
• Form No.: SEN04597-03
• Publication date: 05-08 (01)

Chapters Covered

• 00 Index and foreword
• 01 Specification
• 10 Structure, function and maintenance standard
• 20 Standard value table
• 30 Testing and adjusting
• 40 Troubleshooting
• 50 Disassembly and assembly
• 90 Diagrams and drawings

00 Index and Foreword

Sets out the shop manual structure and how to use it, together with the safety notices, the explanation of terms used for maintenance standards, handling of electric equipment and hydraulic components, how to read electric wire codes, precautions when carrying out work, and the standard tightening torque table and conversion tables.

01 Specification

Contains the specification dimension drawing, the working range drawing, the full machine specifications, the weight table for individual components, and the table of fuel, coolant and lubricants with capacities. This is the section you check first when you need to confirm working ranges, ground pressure or fluid refill quantities.

10 Structure, Function and Maintenance Standard

The largest chapter, covering engine and cooling system, power train, undercarriage and frame, hydraulic system in three parts, work equipment, cab and its attachments, and the electrical system. Each component is explained with its structure, function and maintenance standard, making it the main reference for understanding how the machine is built and how each part is supposed to behave.

20 Standard Value Table

Provides the standard service value tables for engine related parts and chassis related parts, giving the standard value for a new machine together with the service limit values used for judgement during testing, adjusting and troubleshooting.

30 Testing and Adjusting

Explains the measuring instruments and methods for testing and adjusting, including engine speed, valve clearance, compression pressure, engine oil pressure, fuel injection timing, belt tension, control lever play, relief pressures, LS differential pressure, PC valve adjustment, PPC valve output pressure, swing holding brake release pressure, travel deviation and oil leakage checks.

40 Troubleshooting

Divided by failure mode. General information on troubleshooting, then E-mode for the electrical system, H-mode for the hydraulic and mechanical system, and S-mode for the engine. Each fault listing shows the possible causes, standard values in normal state and the checks needed to isolate the problem.

50 Disassembly and Assembly

Covers removal, installation, disassembly and assembly of the major assemblies — engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment, cab and its attachments, and the electrical system. Special tools, coating materials and tightening torques are listed alongside the procedures.

90 Diagrams and Drawings

Includes the hydraulic circuit diagram and the electrical circuit diagrams, together with the connector list and stereogram, so you can trace circuits and piping accurately during diagnosis and repair.

What This Komatsu PC45MR-3 and PC55MR-3 Shop Manual Lets You Do

This is a working manual, not a brochure. It supports the jobs a compact excavator actually needs: engine speed and valve clearance checks, fuel injection timing adjustment, hydraulic relief and LS differential pressure measurement, PPC valve adjustment, travel deviation correction, swing brake release pressure testing, and cylinder oil leakage diagnosis. On the repair side it walks through removal and installation of the fuel injection pump, radiator, hydraulic oil cooler, engine and hydraulic pump assembly, swing motor and machinery, swing circle, track components, center swivel joint, control valve and hydraulic cylinders. When a fault code or a symptom shows up, the E-mode, H-mode and S-mode troubleshooting tables point you to the likely cause and the standard value that tells you whether a component is good or not.

Getting those procedures and specifications right is what separates a repair that lasts from one that comes back. Tightening torques, clearances, relief pressures and adjustment values are all printed where the job needs them, so you are not guessing or relying on memory. For anyone maintaining or repairing a PC45MR-3 or PC55MR-3, this Komatsu shop manual is the reference that keeps the machine within spec.

Delivery is instant. Once payment is complete you receive the PDF immediately — no shipping, no waiting for a disc in the post. It opens on any device, whether you are at the bench with a laptop or out at the machine with a tablet, and every page can be printed for the workshop. Keep the full Komatsu PC45MR-3 PC55MR-3 repair manual on hand and you have the factory procedures and data whenever a job comes in.

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