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KOMATSU PC45MR-3 PC55MR-3 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF
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KOMATSU PC45MR-3 PC55MR-3 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
SERIAL NUMBERS
PC45MR- 5001 and up
PC55MR- 5001 and up
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Description
KOMATSU PC45MR-3 PC55MR-3 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC45MR-3 PC55MR-3 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 704
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
PC45MR- 5001 and up
PC55MR- 5001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC45MR-3 PC55MR-3 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Cover............................................................................................................... 1 00 Index and foreword............................................................................................... 3 100 Index....................................................................................................... 3 Composition of shop manual.................................................................................. 4 Table of contents........................................................................................... 6 200 Foreword and general information............................................................................ 13 Safety notice............................................................................................... 14 How to read the shop manual................................................................................. 20 Explanation of terms for maintenance standard............................................................... 22 Handling of electric equipment and hydraulic component...................................................... 24 Handling of connectors newly used for engines............................................................... 33 How to read electric wire code.............................................................................. 36 Precautions when carrying out work.......................................................................... 39 Method of disassembling and connecting push-pull type coupler............................................... 42 Standard tightening torque table............................................................................ 45 Conversion table............................................................................................ 49 01 Specification.................................................................................................... 55 100 Specification and technical data............................................................................ 55 Specification dimension drawing............................................................................. 56 Working range drawing....................................................................................... 57 Specifications.............................................................................................. 58 Weight table................................................................................................ 66 Table of fuel, coolant and lubricants....................................................................... 70 10 Structure, function and maintenance standard..................................................................... 73 100 Engine and cooling system................................................................................... 73 PTO......................................................................................................... 74 Cooling system.............................................................................................. 76 200 Power train................................................................................................. 79 Power train................................................................................................. 80 Swing circle................................................................................................ 81 Swing machinery............................................................................................. 82 300 Undercarriage and frame..................................................................................... 85 Track frame................................................................................................. 86 Idler cushion............................................................................................... 87 Idler....................................................................................................... 88 Track roller................................................................................................ 90 Carrier roller.............................................................................................. 91 Sprocket.................................................................................................... 92 Track shoe.................................................................................................. 93 410 Hydraulic system, Part 1.................................................................................... 97 Hydraulic components layout drawing......................................................................... 98 Hydraulic tank, filter...................................................................................... 99 Center swivel joint.........................................................................................101 Travel motor................................................................................................102 Hydraulic cylinder..........................................................................................110 Solenoid valve..............................................................................................114 Multi-control valve.........................................................................................119 420 Hydraulic system, Part 2....................................................................................121 Hydraulic pump..............................................................................................122 Control valve...............................................................................................130 Anti-drop valve.............................................................................................144 430 Hydraulic system, Part 3....................................................................................151 CLSS........................................................................................................152 Operation for each function and valve.......................................................................156 Swing motor.................................................................................................178 PPC valve...................................................................................................185 500 Work equipment..............................................................................................199 Work equipment..............................................................................................200 Dimensions of each part of work equipment...................................................................204 600 Cab and its attachments.....................................................................................209 Floor.......................................................................................................210 700 Electrical system...........................................................................................213 Engine control system.......................................................................................214 Electric control system.....................................................................................218 Auto-deceleration function..................................................................................224 Attachment proportional switch, breaker operation switch, work mode selection, flow control function........226 KOMTRAX system..............................................................................................234 Component parts of system...................................................................................237 Monitor system..............................................................................................238 Sensors.....................................................................................................241 20 Standard value table.............................................................................................245 100 Standard service value table................................................................................245 Standard service value table for engine related parts.......................................................246 Standard service value table for chassis related parts......................................................248 30 Testing and adjusting............................................................................................265 100 Testing and adjusting.......................................................................................265 Tools for testing, adjusting, and troubleshooting...........................................................267 Testing engine speed........................................................................................270 Testing exhaust gas color...................................................................................271 Testing and adjusting valve clearance.......................................................................272 Testing compression pressure................................................................................274 Testing engine oil pressure.................................................................................275 Testing and adjusting fuel injection timing.................................................................276 Testing and adjusting alternator belt tension...............................................................280 Testing and adjusting air conditioner compressor belt tension...............................................281 Adjusting fuel control lever................................................................................282 Testing clearance in swing circle bearings..................................................................283 Testing and adjusting track shoe tension....................................................................284 Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits........285 Testing and adjusting LS differential pressure..............................................................290 Adjusting PC valve..........................................................................................293 Testing and adjusting control pump circuit oil pressure.....................................................294 Testing solenoid valve output pressure......................................................................296 Testing PPC valve output pressure...........................................................................297 Adjusting PPC valve.........................................................................................299 Testing swing holding brake release pressure................................................................300 Testing and adjusting travel deviation......................................................................301 Testing oil leakage from work equipment cylinder............................................................303 Bleeding air from each part.................................................................................305 Releasing residual pressure from hydraulic circuit..........................................................307 Releasing residual pressure from hydraulic tank.............................................................308 Pressurizing hydraulic tank.................................................................................308 How to open and close (tilt) floor..........................................................................309 Inspection procedures for diode.............................................................................314 Function and flow of operator and service mode..............................................................316 How to start operation of KOMTRAX terminal..................................................................340 Lamp display of KOMTRAX terminal............................................................................344 Removal and installation of KOMTRAX terminal................................................................347 Preparation work for troubleshooting of electrical system...................................................348 40 Troubleshooting..................................................................................................351 110 Failure code table and fuse locations.......................................................................351 User code and failure code list.............................................................................352 Fuse locations..............................................................................................353 120 General information on troubleshooting......................................................................357 Points to remember when troubleshooting.....................................................................358 Sequence of events in troubleshooting.......................................................................359 Checks before troubleshooting...............................................................................360 Classification and procedures of troubleshooting............................................................361 Information contained in troubleshooting table..............................................................362 Connection table for connector pin numbers..................................................................366 T- branch box and T- branch adapter table...................................................................402 130 Troubleshooting by failure code.............................................................................407 Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller............409 Failure code [DBH1KK] Unswitched power supply error.........................................................411 Failure code [DBH2KK] Solenoid power supply error...........................................................413 Failure code [DBH5KP] 5V sensor power supply output 0 error.................................................415 Failure code [DBH6KP] 5V sensor power supply output 1 error.................................................416 Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit).................................417 Failure code [DDWLKB] Breaker switch error (Hot short circuit)..............................................418 Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)........................419 Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)....................................420 Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error.................................421 Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault).................422 Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit).............................424 Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)..........................426 Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)......................................428 Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)...................430 Failure code [D1E0KB] Motor power supply relay error (Ground fault).........................................432 Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)......................434 Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)............................................436 Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)......................438 Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)............................................440 Failure code [DY10MA] Fuel control motor operation error....................................................442 Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side)......................444 Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)......................446 Failure code [DXEAKA] EPC valve (port A side) error (Disconnection).........................................448 Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)..........................................450 Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit).....................................451 200 Troubleshooting of electrical system (E-mode)...............................................................453 Before carrying out troubleshooting of electrical system....................................................454 E-1 Engine does not start...................................................................................456 E-2 Engine does not stop....................................................................................464 E-3 When starting switch is turned ON, any item does not operate............................................466 E-4 When starting switch is turned ON, some items do not operate............................................468 E-5 Alarm buzzer is abnormal................................................................................469 E-6 Engine oil pressure caution is turned ON................................................................471 E-7 Charge level caution is turned ON.......................................................................472 E-8 Preheating system does not operate or preheater does not become hot.....................................474 E-9 Coolant temperature gauge is abnormal...................................................................476 E-10 Fuel level gauge is abnormal...........................................................................480 E-11 Service meter does not operate while engine is running.................................................484 E-12 2nd travel speed is not selected.......................................................................487 E-13 Working lamp does not light up.........................................................................490 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves....492 E-15 Windshield wiper does not operate......................................................................494 E-16 Windshield washer does not operate.....................................................................496 E-17 Defective air conditioner..............................................................................498 E-18 KOMTRAX system does not operate normally...............................................................506 300 Troubleshooting of hydraulic and mechanical system (H-mode).................................................509 Information contained in troubleshooting table..............................................................511 H-1 Speed or power of whole work equipment, travel, swing, and blade is low.................................512 H-2 Engine speed lowers extremely or engine stalls..........................................................516 H-3 Whole work equipment, travel system, swing system, and blade do not work................................517 H-4 Abnormal sound comes out from around hydraulic pump.....................................................521 H-5 Fine control performance or response is low.............................................................521 H-6 Speed or power of boom is low...........................................................................522 H-7 Speed or power of arm is low............................................................................523 H-8 Speed or power of bucket is low.........................................................................524 H-9 Speed or power of boom swing is low.....................................................................525 H-10 Work equipment does not move singly....................................................................525 H-11 Work equipment hydraulic drift is large................................................................526 H-12 Time lag of work equipment is large....................................................................528 H-13 In compound operation of work equipment, speed of part loaded more is low..............................528 H-14 Machine deviates during travel.........................................................................529 H-15 Travel speed or travel power is low (while work equipment is normal)...................................531 H-16 Machine is not steered well or steering power is low...................................................532 H-17 Travel speed does not change...........................................................................533 H-18 Travel motor does not work.............................................................................534 H-19 Speed or power of swing is low.........................................................................536 H-20 Machine does not swing.................................................................................538 H-21 Swing acceleration performance is low..................................................................540 H-22 Machine overruns when it stops swinging................................................................542 H-23 Large shock is made when machine stops swinging........................................................543 H-24 When upper structure stops swinging, it makes large sound..............................................543 H-25 Hydraulic drift of swing is large......................................................................544 H-26 Speed or power of blade is low.........................................................................545 H-27 Blade does not move....................................................................................546 H-28 Hydraulic drift of blade is large......................................................................547 400 Troubleshooting of engine (S-mode)..........................................................................549 Method of using troubleshooting charts......................................................................551 S-1 Starting performance is poor............................................................................554 S-2 Engine does not start...................................................................................555 S-3 Engine does not pick up smoothly........................................................................558 S-4 Engine stops during operations..........................................................................559 S-5 Engine does not rotate smoothly.........................................................................560 S-6 Engine lacks output (or lacks power)....................................................................561 S-7 Exhaust smoke is black (incomplete combustion)..........................................................562 S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................563 S-9 Oil becomes contaminated quickly........................................................................564 S-10 Fuel consumption is excessive..........................................................................565 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................566 S-12 Oil pressure drops.....................................................................................567 S-13 Oil level rises (Entry of coolant/fuel)................................................................568 S-14 Coolant temperature becomes too high (overheating).....................................................569 S-15 Abnormal noise is made.................................................................................570 S-16 Vibration is excessive.................................................................................571 50 Disassembly and assembly.........................................................................................573 100 General information on disassembly and assembly.............................................................573 How to read this manual.....................................................................................574 Coating materials list......................................................................................576 Special tool list...........................................................................................579 Sketches of special tools...................................................................................582 200 Engine and cooling system...................................................................................585 Removal and installation of fuel injection pump assembly....................................................586 Removal and installation of radiator assembly...............................................................588 Removal and installation of hydraulic oil cooler assembly...................................................590 Removal and installation of engine and hydraulic pump assembly..............................................594 300 Power train.................................................................................................601 Removal and installation of swing motor and swing machinery assembly........................................602 Disassembly and assembly of swing motor and swing machinery assembly........................................603 Removal and installation of swing circle assembly...........................................................608 400 Undercarriage and frame.....................................................................................611 Removal and installation of track shoe assembly.............................................................612 Disassembly and assembly of idler assembly..................................................................613 Disassembly and assembly of recoil spring assembly..........................................................615 Disassembly and assembly of track roller assembly...........................................................618 Disassembly and assembly of carrier roller assembly.........................................................619 Removal and installation of revolving frame assembly........................................................620 500 Hydraulic system............................................................................................623 Removal and installation of center swivel joint assembly....................................................624 Disassembly and assembly of center swivel joint assembly....................................................626 Removal and installation of work equipment pump assembly....................................................630 Disassembly and assembly of control valve assembly..........................................................632 Disassembly and assembly of hydraulic cylinder assembly.....................................................633 600 Work equipment..............................................................................................639 Removal and installation of bladeassembly...................................................................640 Removal and installation of work equipment assembly.........................................................641 700 Cab and its attachments.....................................................................................645 Removal and installation of operator’s cab glass (stuck glass)..............................................646 Removal and installation of front window assembly...........................................................655 Removal and installation of floor frame assembly (Canopy specification).....................................656 Removal and installation of operator cab and floor frame assembly (Operator cab specification)..............659 800 Electrical system...........................................................................................663 Removal and installation of air conditioner unit assembly (If equipped).....................................664 Removal and installation of KOMTRAX terminal................................................................667 90 Diagrams and drawings............................................................................................669 100 Hydraulic diagrams and drawings.............................................................................669 Hydraulic circuit diagram...................................................................................671 200 Electrical diagrams and drawings............................................................................679 Electrical circuit diagram..................................................................................681 Connector list and stereogram...............................................................................697 Related circuit diagram of proportional switch..............................................................699
DESCRIPTION:
KOMATSU PC45MR-3 PC55MR-3 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 21/12/24
