Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU PC45MR-3 PC55MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN04597- 06) KOMATSU PC45MR-3 – PDF DOWNLOAD
Original price was: $95.95.$27.95Current price is: $27.95.
- KOMATSU PC45MR-3 PC55MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEN04597- 06
- SERIAL NUMBERS: PC45MR- 5001 and up
PC55MR-15001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU PC45MR-3 PC55MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN04597- 06) KOMATSU PC45MR-3
KOMATSU PC45MR-3 PC55MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN04597- 06) KOMATSU PC45MR-3 – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU PC45MR-3 PC55MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN04597- 06) KOMATSU PC45MR-3
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains table of contents, and safety and basic information. If any revision of the shop manual is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix
The section explains the equipment which can not be included in the other sections. This section explains
the structure, function, testing, adjusting, and troubleshooting fo the equipment.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume:This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume:This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
KOMATSU PC45MR-3 PC55MR-3 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN04597- 06) KOMATSU PC45MR-3
COVER .............................................................................................................. 1 00 Index and foreword............................................................................................... 0 100 Index....................................................................................................... 2 Composition of shop manual.................................................................................. 3 Table of contents........................................................................................... 5 200 Foreword and general information............................................................................ 12 Safety notice............................................................................................... 13 How to read the shop manual................................................................................. 19 Explanation of terms for maintenance standard............................................................... 21 Handling of electric equipment and hydraulic component...................................................... 23 Handling of connectors newly used for engines............................................................... 32 How to read electric wire code.............................................................................. 35 Precautions when carrying out work.......................................................................... 38 Method of disassembling and connecting push-pull type coupler............................................... 41 Standard tightening torque table............................................................................ 44 Conversion table............................................................................................ 48 01 Specification.................................................................................................... 0 100 Specification and technical data............................................................................ 54 Specification dimension drawing............................................................................. 55 Working range drawing....................................................................................... 56 Specifications.............................................................................................. 57 Weight table................................................................................................ 63 Table of fuel, coolant and lubricants....................................................................... 67 10 Structure, function and maintenance standard..................................................................... 0 100 Engine and cooling system................................................................................... 70 PTO......................................................................................................... 71 Cooling system.............................................................................................. 73 200 Power train................................................................................................. 76 Power train................................................................................................. 77 Swing circle................................................................................................ 78 Swing machinery............................................................................................. 79 300 Undercarriage and frame..................................................................................... 82 Track frame................................................................................................. 83 Idler cushion............................................................................................... 84 Idler....................................................................................................... 85 Track roller................................................................................................ 87 Carrier roller.............................................................................................. 88 Sprocket.................................................................................................... 89 Track shoe.................................................................................................. 90 410 Hydraulic system, Part 1.................................................................................... 94 Hydraulic components layout drawing......................................................................... 95 Hydraulic tank, filter...................................................................................... 96 Center swivel joint......................................................................................... 98 Travel motor................................................................................................ 99 Hydraulic cylinder..........................................................................................107 Solenoid valve..............................................................................................111 Multi-control valve.........................................................................................116 420 Hydraulic system, Part 2....................................................................................118 Hydraulic pump..............................................................................................119 Control valve...............................................................................................127 Anti-drop valve.............................................................................................141 430 Hydraulic system, Part 3....................................................................................148 CLSS........................................................................................................149 Operation for each function and valve.......................................................................153 Swing motor.................................................................................................175 PPC valve...................................................................................................182 500 Work equipment..............................................................................................196 Work equipment..............................................................................................197 Dimensions of each part of work equipment...................................................................201 600 Cab and its attachments.....................................................................................206 Floor.......................................................................................................207 700 Electrical system...........................................................................................210 Engine control system.......................................................................................211 Electrical control system...................................................................................215 Auto-deceleration function..................................................................................221 Attachment proportional switch, breaker operation switch, work mode selection, flow control function........223 KOMTRAX system..............................................................................................231 Component parts of system...................................................................................234 Monitor system..............................................................................................235 Sensors.....................................................................................................238 20 Standard value table............................................................................................. 0 100 Standard service value table................................................................................242 Standard service value table for engine related parts.......................................................243 Standard service value table for chassis related parts......................................................245 30 Testing and adjusting............................................................................................ 0 100 Testing and adjusting.......................................................................................262 Tools for testing, adjusting, and troubleshooting...........................................................264 Testing engine speed........................................................................................267 Testing exhaust gas color...................................................................................268 Testing and adjusting valve clearance.......................................................................269 Testing compression pressure................................................................................271 Testing engine oil pressure.................................................................................272 Testing and adjusting fuel injection timing.................................................................273 Testing and adjusting alternator belt tension...............................................................277 Testing and adjusting air conditioner compressor belt tension...............................................278 Adjusting fuel control lever................................................................................279 Testing clearance in swing circle bearings..................................................................280 Testing and adjusting track shoe tension....................................................................281 Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits........282 Testing and adjusting LS differential pressure..............................................................287 Adjusting PC valve..........................................................................................290 Testing and adjusting control pump circuit oil pressure.....................................................291 Testing solenoid valve output pressure......................................................................293 Testing PPC valve output pressure...........................................................................294 Adjusting PPC valve.........................................................................................296 Testing swing holding brake release pressure................................................................297 Testing and adjusting travel deviation......................................................................298 Testing oil leakage from work equipment cylinder............................................................300 Bleeding air from each part.................................................................................302 Releasing residual pressure from hydraulic circuit..........................................................304 Releasing residual pressure from hydraulic tank.............................................................305 Pressurizing hydraulic tank.................................................................................305 How to open and close (tilt) floor..........................................................................306 Inspection procedures for diode.............................................................................311 Function and flow of operator and service mode..............................................................313 How to start operation of KOMTRAX terminal..................................................................337 Lamp display of KOMTRAX terminal............................................................................341 Removal and installation of KOMTRAX terminal................................................................344 Preparation work for troubleshooting of electrical system...................................................345 40 Troubleshooting.................................................................................................. 0 100 General information on troubleshooting......................................................................348 Points to remember when troubleshooting.....................................................................349 Sequence of events in troubleshooting.......................................................................350 Checks before troubleshooting...............................................................................351 Classification and procedures of troubleshooting............................................................352 Information contained in troubleshooting table..............................................................353 Connection table for connector pin numbers..................................................................357 T- branch box and T- branch adapter table...................................................................393 110 Failure code table and fuse locations.......................................................................398 User code and failure code list.............................................................................399 Fuse locations..............................................................................................400 120 General information on troubleshooting......................................................................404 Points to remember when troubleshooting.....................................................................405 Sequence of events in troubleshooting.......................................................................406 Checks before troubleshooting...............................................................................407 Classification and procedures of troubleshooting............................................................408 Information contained in troubleshooting table..............................................................409 Connection table for connector pin numbers..................................................................413 T- branch box and T- branch adapter table...................................................................449 130 Troubleshooting by failure code.............................................................................454 Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller............456 Failure code [DBH1KK] Unswitched power supply error.........................................................458 Failure code [DBH2KK] Solenoid power supply error...........................................................460 Failure code [DBH5KP] 5V sensor power supply output 0 error.................................................462 Failure code [DBH6KP] 5V sensor power supply output 1 error.................................................463 Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit).................................464 Failure code [DDWLKB] Breaker switch error (Hot short circuit)..............................................465 Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)........................466 Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)....................................467 Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error.................................468 Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault).................469 Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit).............................471 Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)..........................473 Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)......................................475 Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)...................477 Failure code [D1E0KB] Motor power supply relay error (Ground fault).........................................479 Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)......................481 Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)............................................483 Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)......................485 Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)............................................487 Failure code [DY10MA] Fuel control motor operation error....................................................489 Failure code [D1E0KA] Fuel control motor power supply relay contactsticking (NC side)......................491 Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)......................493 Failure code [DXEAKA] EPC valve (port A side) error (Disconnection).........................................495 Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)..........................................497 Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit).....................................498 200 Troubleshooting of electrical system (E-mode)...............................................................500 Before carrying out troubleshooting of electrical system....................................................501 E-1 Engine does not start...................................................................................503 E-2 Engine does not stop....................................................................................511 E-3 When starting switch is turned ON, any item does not operate............................................513 E-4 When starting switch is turned ON, some items do not operate............................................515 E-5 Alarm buzzer is abnormal................................................................................516 E-6 Engine oil pressure caution is turned ON................................................................518 E-7 Charge level caution is turned ON.......................................................................519 E-8 Preheating system does not operate or preheater does not become hot.....................................521 E-9 Coolant temperature gauge is abnormal...................................................................523 E-10 Fuel level gauge is abnormal...........................................................................527 E-11 Service meter does not operate while engine is running.................................................531 E-12 2nd travel speed is not selected.......................................................................534 E-13 Working lamp does not light up.........................................................................537 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves....539 E-15 Windshield wiper does not operate......................................................................541 E-16 Windshield washer does not operate.....................................................................543 E-17 Defective air conditioner..............................................................................545 E-18 KOMTRAX system does not operate normally...............................................................553 300 Troubleshooting of hydraulic and mechanical system (H-mode).................................................556 Information contained in troubleshooting table..............................................................558 H-1 Speed or power of whole work equipment, travel, swing, and blade is low.................................559 H-2 Engine speed lowers extremely or engine stalls..........................................................563 H-3 Whole work equipment, travel system, swing system, and blade do not work................................564 H-4 Abnormal sound comes out from around hydraulic pump.....................................................568 H-5 Fine control performance or response is low.............................................................568 H-6 Speed or power of boom is low...........................................................................569 H-7 Speed or power of arm is low............................................................................570 H-8 Speed or power of bucket is low.........................................................................571 H-9 Speed or power of boom swing is low.....................................................................572 H-10 Work equipment does not move singly....................................................................572 H-11 Work equipment hydraulic drift is large................................................................573 H-12 Time lag of work equipment is large....................................................................575 H-13 In compound operation of work equipment, speed of part loaded more is low..............................575 H-14 Machine deviates during travel.........................................................................576 H-15 Travel speed or travel power is low (while work equipment is normal)...................................578 H-16 Machine is not steered well or steering power is low...................................................579 H-17 Travel speed does not change...........................................................................580 H-18 Travel motor does not work.............................................................................581 H-19 Speed or power of swing is low.........................................................................583 H-20 Machine does not swing.................................................................................585 H-21 Swing acceleration performance is low..................................................................587 H-22 Machine overruns when it stops swinging................................................................589 H-23 Large shock is made when machine stops swinging........................................................590 H-24 When upper structure stops swinging, it makes large sound..............................................590 H-25 Hydraulic drift of swing is large......................................................................591 H-26 Speed or power of blade is low.........................................................................592 H-27 Blade does not move....................................................................................593 H-28 Hydraulic drift of blade is large......................................................................594 400 Troubleshooting of engine (S-mode)..........................................................................596 Method of using troubleshooting charts......................................................................598 S-1 Starting performance is poor............................................................................601 S-2 Engine does not start...................................................................................602 S-3 Engine does not pick up smoothly........................................................................605 S-4 Engine stops during operations..........................................................................606 S-5 Engine does not rotate smoothly.........................................................................607 S-6 Engine lacks output (or lacks power)....................................................................608 S-7 Exhaust smoke is black (incomplete combustion)..........................................................609 S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................610 S-9 Oil becomes contaminated quickly........................................................................611 S-10 Fuel consumption is excessive..........................................................................612 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................613 S-12 Oil pressure drops.....................................................................................614 S-13 Oil level rises (Entry of coolant/fuel)................................................................615 S-14 Coolant temperature becomes too high (overheating).....................................................616 S-15 Abnormal noise is made.................................................................................617 S-16 Vibration is excessive.................................................................................618 50 Disassembly and assembly......................................................................................... 0 100 General information on disassembly and assembly.............................................................620 How to read this manual.....................................................................................621 Coating materials list......................................................................................623 Special tool list...........................................................................................626 Sketches of special tools...................................................................................629 200 Engine and cooling system...................................................................................632 Removal and installation of fuel injection pump assembly....................................................633 Removal and installation of radiator assembly...............................................................635 Removal and installation of hydraulic oil cooler assembly...................................................637 Removal and installation of engine and hydraulic pump assembly..............................................641 300 Power train.................................................................................................648 Removal and installation of swing motor and swing machinery assembly........................................649 Disassembly and assembly of swing motor and swing machinery assembly........................................650 Removal and installation of swing circle assembly...........................................................655 400 Undercarriage and frame.....................................................................................658 Removal and installation of track shoe assembly.............................................................659 Disassembly and assembly of idler assembly..................................................................660 Disassembly and assembly of recoil spring assembly..........................................................662 Disassembly and assembly of track roller assembly...........................................................665 Disassembly and assembly of carrier roller assembly.........................................................666 Removal and installation of revolving frame assembly........................................................667 500 Hydraulic system............................................................................................670 Removal and installation of center swivel joint assembly....................................................671 Disassembly and assembly of center swivel joint assembly....................................................673 Removal and installation of work equipment pump assembly....................................................677 Disassembly and assembly of control valve assembly..........................................................679 Disassembly and assembly of hydraulic cylinder assembly.....................................................680 600 Work equipment..............................................................................................686 Removal and installation of work equipment assembly.........................................................687 700 Cab and its attachments.....................................................................................690 Removal and installation of operator’s cab glass (stuck glass)..............................................691 Removal and installation of front window assembly...........................................................700 Removal and installation of floor frame assembly (Canopy specification).....................................701 Removal and installation of operator cab and floor frame assembly (Operator cab specification)..............704 800 Electrical system...........................................................................................708 Removal and installation of air conditioner unit assembly (If equipped).....................................709 Removal and installation of KOMTRAX terminal................................................................712 90 Diagrams and Drawings............................................................................................ 0 100 Hydraulic diagrams and drawings.............................................................................714 Hydraulic circuit diagram...................................................................................716 200 Electrical diagrams and drawings............................................................................ 0 Electrical circuit diagram (1/3)............................................................................723 Electrical circuit diagram (2/3)............................................................................724 Electrical circuit diagram (3/3)............................................................................725 Connector list and stereogram...............................................................................726 Related circuit diagram of proportional swithch.............................................................727
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
