Komatsu PC45MR-3 PC55MR-3 Hydraulic Excavator Shop Manual SEN04597-C9 PDF

Description

Komatsu PC45MR-3 PC55MR-3 Hydraulic Excavator Shop Manual SEN04597-C9 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC45MR-3 PC55MR-3 Hydraulic Excavator Shop Manual SEN04597-C9 – PDF DOWNLOAD 

Language : English
Pages : 686
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC45MR-3 PC55MR-3 Hydraulic Excavator Shop Manual SEN04597-C9 – PDF DOWNLOAD 

SERIAL NUMBERS PC45MR – C70001 and up

How to read the shop manual 
1. Composition of shop manual
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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
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 judgement 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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC45MR-3 PC55MR-3 Hydraulic Excavator Shop Manual SEN04597-C9 – PDF DOWNLOAD 

SERIAL NUMBERS PC45MR – C70001 and up

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 64
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 71
100 Engine and cooling system 71
PTO 72
Cooling system 74
200 Power train 77
Power train 78
Swing circle 79
Swing machinery 80
300 Undercarriage and frame 83
Track frame 84
Idler cushion 85
Idler 86
Track roller 88
Carrier roller 89
Sprocket 90
Track shoe 91
410 Hydraulic system, Part 1 95
Hydraulic components layout drawing 96
Hydraulic tank, filter 97
Center swivel joint 99
Travel motor 100
Hydraulic cylinder 108
Solenoid valve 112
Multi-control valve 117
420 Hydraulic system, Part 2 119
Hydraulic pump 120
Control valve 128
Anti-drop valve 142
430 Hydraulic system, Part 3 149
CLSS 150
Operation for each function and valve 154
Swing motor 176
PPC valve 183
500 Work equipment 197
Work equipment 198
Dimensions of each part of work equipment 202
600 Cab and its attachments 207
Floor 208
700 Electrical system 211
Engine control system 212
Electric control system 216
Auto-deceleration function 222
Attachment proportional switch, breaker operation switch, work mode selection, flow control function 224
KOMTRAX system 232
Component parts of system 235
Monitor system 236
Sensors 239
20 Standard value table 243
100 Standard service value table 243
Standard service value table for engine related parts 244
Standard service value table for chassis related parts 246
30 Testing and adjusting 263
100 Testing and adjusting 263
Tools for testing, adjusting, and troubleshooting 265
Testing engine speed 268
Testing exhaust gas color 269
Testing and adjusting valve clearance 270
Testing compression pressure 272
Testing engine oil pressure 273
Testing and adjusting fuel injection timing 274
Testing and adjusting alternator belt tension 278
Testing and adjusting air conditioner compressor belt tension 279
Adjusting fuel control lever 280
Testing clearance in swing circle bearings 281
Testing and adjusting track shoe tension 282
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits 283
Testing and adjusting LS differential pressure 288
Adjusting PC valve 291
Testing and adjusting control pump circuit oil pressure 292
Testing solenoid valve output pressure 294
Testing PPC valve output pressure 295
Adjusting PPC valve 297
Testing swing holding brake release pressure 298
Testing and adjusting travel deviation 299
Testing oil leakage from work equipment cylinder 301
Bleeding air from each part 303
Releasing residual pressure from hydraulic circuit 305
Releasing residual pressure from hydraulic tank 306
Pressurizing hydraulic tank 306
How to open and close (tilt) floor 307
Inspection procedures for diode 312
Function and flow of operator and service mode 314
How to start operation of KOMTRAX terminal 338
Lamp display of KOMTRAX terminal 342
Removal and installation of KOMTRAX terminal 345
Preparation work for troubleshooting of electrical system 346
40 Troubleshooting 349
110 Failure code table and fuse locations 349
User code and failure code list 350
Fuse locations 351
120 General information on troubleshooting 355
Points to remember when troubleshooting 356
Sequence of events in troubleshooting 357
Checks before troubleshooting 358
Classification and procedures of troubleshooting 359
Information contained in troubleshooting table 360
Connection table for connector pin numbers 364
T- branch box and T- branch adapter table 400
130 Troubleshooting by failure code 405
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller 407
Failure code [DBH1KK] Unswitched power supply error 409
Failure code [DBH2KK] Solenoid power supply error 411
Failure code [DBH5KP] 5V sensor power supply output 0 error 413
Failure code [DBH6KP] 5V sensor power supply output 1 error 414
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit) 415
Failure code [DDWLKB] Breaker switch error (Hot short circuit) 416
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault) 417
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit) 418
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error 419
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault) 420
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit) 422
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault) 424
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit) 426
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit) 428
Failure code [D1E0KB] Motor power supply relay error (Ground fault) 430
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit) 432
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault) 434
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit) 436
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault) 438
Failure code [DY10MA] Fuel control motor operation error 440
Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side) 442
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side) 444
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection) 446
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault) 448
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit) 449
200 Troubleshooting of electrical system (E-mode) 451
Before carrying out troubleshooting of electrical system 452
E-1 Engine does not start 454
E-2 Engine does not stop 462
E-3 When starting switch is turned ON, any item does not operate 464
E-4 When starting switch is turned ON, some items do not operate 466
E-5 Alarm buzzer is abnormal 467
E-6 Engine oil pressure caution is turned ON 469
E-7 Charge level caution is turned ON 470
E-8 Preheating system does not operate or preheater does not become hot 472
E-9 Coolant temperature gauge is abnormal 474
E-10 Fuel level gauge is abnormal 478
E-11 Service meter does not operate while engine is running 482
E-12 2nd travel speed is not selected 485
E-13 Working lamp does not light up 488
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves 490
E-15 Windshield wiper does not operate 492
E-16 Windshield washer does not operate 494
E-17 Defective air conditioner 496
E-18 KOMTRAX system does not operate normally 504
300 Troubleshooting of hydraulic and mechanical system (H-mode) 507
Information contained in troubleshooting table 509
H-1 Speed or power of whole work equipment, travel, swing, and blade is low 510
H-2 Engine speed lowers extremely or engine stalls 514
H-3 Whole work equipment, travel system, swing system, and blade do not work 515
H-4 Abnormal sound comes out from around hydraulic pump 519
H-5 Fine control performance or response is low 519
H-6 Speed or power of boom is low 520
H-7 Speed or power of arm is low 521
H-8 Speed or power of bucket is low 522
H-9 Speed or power of boom swing is low 523
H-10 Work equipment does not move singly 523
H-11 Work equipment hydraulic drift is large 524
H-12 Time lag of work equipment is large 526
H-13 In compound operation of work equipment, speed of part loaded more is low 526
H-14 Machine deviates during travel 527
H-15 Travel speed or travel power is low (while work equipment is normal) 529
H-16 Machine is not steered well or steering power is low 530
H-17 Travel speed does not change 531
H-18 Travel motor does not work 532
H-19 Speed or power of swing is low 534
H-20 Machine does not swing 536
H-21 Swing acceleration performance is low 538
H-22 Machine overruns when it stops swinging 540
H-23 Large shock is made when machine stops swinging 541
H-24 When upper structure stops swinging, it makes large sound 541
H-25 Hydraulic drift of swing is large 542
H-26 Speed or power of blade is low 543
H-27 Blade does not move 544
H-28 Hydraulic drift of blade is large 545
400 Troubleshooting of engine (S-mode) 547
Method of using troubleshooting charts 549
S-1 Starting performance is poor 552
S-2 Engine does not start 553
S-3 Engine does not pick up smoothly 556
S-4 Engine stops during operations 557
S-5 Engine does not rotate smoothly 558
S-6 Engine lacks output (or lacks power) 559
S-7 Exhaust smoke is black (incomplete combustion) 560
S-8 Oil consumption is excessive (or exhaust smoke is blue) 561
S-9 Oil becomes contaminated quickly 562
S-10 Fuel consumption is excessive 563
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 564
S-12 Oil pressure drops 565
S-13 Oil level rises (Entry of coolant/fuel) 566
S-14 Coolant temperature becomes too high (overheating) 567
S-15 Abnormal noise is made 568
S-16 Vibration is excessive 569
50 Disassembly and assembly 571
100 General information on disassembly and assembly 571
How to read this manual 572
Coating materials list 574
Special tool list 577
Sketches of special tools 580
200 Engine and cooling system 583
Removal and installation of fuel injection pump assembly 584
Removal and installation of radiator assembly 586
Removal and installation of hydraulic oil cooler assembly 588
Removal and installation of engine and hydraulic pump assembly 592
300 Power train 599
Removal and installation of swing motor and swing machinery assembly 600
Disassembly and assembly of swing motor and swing machinery assembly 601
Removal and installation of swing circle assembly 606
400 Undercarriage and frame 609
Removal and installation of track shoe assembly 610
Disassembly and assembly of idler assembly 611
Disassembly and assembly of recoil spring assembly 613
Disassembly and assembly of track roller assembly 616
Disassembly and assembly of carrier roller assembly 617
Removal and installation of revolving frame assembly 618
500 Hydraulic system 621
Removal and installation of center swivel joint assembly 622
Disassembly and assembly of center swivel joint assembly 624
Removal and installation of work equipment pump assembly 628
Disassembly and assembly of control valve assembly 630
Disassembly and assembly of hydraulic cylinder assembly 631
600 Work equipment 637
Removal and installation of work equipment assembly 638
700 Cab and its attachments 641
Removal and installation of operator’s cab glass (stuck glass) 642
Removal and installation of front window assembly 651
Removal and installation of floor frame assembly (Canopy specification) 652
Removal and installation of operator cab and floor frame assembly (Operator cab specification) 655
800 Electrical system 659
Removal and installation of air conditioner unit assembly (If equipped) 660
Removal and installation of KOMTRAX terminal 663
90 Diagrams and drawings 665
100 Hydraulic diagrams and drawings 665
Hydraulic circuit diagram 667
200 Electrical diagrams and drawings 672
Electrical circuit diagram 674
Connector list and stereogram 682
Related circuit diagram of proportional switch 683

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S.V 27/12/24