Komatsu PC45MR-5 & PC55MR-5 Hydraulic Excavator Operation & Maintenance Manual – PDF Download

Description

Komatsu PC45MR-5 & PC55MR-5 Hydraulic Excavator Operation & Maintenance Manual

This complete Operation & Maintenance Manual covers the Komatsu PC45MR-5 and PC55MR-5 hydraulic excavators from serial numbers PC45MR-30403 and up, and PC55MR-20398 and up. Published under Form No. TEN00763-04 in February 2018, this 475-page PDF is the definitive reference for operating, maintaining, and servicing these compact excavators.

File Details

• Manual Type: Operation & Maintenance Manual
• Brand: Komatsu
• Models Covered: PC45MR-5, PC55MR-5
• Serial Numbers: PC45MR-30403 and up, PC55MR-20398 and up
• Engine: Komatsu 4D88E-7 diesel engine
• Language: English
• Page Count: 475
• File Format: PDF
• Document Number: TEN00763-04
• Publication Date: February 2018

Chapters Covered

• Introduction
• Safety
• Operation
• Maintenance
• Specifications
• Attachments and Options
• Replacement Parts
• Index

Introduction

The Introduction section covers the main uses of the machine — digging, ditching, loading, leveling, and demolition — along with the machine’s directional conventions, protective structures (ROPS conforming to ISO3471:2008), and product identification information. It explains where to locate the PIN/machine serial number plate, engine number plate, and service meter, and provides space to record your machine’s serial numbers and distributor details.

Safety

This is the most critical section for any operator or technician. It opens with general precautions common to operation and maintenance, then works through safety labels and their locations across the machine. Every warning, caution, and notice is documented — from preventing fires and handling high-temperature coolant, high-pressure oil, and high-pressure fuel, to precautions for working under the machine, handling the battery, and using the accumulator and gas spring. The section also covers emergency procedures, including actions if a fire occurs, emergency exit from the operator’s cab, and the correct use of warning tags during maintenance. For anyone working on or around the PC45MR-5 or PC55MR-5, this section is essential reading before any task.

Operation

The Operation section is the largest and most detailed part of the manual, spanning hundreds of pages. It begins with an explanation of components: the machine monitor and its displays, switches (starting switch, lamp switch, horn switch, travel speed selector, wiper, room lamp, pump secondary drive switch, lock lever automatic lock cancel switch, engine shutdown secondary switch), lock lever, travel levers and pedals, blade control lever, swing lock cover, boom swing control pedal, floor lock release lever, and work equipment control levers. It then covers the other equipment: cab front window operation, slide window, emergency escape hammer, cab door, cup holder, ashtray, floor opening and closing procedures (canopy and cab specifications), 12V power supply, fuses, fusible links, toolbox, grease pump holder, and KDPF handling.

Operation procedures are covered in depth: checks and adjustment before starting the engine (walk-around check, fuel tank draining, dust indicator, water separator, hydraulic oil level, coolant level, engine oil level, electric wiring, fuel level, horn, floor tilt fixing bolt), methods for operations and checks before starting the engine, starting the engine, operations and checks after starting the engine, engine warm-up, hydraulic system warm-up, stopping the engine, starting and stopping the machine (travel forward and reverse), steering, swinging, operating the work equipment, working mode selection, prohibited operations, precautions for operation, precautions for working on slopes, escaping from mud, recommended applications (digging, backhoe work, ditching, side ditching, loading, leveling), replacing the bucket, parking the machine, checking after finishing work, locking, handling the air conditioner, handling rubber and road liners shoes, transportation (loading/unloading with trailer, lifting machine), cold weather operation, long-term storage, and troubles and actions (running out of fuel, phenomena that are not failures, towing, discharged battery, other trouble).

Maintenance

The Maintenance section lays out the complete service schedule, from initial 10-hour maintenance through every 100, 250, 500, 1000, 1500, 2000, 3000, 4000, and 6000-hour intervals. It covers all the procedures a technician needs: checking, cleaning, and replacing the air cleaner; cleaning the cooling system; checking battery electrolyte; cleaning the fuel prefilter element; checking and tightening track shoe bolts; checking and adjusting track tension (steel shoes, road liners, and rubber shoes); replacing road liners, rubber shoes, and bucket teeth; checking window washer fluid; maintaining the air conditioner; lubricating the boom swing cylinder foot pin; washing the washable floor; checking the gas spring; bleeding air from the hydraulic circuit; checking swing pinion grease; lubricating the swing system and work equipment; checking and adjusting air conditioner compressor belt tension; cleaning air conditioner filters; changing engine oil and replacing the engine oil filter cartridge; replacing fuel prefilter and main filter cartridges; cleaning radiator, oil cooler, fuel cooler, and condenser fins; replacing hydraulic tank breather element; checking oil level in the final drive case; checking and replacing the fan belt; replacing hydraulic oil filter element; changing oil in the final drive case; checking and adjusting engine valve clearance; checking the crankcase breather; changing hydraulic tank oil and cleaning the strainer; checking and releasing nitrogen gas charge pressure in the accumulator; checking the alternator and starting motor; checking and cleaning the fuel injection system; replacing defined life parts; replacing the accumulator; and cleaning KDPF.

It also includes the maintenance schedule table, maintenance interval for hydraulic breakers, standard tightening torque for bolts and nuts, and the recommended fuel, coolant, and lubricant specifications.

Specifications

Dedicated specification tables for both the PC45MR-5 and PC55MR-5, covering operating weight, bucket capacity, engine model and rated horsepower (SAE J1995 gross and ISO 9249/SAE J1349 net), overall dimensions (length, height, width), track width, tail swing radius, track length, distance between tumbler centers, minimum ground clearance, travel speed (Lo/Hi for rubber shoes and steel shoes/road liners), continuous swing speed, and working ranges including maximum digging reach, maximum digging depth, maximum digging height, maximum vertical wall digging depth, maximum dumping height, minimum swing radius of work equipment and boom, maximum reach at ground level, and maximum blade lift/drop.

Attachments and Options

Covers precautions for using attachments and options, handling buckets with hooks, machines ready for attachment installation (components, hydraulic circuit changeover and connection, operating procedures for breakers and general attachments like crushers), long-term storage, specifications, other trouble, battery disconnect switch, system operating lamp, heater, radio, control patterns other than standard (with operation pattern change-over valve), installing attachments, and recommended attachment operations (hydraulic breaker, breakers).

Replacement Parts

Lists the periodic replacement of defined life parts (fuel hoses, spill hoses, engine oil filter hose, main pump delivery hose, pump delivery hose, pump branch hose, main pump LS hose, external work equipment hoses, PPC accumulator, seat belt) with replacement intervals, and consumable parts (engine oil filter, fuel prefilter, fuel main filter, hydraulic tank breather, hydraulic oil filter, hydraulic tank strainer, air cleaner outer and inner elements, bucket teeth, pins, locks, cutters, bolts, nuts). Also includes the lubrication chart and recommended fuel, coolant, and lubricant specifications with ambient temperature ranges and capacities.

Why This Manual Matters

Whether you’re an owner-operator performing daily checks, a technician tackling a hydraulic system repair, or a fleet manager planning maintenance intervals, having the correct procedures and specifications on hand prevents costly mistakes. The Komatsu PC45MR-5 and PC55MR-5 are compact excavators used in demanding applications — digging, ditching, loading, demolition — and improper operation or maintenance can lead to premature wear, component failure, or safety incidents. This manual gives you the manufacturer’s own procedures, torque values, service intervals, and diagnostic information, so you can work confidently and correctly.

From the safety labels section that tells you exactly where every warning decal belongs, to the maintenance schedule that tells you when to change every filter and fluid, to the specifications tables that give you the exact working ranges and capacities, this manual is the single most important reference for anyone responsible for these machines.

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This Komatsu PC45MR-5 & PC55MR-5 Operation & Maintenance Manual is delivered as an instant PDF download. No shipping, no waiting. Once your order is complete, you can download the manual immediately and access it on any device — computer, tablet, or smartphone. Need a physical copy for the shop? Print the pages you need, whenever you need them. The PDF format lets you zoom in on detailed diagrams, view specifications tables clearly, and keep the entire manual organized and searchable on your device.