Komatsu PC45MR-5E0 PC55MR-5E0 Hydraulic Excavator Shop Manual PDF

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Komatsu PC45MR-5E0 PC55MR-5E0 Hydraulic Excavator Shop Manual WENBM00230 – PDF DOWNLOAD

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Komatsu PC45MR-5E0 PC55MR-5E0 Hydraulic Excavator Shop Manual WENBM00230 – PDF DOWNLOAD 

Language : English
Pages : 1266
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC45MR-5E0 PC55MR-5E0 Hydraulic Excavator Shop Manual WENBM00230 – PDF DOWNLOAD 

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 13
FOREWORD, SAFETY, BASIC INFORMATION 19
HOW TO READ THE SHOP MANUAL 19
SAFETY NOTICE FOR OPERATION 21
PRECAUTIONS TO PREVENT FIRE 29
ACTIONS IF FIRE OCCURS 31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 36
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 45
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 46
PRACTICAL USE OF KOMTRAX 47
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 52
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 56
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 62
HOW TO READ ELECTRICAL WIRE CODE 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 67
STANDARD TIGHTENING TORQUE TABLE 70
CONVERSION TABLE 77
01 SPECIFICATIONS 83
CONTENTS 84
ABBREVIATION LIST 85
SPECIFICATIONS 91
SPECIFICATION DRAWING 91
SPECIFICATION DRAWING: PC45MR-5E0 91
SPECIFICATION DRAWING: PC55MR-5E0 93
WORKING RANGE DRAWINGS 95
WORKING RANGE: PC45MR-5E0 95
WORKING RANGE: PC55MR-5E0 96
SPECIFICATIONS 97
SPECIFICATIONS: PC45MR-5E0 97
SPECIFICATIONS: PC55MR-5E0 101
WEIGHT TABLE 105
WEIGHT TABLE: PC45MR-5E0 105
WEIGHT TABLE: PC55MR-5E0 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION 111
CONTENTS 112
ABBREVIATION LIST 114
NOx CONTROL SYSTEM 120
FUNCTION OF NOx CONTROL SYSTEM 120
BOOT-UP SYSTEM 123
LAYOUT DRAWING OF BOOT-UP SYSTEM 123
SYSTEM OPERATING LAMP SYSTEM 125
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 125
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 125
QUICK RELEASE BATTERY TERMINAL (-) 127
FUNCTION OF QUICK RELEASE BATTERY TERMINAL (-) 127
ENGINE SYSTEM 128
LAYOUT DRAWING OF ENGINE SYSTEM 128
ENGINE CONTROL SYSTEM 129
ENGINE CONTROL SYSTEM DIAGRAM 129
FUNCTION OF ENGINE CONTROL SYSTEM 130
AUTO-DECELERATION SYSTEM 133
AUTO-DECELERATION SYSTEM DIAGRAM 133
FUNCTION OF AUTO-DECELERATION SYSTEM 133
OPERATION OF AUTO-DECELERATION SYSTEM 134
OVERHEAT PREVENTION SYSTEM 135
OVERHEAT PREVENTION SYSTEM DIAGRAM 135
FUNCTION OF OVERHEAT PREVENTION SYSTEM 136
AUTOMATIC IDLE STOP SYSTEM 137
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 137
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 137
COMPONENT PARTS OF ENGINE SYSTEM 139
PTO 139
COOLING SYSTEM 140
LAYOUT DRAWING OF COOLING SYSTEM 140
SPECIFICATIONS OF COOLING SYSTEM 141
CONTROL SYSTEM 142
LAYOUT DRAWING OF CONTROL SYSTEM 142
MACHINE MONITOR SYSTEM 143
MACHINE MONITOR SYSTEM DIAGRAM 143
KOMTRAX SYSTEM 144
KOMTRAX SYSTEM DIAGRAM 144
FUNCTION OF KOMTRAX SYSTEM 144
COMPONENT PARTS OF CONTROL SYSTEM 145
MACHINE MONITOR 145
KOMTRAX TERMINAL 154
MACHINE CONTROLLER 156
FUEL CONTROL DIAL 160
HYDRAULIC SYSTEM 162
LAYOUT DRAWING OF HYDRAULIC SYSTEM 162
CLSS 164
STRUCTURE OF CLSS 164
FUNCTION OF CLSS 165
ENGINE AND PUMP COMBINED CONTROL SYSTEM 167
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 167
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 168
COMPONENT PARTS OF HYDRAULIC SYSTEM 170
HYDRAULIC TANK 170
MAIN PUMP 174
CONTROL VALVE 186
WORK EQUIPMENT SYSTEM 231
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 231
STRUCTURE OF VALVE CONTROL 235
PPC LOCK SYSTEM 237
PPC LOCK SYSTEM DIAGRAM 237
FUNCTION OF PPC LOCK SYSTEM 238
HYDRAULIC QUICK COUPLER WORKING SYSTEM 239
QUICK COUPLER WORKING SYSTEM DIAGRAM 239
FUNCTION OF QUICK COUPLER WORKING SYSTEM 240
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 241
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 241
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 241
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 242
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 242
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 243
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 244
WORK EQUIPMENT AND SWING PPC VALVE 244
ATTACHMENT PPC VALVE 249
BLADE PPC VALVE 251
BOOM SWING PPC VALVE 253
BIPARTITE SOLENOID VALVE 255
QUICK COUPLER SOLENOID VALVE 258
PILOT CIRCUIT ACCUMULATOR 259
SWING SYSTEM 260
LAYOUT DRAWING OF SWING SYSTEM 260
COMPONENT PARTS OF SWING SYSTEM 261
SWING MOTOR 261
SWING MACHINERY 268
SWING CIRCLE 270
TRAVEL SYSTEM 271
LAYOUT DRAWING OF TRAVEL SYSTEM 271
TRAVEL CONTROL SYSTEM DIAGRAM 273
FUNCTION OF TRAVEL CONTROL SYSTEM 273
COMPONENT PARTS OF TRAVEL SYSTEM 275
TRAVEL MOTOR 275
TRAVEL PPC VALVE 283
CENTER SWIVEL JOINT 285
UNDERCARRIAGE AND FRAME 286
LAYOUT DRAWING OF UNDERCARRIAGE 286
SPECIFICATIONS OF UNDERCARRIAGE 286
IDLER CUSHION 287
STRUCTURE OF IDLER CUSHION 287
SPECIFICATIONS OF IDLER CUSHION 287
WORK EQUIPMENT 288
STRUCTURE OF WORK EQUIPMENT 288
FUNCTION OF WORK EQUIPMENT 289
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 290
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 290
CAB AND ITS ATTACHMENTS 291
ROPS CAB 291
STRUCTURE OF ROPS CAB 291
FUNCTION OF ROPS CAB 291
TILT TYPE FLOOR 292
STRUCTURE OF TILT TYPE FLOOR 292
FUNCTION OF TILT TYPE FLOOR 292
20 STANDARD VALUE TABLE 293
CONTENTS 294
ABBREVIATION LIST 295
STANDARD VALUE TABLE FOR ENGINE 301
STANDARD VALUE TABLE FOR ENGINE: PC45MR-5E0 301
STANDARD VALUE TABLE FOR ENGINE: PC55MR-5E0 303
STANDARD VALUE TABLE FOR MACHINE 305
STANDARD VALUE TABLE FOR MACHINE: PC45MR-5E0 305
STANDARD VALUE TABLE FOR MACHINE: PC55MR-5E0 317
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 329
30 TESTING AND ADJUSTING 335
CONTENTS 336
ABBREVIATION LIST 339
RELATED INFORMATION ON TESTING AND ADJUSTING 345
TOOLS FOR TESTING AND ADJUSTING 345
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 349
ENGINE AND COOLING SYSTEM 351
TEST ENGINE SPEED 351
METHOD FOR TESTING ENGINE SPEED 351
TEST EXHAUST GAS COLOR 353
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 353
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 354
TEST AND ADJUST VALVE CLEARANCE 355
METHOD FOR TESTING VALVE CLEARANCE 355
METHOD FOR ADJUSTING VALVE CLEARANCE 356
TEST COMPRESSION PRESSURE 357
METHOD FOR TESTING COMPRESSION PRESSURE 357
TEST ENGINE OIL PRESSURE 359
METHOD FOR TESTING ENGINE OIL PRESSURE 359
BLEED AIR FROM FUEL SYSTEM 361
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 361
TEST FUEL CIRCUIT FOR LEAKAGE 363
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 363
HANDLE CYLINDER CUT-OUT MODE OPERATION 364
TEST AND ADJUST ALTERNATOR BELT TENSION 365
METHOD FOR TESTING ALTERNATOR BELT TENSION 365
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION 365
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 366
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 366
POWER TRAIN 368
TEST SWING CIRCLE BEARING CLEARANCE 368
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 368
UNDERCARRIAGE AND FRAME 369
TEST AND ADJUST TRACK TENSION 369
METHOD FOR TESTING TRACK TENSION 369
METHOD FOR ADJUSTING TRACK TENSION 369
HYDRAULIC SYSTEM 371
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 371
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 371
METHOD FOR RELEASING REMAINING PRESSURE IN PPC ACCUMULATOR CIRCUIT 371
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 371
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 376
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 376
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 377
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 377
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 387
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 388
METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE 388
METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE 393
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 395
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 395
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 397
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 399
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 399
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 401
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 401
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 402
METHOD FOR ADJUSTING LS VALVE 404
TEST OUTLET PRESSURE OF SOLENOID VALVE 405
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR 405
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL 406
OPERATING CONDITION OF SOLENOID VALVE 407
TEST PPC VALVE OUTLET PRESSURE 408
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR 408
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 411
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 414
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 414
TEST SWING PARKING BRAKE RELEASE PRESSURE 415
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE WITH MACHINE MONITOR 415
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE BY TESTING TOOL 415
TEST AND ADJUST TRAVEL DEVIATION 417
METHOD FOR TESTING TRAVEL DEVIATION 417
METHOD FOR ADJUSTING TRAVEL DEVIATION 417
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 420
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 420
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 420
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 421
TEST OIL LEAKAGE 422
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 422
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 422
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 423
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 423
BLEED AIR FROM HYDRAULIC CIRCUIT 425
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 426
PRESSURIZE HYDRAULIC TANK 428
METHOD FOR PRESSURIZING HYDRAULIC TANK 428
CAB AND ITS ATTACHMENTS 429
METHOD FOR OPENING AND CLOSING FLOOR UNIT 429
METHOD FOR OPENING FLOOR UNIT 430
METHOD FOR CLOSING FLOOR UNIT 435
ELECTRICAL SYSTEM 439
SET AND OPERATE MACHINE MONITOR 439
OPERATOR MODE 442
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 442
CHECKING FUNCTION OF SERVICE METER 442
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 442
SERVICE MODE 445
METHOD FOR OPERATING SERVICE MODE 445
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 447
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 450
ABNORMALITY RECORD MENU 457
METHOD FOR CONFIRMING MAINTENANCE RECORD 460
METHOD FOR OPERATING MAINTENANCE MODE SETTING 461
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 465
DEFAULT MENU 467
DIAGNOSTIC TESTS MENU 473
ADJUSTMENT MENU 481
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING 489
KOMTRAX SETTINGS MENU 491
METHOD FOR DISPLAYING SERVICE MESSAGE 493
METHOD FOR STARTING UP KOMTRAX TERMINAL 495
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 500
TEST DIODES 501
METHOD FOR TESTING DIODE USING DIGITAL TESTER 501
METHOD FOR TESTING DIODE USING ANALOG TESTER 501
40 TROUBLESHOOTING 503
CONTENTS 504
ABBREVIATION LIST 509
RELATED INFORMATION ON TROUBLESHOOTING 515
GENERAL TROUBLESHOOTING POINTS 515
SEQUENCE OF EVENTS IN TROUBLESHOOTING 516
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 518
CHECKS BEFORE TROUBLESHOOTING 526
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 528
WALK-AROUND CHECK 528
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 530
CHECK FUEL LEVEL AND TYPE 530
CHECK FUEL PREFILTER 531
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 533
CHECK MAIN FILTER 534
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 537
CHECK COOLANT LEVEL (RESERVOIR TANK) 538
CHECK CLOGGING OF AIR CLEANER 539
CLEAN OUTER ELEMENT (SINGLE ELEMENT) 540
CLEAN OUTER ELEMENT (DOUBLE ELEMENT) 543
REPLACE SINGLE ELEMENT 545
REPLACE DOUBLE ELEMENT 547
CHECK HYDRAULIC OIL LEVEL 549
CHECK HYDRAULIC OIL STRAINER 553
CHECK HYDRAULIC FILTER 554
CHECK OIL LEVEL IN FINAL DRIVE CASE 556
BLEED AIR FROM FUEL SYSTEM 556
BLEED AIR FROM HYDRAULIC SYSTEM 556
ELECTRICAL EQUIPMENT – CHECK METHOD 556
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 563
PROCEDURE FOR TESTING AND TROUBLESHOOTING 567
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 570
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 574
CONNECTORS LIST AND LAYOUT 576
CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) 592
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 596
FUSE LOCATION TABLE 602
FAILURE CODES TABLE 606
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 617
FAILURE CODE [6AZ0ZG] 617
FAILURE CODE [989L00] 619
FAILURE CODE [989M00] 620
FAILURE CODE [989N00] 621
FAILURE CODE [AQ20R1] 622
FAILURE CODE [AS00R2] 623
FAILURE CODE [AS00R3] 624
FAILURE CODE [AS00R4] 625
FAILURE CODE [B@BCNS] 626
FAILURE CODE [D19JKZ] 627
FAILURE CODE [D811MC] 630
FAILURE CODE [D862KA] 631
FAILURE CODE [D8ALKA] 632
FAILURE CODE [D8ALKB] 634
FAILURE CODE [D8AQKR] 636
FAILURE CODE [DAF0KT] 638
FAILURE CODE [DAF0MB] 639
FAILURE CODE [DAF0MC] 640
FAILURE CODE [DAF3KK] 641
FAILURE CODE [DAF9KQ] 643
FAILURE CODE [DAFGMC] 644
FAILURE CODE [DAFLKA] 645
FAILURE CODE [DAFLKB] 647
FAILURE CODE [DAFQKR] 649
FAILURE CODE [DB2QKR] 650
FAILURE CODE [DBH0MC] 654
FAILURE CODE [DBH2KK] 655
FAILURE CODE [DBH5KP] 657
FAILURE CODE [DBH5KP] 659
FAILURE CODE [DBH9KQ] 661
FAILURE CODE [DBHLKA] 663
FAILURE CODE [DBHLKB] 665
FAILURE CODE [DBHQKR] 667
FAILURE CODE [DDNRKA] 672
FAILURE CODE [DDNRKY] 674
FAILURE CODE [DDNS00] 676
FAILURE CODE [DDWLKA] 678
FAILURE CODE [DDWLKB] 680
FAILURE CODE [DFB1KZ] 682
FAILURE CODE [DFB2KZ] 684
FAILURE CODE [DFB3L8] 686
FAILURE CODE [DFB4L8] 689
FAILURE CODE [DFB5KZ] 692
FAILURE CODE [DFB6KZ] 694
FAILURE CODE [DHS1MA] 696
FAILURE CODE [DHS5MA] 698
FAILURE CODE [DHX1MA] 700
FAILURE CODE [DKULKA] 702
FAILURE CODE [DKULKB] 704
FAILURE CODE [DKULKY] 706
FAILURE CODE [DV00KB] 708
FAILURE CODE [DV20KB] 709
FAILURE CODE [DV50KB] 711
FAILURE CODE [DV50KY] 713
FAILURE CODE [DW43KA] 715
FAILURE CODE [DW43KB] 717
FAILURE CODE [DW43KY] 719
FAILURE CODE [DW4CKY] 720
FAILURE CODE [DXA8KA] 722
FAILURE CODE [DXA8KB] 724
FAILURE CODE [DXE7KA] 726
FAILURE CODE [DXE7KB] 728
FAILURE CODE [DXE7KY] 730
FAILURE CODE [DXE8KA] 732
FAILURE CODE [DXE8KB] 734
FAILURE CODE [DXE8KY] 736
FAILURE CODE [DXE9KA] 738
FAILURE CODE [DXE9KB] 740
FAILURE CODE [DXE9KY] 742
FAILURE CODE [DXEAKA] 744
FAILURE CODE [DXEAKB] 746
FAILURE CODE [DXEAKY] 748
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 750
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 750
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 756
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 758
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 760
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 763
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 764
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 765
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 766
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 767
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 768
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 770
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 771
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 772
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 773
E-15 FUNCTION SWITCH DOES NOT OPERATE 774
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 775
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 776
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 777
E-19 ALARM BUZZER DOES NOT SOUND 779
E-20 ALARM BUZZER CANNOT BE CANCELED 780
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 781
E-22 SERVICE MODE CANNOT BE SELECTED 782
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 783
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 785
E-25 ALARM DOES NOT SOUND DURING TRAVEL 787
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 789
E-27 HORN DOES NOT SOUND 790
E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC) 792
E-29 HORN DOES NOT STOP SOUNDING 794
E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER SPEC) 796
E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP (CANOPY SPEC) 798
E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP (CAB SPEC) 802
E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 806
E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 808
E-35 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 810
E-36 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 811
E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 812
E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 814
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 815
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 815
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 816
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 817
H-3 TRAVEL OR BLADE DOES NOT OPERATE 818
H-4 SWING OR BLADE DOES NOT OPERATE 819
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 820
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 821
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 822
H-8 SWING AND BLADE SPEED OR POWER IS LOW 823
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 824
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 825
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 826
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 828
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 829
H-14 BLADE DOES NOT OPERATE 830
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 831
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 832
H-17 SPEED OR POWER OF BOOM IS LOW 833
H-18 ARM SPEED OR POWER IS LOW 835
H-19 BUCKET SPEED OR POWER IS LOW 836
H-20 BLADE SPEED OR POWER IS LOW 837
H-21 BOOM SWING SPEED OR POWER IS LOW 839
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 840
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE 841
H-24 HYDRAULIC DRIFT OF ARM IS LARGE 842
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE 843
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 844
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 846
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 847
H-29 MACHINE DOES NOT TRAVEL STRAIGHT 848
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 850
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 851
H-32 TRAVEL SPEED IS LOW 853
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE 855
H-34 ONE OF TRACKS DOES NOT RUN 856
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 858
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 859
H-37 SWINGS ONLY IN ONE DIRECTION 861
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 863
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 865
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 866
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 867
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 868
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 869
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 870
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 871
TROUBLESHOOTING OF ENGINE (S-MODE) 872
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 872
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 873
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 874
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 875
S-4 ENGINE STARTABILITY IS POOR 876
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 878
S-6 ENGINE STOPS DURING OPERATION 880
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 881
S-8 ENGINE LACKS POWER 882
S-9 KDPF GETS CLOGGED IN A SHORT TIME 884
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 885
S-11 OIL BECOMES CONTAMINATED QUICKLY 886
S-12 FUEL CONSUMPTION IS EXCESSIVE 887
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 888
S-14 OIL PRESSURE DROPS 889
S-15 FUEL MIXES INTO ENGINE OIL 891
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 892
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 893
S-18 UNUSUAL NOISE IS HEARD 894
S-19 VIBRATION IS EXCESSIVE 895
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 896
50 DISASSEMBLY AND ASSEMBLY 897
CONTENTS 898
ABBREVIATION LIST 901
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 907
HOW TO READ THIS MANUAL 907
COATING MATERIALS LIST 909
SPECIAL TOOLS LIST 913
SKETCHES OF SPECIAL TOOLS 918
ENGINE AND COOLING SYSTEM 919
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 919
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 919
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 922
REMOVE AND INSTALL STARTER ASSEMBLY 926
METHOD FOR REMOVING STARTER ASSEMBLY 926
METHOD FOR INSTALLING STARTER ASSEMBLY 927
REMOVE AND INSTALL RADIATOR ASSEMBLY 928
METHOD FOR REMOVING RADIATOR ASSEMBLY 928
METHOD FOR INSTALLING RADIATOR ASSEMBLY 931
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 935
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 935
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 938
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 942
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 942
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 948
REMOVE AND INSTALL FUEL TANK ASSEMBLY 955
METHOD FOR REMOVING FUEL TANK ASSEMBLY 955
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 957
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 960
POWER TRAIN 961
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 961
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 961
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 963
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 965
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 965
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 966
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 967
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 967
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 970
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 974
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 974
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 974
UNDERCARRIAGE AND FRAME 976
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 976
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 976
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 977
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 979
METHOD FOR SEPARATING TRACK ASSEMBLY 979
METHOD FOR INSTALLING TRACK ASSEMBLY 979
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 981
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 981
METHOD FOR ASSEMBLING IDLER ASSEMBLY 982
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 984
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 984
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 985
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 987
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 987
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 988
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 990
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 990
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 991
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 993
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 993
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 996
HYDRAULIC SYSTEM 1001
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 1001
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 1001
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 1002
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1005
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1006
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1007
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1008
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 1008
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 1011
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 1014
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 1014
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 1016
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY 1020
METHOD FOR REMOVING ACCUMULATOR ASSEMBLY (EU SPECIFICATION) 1020
METHOD FOR REMOVING ACCUMULATOR ASSEMBLY (NORTH AMERICA SPECIFICATION, FOR MACHINE WITH QUICK COUPLER) 1021
METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY (EU SPECIFICATION) 1023
METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY (NORTH AMERICA SPECIFICATION, FOR MACHINE WITH QUICK COUPLER) 1024
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1026
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1026
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1027
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1029
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1029
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1030
WORK EQUIPMENT 1032
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1032
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 1032
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 1034
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 1036
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 1037
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 1040
CAB AND ITS ATTACHMENTS 1045
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY (CAB SPEC) 1045
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY (CAB SPEC) 1045
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY (CAB SPEC) 1048
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC) 1052
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY (CANOPY SPEC) 1052
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY (CANOPY SPEC) 1055
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1058
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 1059
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 1060
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1068
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 1068
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 1069
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 1071
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 1071
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 1075
REMOVE AND INSTALL OPERATOR’S SEAT 1080
METHOD FOR REMOVING OPERATOR’S SEAT 1080
METHOD FOR INSTALLING OPERATOR’S SEAT 1080
REMOVE AND INSTALL SEAT BELT 1082
METHOD FOR REMOVING SEAT BELT 1082
METHOD FOR INSTALLING SEAT BELT 1082
ELECTRICAL SYSTEM 1083
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 1083
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 1083
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 1084
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 1085
METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY 1085
METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY 1086
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 1088
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 1088
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 1089
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 1091
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 1091
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 1092
60 MAINTENANCE STANDARD 1095
CONTENTS 1096
ABBREVIATION LIST 1097
ENGINE AND COOLING SYSTEM 1103
MAINTENANCE STANDARD FOR PTO 1103
MAINTENANCE STANDARD OF COOLING SYSTEM 1104
POWER TRAIN 1105
MAINTENANCE STANDARD OF SWING CIRCLE 1105
MAINTENANCE STANDARD OF SWING MACHINERY 1106
MAINTENANCE STANDARD OF SPROCKET 1108
UNDERCARRIAGE AND FRAME 1109
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1109
MAINTENANCE STANDARD OF IDLER 1110
MAINTENANCE STANDARD OF TRACK ROLLER 1112
MAINTENANCE STANDARD OF CARRIER ROLLER 1113
MAINTENANCE STANDARD OF TRACK SHOE 1114
MAINTENANCE STANDARD OF TRIPLE SHOE 1116
MAINTENANCE STANDARD OF ROAD LINER 1117
MAINTENANCE STANDARD FOR RUBBER SHOE 1118
HYDRAULIC SYSTEM 1119
MAINTENANCE STANDARD OF HYDRAULIC TANK 1119
MAINTENANCE STANDARD OF MAIN PUMP 1120
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE 1121
MAINTENANCE STANDARD OF PC-EPC VALVE 1122
MAINTENANCE STANDARD OF SWING MOTOR 1123
MAINTENANCE STANDARD OF TRAVEL MOTOR 1125
MAINTENANCE STANDARD OF CONTROL VALVE 1126
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1136
MAINTENANCE STANDARD OF BLADE PPC VALVE 1139
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 1141
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1143
MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE 1146
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 1148
WORK EQUIPMENT 1149
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1149
DIMENSION OF ARM 1155
DIMENSIONS OF BUCKET 1159
MAINTENANCE STANDARD OF BOOM CYLINDER 1161
MAINTENANCE STANDARD OF ARM CYLINDER 1162
MAINTENANCE STANDARD OF BUCKET CYLINDER 1164
MAINTENANCE STANDARD OF BLADE CYLINDER 1166
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 1167
80 APPENDIX 1169
CONTENTS 1170
ABBREVIATION LIST 1171
AIR CONDITIONER SYSTEM 1177
PRECAUTIONS FOR REFRIGERANT 1177
AIR CONDITIONER COMPONENT 1178
SPECIFICATIONS OF AIR CONDITIONER 1179
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 1180
OUTLINE OF REFRIGERATION CYCLE 1181
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1183
AIR CONDITIONER UNIT 1183
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 1183
COMPRESSOR 1185
STRUCTURE OF COMPRESSOR 1185
SPECIFICATIONS OF COMPRESSOR 1185
FUNCTION OF COMPRESSOR 1185
CONDENSER 1187
STRUCTURE OF CONDENSER 1187
SPECIFICATIONS OF CONDENSER 1187
FUNCTION OF CONDENSER 1187
RECEIVER DRIER 1189
STRUCTURE OF RECEIVER DRIER 1189
SPECIFICATIONS OF RECEIVER DRIER 1189
FUNCTION OF RECEIVER DRIER 1189
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1190
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1192
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1195
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 1199
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM) 1202
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS) 1206
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 1207
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 1208
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 1209
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1210
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1211
HANDLE COMPRESSOR OIL 1213
90 CIRCUIT DIAGRAMS 1215
CONTENTS 1216
ABBREVIATION LIST 1217
HYDRAULIC CIRCUIT DIAGRAM 1223
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1223
HYDRAULIC CIRCUIT DIAGRAM (1/2) 1227
HYDRAULIC CIRCUIT DIAGRAM (2/2) 1229
ELECTRICAL CIRCUIT DIAGRAM 1231
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1231
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (1/4) 1235
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (2/4) 1237
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (3/4) 1239
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (4/4) 1241
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (1/6) 1243
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (2/6) 1245
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (3/6) 1247
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (4/6) 1249
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (5/6) 1251
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (6/6) 1253
INDEX 1255

DESCRIPTION:

Komatsu PC45MR-5E0 PC55MR-5E0 Hydraulic Excavator Shop Manual WENBM00230 – PDF DOWNLOAD 

PC45MR-5E0  SERIAL NUMBERS     F20001 and up
PC55MR-5E0  SERIAL NUMBERS     F40001 and up
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams

S.V 26/12/24