Komatsu PC45MR-5 PC55MR-5 Compact Hydraulic Excavator Shop Manual SEN06574-10 – PDF DOWNLOAD

Komatsu PC45MR-5 PC55MR-5 Compact Hydraulic Excavator Shop Manual SEN06574-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC45MR-5 PC55MR-5 Compact Hydraulic Excavator Shop Manual SEN06574-10 – PDF DOWNLOAD

Language : English
Pages : 1266
Downloadable : Yes
File Type : PDF
Size: 30.1 MB

DESCRIPTION:

Komatsu PC45MR-5 PC55MR-5 Compact Hydraulic Excavator Shop Manual SEN06574-10 – PDF DOWNLOAD

SERIAL NUMBERS

PC45MR-30001 and up
PC55MR-20001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
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.

General precautions
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation
and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, always
agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator’s
compartment Before starting work.
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work:
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible,
insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.

TABLE OF CONTENTS:

Komatsu PC45MR-5 PC55MR-5 Compact Hydraulic Excavator Shop Manual SEN06574-10 – PDF DOWNLOAD

INDEX
00 INDEX AND FOREWORD 00-1
ABBREVIATION LIST 00-11
FOREWORD, SAFETY, BASIC INFORMATION 00-17
HOW TO READ THE SHOP MANUAL 00-17
SAFETY NOTICE FOR OPERATION 00-19
PRECAUTIONS TO PREVENT FIRE 00-27
ACTIONS IF FIRE OCCURS 00-29
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00-30
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-31
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-34
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-41
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-43
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-44
PRACTICAL USE OF KOMTRAX 00-45
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-50
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-54
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-60
HOW TO READ ELECTRICAL WIRE CODE 00-61
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-65
STANDARD TIGHTENING TORQUE TABLE 00-68
CONVERSION TABLE 00-75
01 SPECIFICATIONS 01-1
CONTENTS 01-2
ABBREVIATION LIST 01-3
SPECIFICATIONS 01-9
SPECIFICATION DRAWING 01-9
WORKING RANGE DRAWINGS 01-13
SPECIFICATIONS 01-15
WEIGHT TABLE 01-23
TABLE OF FUEL, COOLANT, AND LUBRICANTS 01-27
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
ABBREVIATION LIST 10-4
BOOT-UP SYSTEM 10-10
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-10
SYSTEM OPERATING LAMP SYSTEM 10-12
BATTERY DISCONNECT SWITCH 10-14
ENGINE SYSTEM 10-15
LAYOUT DRAWING OF ENGINE SYSTEM 10-15
ENGINE CONTROL SYSTEM 10-16
AUTO-DECELERATION SYSTEM 10-20
OVERHEAT PREVENTION SYSTEM 10-22
AUTOMATIC IDLE STOP SYSTEM 10-24
COMPONENT PARTS OF ENGINE SYSTEM 10-26
COOLING SYSTEM 10-27
LAYOUT DRAWING OF COOLING SYSTEM 10-27
CONTROL SYSTEM 10-29
LAYOUT DRAWING OF CONTROL SYSTEM 10-29
MACHINE MONITOR SYSTEM 10-30
KOMTRAX SYSTEM 10-31
COMPONENT PARTS OF CONTROL SYSTEM 10-32
INDEX 00 INDEX AND FOREWORD
00-2 PC45MR-5, PC55MR-5
HYDRAULIC SYSTEM 10-48
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-48
CLSS 10-50
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10-53
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-56
WORK EQUIPMENT SYSTEM 10-118
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-118
STRUCTURE OF VALVE CONTROL 10-122
PPC LOCK SYSTEM 10-124
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10-126
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10-127
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-129
SWING SYSTEM 10-145
LAYOUT DRAWING OF SWING SYSTEM 10-145
COMPONENT PARTS OF SWING SYSTEM 10-146
TRAVEL SYSTEM 10-156
LAYOUT DRAWING OF TRAVEL SYSTEM 10-156
TRAVEL CONTROL SYSTEM DIAGRAM 10-158
COMPONENT PARTS OF TRAVEL SYSTEM 10-160
UNDERCARRIAGE AND FRAME 10-171
LAYOUT DRAWING OF UNDERCARRIAGE 10-171
IDLER CUSHION 10-172
WORK EQUIPMENT 10-173
STRUCTURE OF WORK EQUIPMENT 10-173
FUNCTION OF WORK EQUIPMENT 10-174
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10-175
CAB AND ITS ATTACHMENTS 10-176
ROPS CAB 10-176
TILT TYPE FLOOR 10-177
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
ABBREVIATION LIST 20-3
STANDARD VALUE TABLE FOR ENGINE 20-9
STANDARD VALUE TABLE FOR ENGINE: PC45MR-5 20-9
STANDARD VALUE TABLE FOR ENGINE: PC55MR-5 20-11
STANDARD VALUE TABLE FOR MACHINE 20-13
STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 20-13
STANDARD VALUE TABLE FOR MACHINE: PC55MR-5 20-25
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20-37
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
ABBREVIATION LIST 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING 30-11
TOOLS FOR TESTING AND ADJUSTING 30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30-15
ENGINE AND COOLING SYSTEM 30-17
TEST ENGINE SPEED 30-17
TEST EXHAUST GAS COLOR 30-19
TEST AND ADJUST VALVE CLEARANCE 30-21
TEST COMPRESSION PRESSURE 30-23
TEST ENGINE OIL PRESSURE 30-25
BLEED AIR FROM FUEL SYSTEM 30-27
TEST FUEL CIRCUIT FOR LEAKAGE 30-29
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-30
TEST AND ADJUST ALTERNATOR BELT TENSION 30-31
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 30-32
POWER TRAIN 30-34
TEST SWING CIRCLE BEARING CLEARANCE 30-34
00 INDEX AND FOREWORD INDEX
PC45MR-5, PC55MR-5 00-3
UNDERCARRIAGE AND FRAME 30-35
TEST AND ADJUST TRACK TENSION 30-35
HYDRAULIC SYSTEM 30-37
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-37
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS
30-43
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30-54
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 30-61
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30-65
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30-67
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-71
TEST PPC VALVE OUTLET PRESSURE 30-74
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30-79
TEST SWING PARKING BRAKE RELEASE PRESSURE 30-80
TEST AND ADJUST TRAVEL DEVIATION 30-82
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-85
TEST OIL LEAKAGE 30-87
BLEED AIR FROM HYDRAULIC CIRCUIT 30-90
PRESSURIZE HYDRAULIC TANK 30-93
CAB AND ITS ATTACHMENTS 30-94
METHOD FOR OPENING AND CLOSING FLOOR UNIT 30-94
ELECTRICAL SYSTEM 30-104
SET AND OPERATE MACHINE MONITOR 30-104
METHOD FOR STARTING UP KOMTRAX TERMINAL 30-155
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-159
TEST DIODES 30-160
Pm CLINIC 30-161
Pm CLINIC SERVICE 30-161
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
ABBREVIATION LIST 40-6
RELATED INFORMATION ON TROUBLESHOOTING 40-12
GENERAL TROUBLESHOOTING POINTS 40-12
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-13
CHECKS BEFORE TROUBLESHOOTING 40-15
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-17
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-19
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 40-53
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-57
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40-60
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-64
CONNECTORS LIST AND LAYOUT 40-66
CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) 40-82
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-86
FUSE LOCATION TABLE 40-92
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40-96
FAILURE CODES TABLE 40-98
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-108
FAILURE CODE [989L00] 40-108
FAILURE CODE [989M00] 40-109
FAILURE CODE [989N00] 40-110
FAILURE CODE [AQ20R1] 40-111
FAILURE CODE [B@BCNS] 40-112
FAILURE CODE [D19JKZ] 40-113
FAILURE CODE [D811MC] 40-116
FAILURE CODE [D862KA] 40-117
FAILURE CODE [D8ALKA] 40-118
FAILURE CODE [D8ALKB] 40-120
INDEX 00 INDEX AND FOREWORD
00-4 PC45MR-5, PC55MR-5
FAILURE CODE [D8AQKR] 40-122
FAILURE CODE [DAF0KT] 40-124
FAILURE CODE [DAF0MB] 40-125
FAILURE CODE [DAF0MC] 40-126
FAILURE CODE [DAF3KK] 40-127
FAILURE CODE [DAF9KQ] 40-129
FAILURE CODE [DAFGMC] 40-130
FAILURE CODE [DAFLKA] 40-131
FAILURE CODE [DAFLKB] 40-133
FAILURE CODE [DAFQKR] 40-135
FAILURE CODE [DB2QKR] 40-136
FAILURE CODE [DBH0MC] 40-140
FAILURE CODE [DBH2KK] 40-141
FAILURE CODE [DBH5KP] 40-144
FAILURE CODE [DBH5KP] 40-146
FAILURE CODE [DBH9KQ] 40-148
FAILURE CODE [DBHLKA] 40-150
FAILURE CODE [DBHLKB] 40-152
FAILURE CODE [DBHQKR] 40-154
FAILURE CODE [DDNRKA] 40-159
FAILURE CODE [DDNRKY] 40-161
FAILURE CODE [DDNS00] 40-163
FAILURE CODE [DDWLKA] 40-165
FAILURE CODE [DDWLKB] 40-167
FAILURE CODE [DFB1KZ] 40-169
FAILURE CODE [DFB3L8] 40-171
FAILURE CODE [DFB5KZ] 40-173
FAILURE CODE [DHS1MA] 40-175
FAILURE CODE [DHS5MA] 40-177
FAILURE CODE [DKULKA] 40-179
FAILURE CODE [DKULKB] 40-181
FAILURE CODE [DKULKY] 40-183
FAILURE CODE [DV00KB] 40-185
FAILURE CODE [DV20KB] 40-186
FAILURE CODE [DW43KA] 40-188
FAILURE CODE [DW43KB] 40-190
FAILURE CODE [DW43KY] 40-192
FAILURE CODE [DW4CKY] 40-193
FAILURE CODE [DXA8KA] 40-195
FAILURE CODE [DXA8KB] 40-197
FAILURE CODE [DXE7KA] 40-199
FAILURE CODE [DXE7KB] 40-201
FAILURE CODE [DXE7KY] 40-203
FAILURE CODE [DXEAKA] 40-205
FAILURE CODE [DXEAKB] 40-207
FAILURE CODE [DXEAKY] 40-209
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-211
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-211
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 40-217
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-219
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-221
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-224
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-225
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-226
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-227
00 INDEX AND FOREWORD INDEX
PC45MR-5, PC55MR-5 00-5
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-228
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40-229
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 40-231
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM 40-232
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE 40-233
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40-234
E-15 FUNCTION SWITCH DOES NOT OPERATE 40-235
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 40-236
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED 40-237
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE 40-238
E-19 ALARM BUZZER DOES NOT SOUND 40-240
E-20 ALARM BUZZER CANNOT BE CANCELED 40-241
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-242
E-22 SERVICE MODE CANNOT BE SELECTED 40-243
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 40-244
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 40-246
E-25 ALARM DOES NOT SOUND DURING TRAVEL 40-248
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 40-250
E-27 HORN DOES NOT SOUND 40-251
E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC) 40-253
E-29 HORN DOES NOT STOP SOUNDING 40-255
E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER SPEC) 40-257
E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP (CANOPY SPEC) 40-259
E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP
(CAB SPEC) 40-263
E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 40-267
E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE
40-269
E-35 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-271
E-36 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 40-272
E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 40-273
E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-275
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-276
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-276
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 40-277
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 40-278
H-3 TRAVEL OR BLADE DOES NOT OPERATE 40-279
H-4 SWING OR BLADE DOES NOT OPERATE 40-280
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 40-281
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 40-282
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 40-283
H-8 SWING AND BLADE SPEED OR POWER IS LOW 40-284
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40-285
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 40-286
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-287
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 40-289
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 40-290
H-14 BLADE DOES NOT OPERATE 40-291
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 40-292
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 40-293
H-17 SPEED OR POWER OF BOOM IS LOW 40-294
H-18 ARM SPEED OR POWER IS LOW 40-296
H-19 BUCKET SPEED OR POWER IS LOW 40-297
INDEX 00 INDEX AND FOREWORD
00-6 PC45MR-5, PC55MR-5
H-20 BLADE SPEED OR POWER IS LOW 40-298
H-21 BOOM SWING SPEED OR POWER IS LOW 40-300
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40-301
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE 40-302
H-24 HYDRAULIC DRIFT OF ARM IS LARGE 40-303
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-304
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 40-305
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 40-307
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER 40-308
H-29 MACHINE DOES NOT TRAVEL STRAIGHT 40-309
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 40-311
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 40-312
H-32 TRAVEL SPEED IS LOW 40-314
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE 40-316
H-34 ONE OF TRACKS DOES NOT RUN 40-317
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 40-319
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 40-320
H-37 SWINGS ONLY IN ONE DIRECTION 40-322
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) 40-324
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION 40-326
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT) 40-327
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT) 40-328
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 40-329
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 40-330
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 40-331
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40-332
TROUBLESHOOTING OF ENGINE (S-MODE) 40-333
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-333
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-334
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-335
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-336
S-4 ENGINE STARTABILITY IS POOR 40-337
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-339
S-6 ENGINE STOPS DURING OPERATION 40-341
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-342
S-8 ENGINE LACKS POWER 40-343
S-9 KDPF GETS CLOGGED IN A SHORT TIME 40-345
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-346
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-347
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-348
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-349
S-14 OIL PRESSURE DROPS 40-350
S-15 FUEL MIXES INTO ENGINE OIL 40-352
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-353
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-354
S-18 UNUSUAL NOISE IS HEARD 40-355
S-19 VIBRATION IS EXCESSIVE 40-356
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-357
50 DISASSEMBLY AND ASSEMBLY 50-1
00 INDEX AND FOREWORD INDEX
PC45MR-5, PC55MR-5 00-7
CONTENTS 50-2
ABBREVIATION LIST 50-5
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-11
HOW TO READ THIS MANUAL 50-11
COATING MATERIALS LIST 50-13
SPECIAL TOOLS LIST 50-17
SKETCHES OF SPECIAL TOOLS 50-22
ENGINE AND COOLING SYSTEM 50-23
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-23
REMOVE AND INSTALL STARTER ASSEMBLY 50-30
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-32
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-39
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 50-46
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-59
REMOVE AND INSTALL KDPF ASSEMBLY 50-64
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 50-68
POWER TRAIN 50-69
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-69
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50-73
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 50-75
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 50-82
UNDERCARRIAGE AND FRAME 50-84
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 50-84
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 50-87
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-89
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-92
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 50-95
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 50-98
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-101
HYDRAULIC SYSTEM 50-109
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 50-109
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 50-113
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-116
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 50-122
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY 50-128
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50-134
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50-137
WORK EQUIPMENT 50-140
REMOVE AND INSTALL BLADE ASSEMBLY 50-140
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-142
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 50-146
CAB AND ITS ATTACHMENTS 50-155
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY (CAB SPEC) 50-155
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC) 50-162
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 50-168
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 50-178
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-181
REMOVE AND INSTALL OPERATOR’S SEAT 50-190
REMOVE AND INSTALL SEAT BELT 50-192
ELECTRICAL SYSTEM 50-193
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-193
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 50-195
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-198
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50-201
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ABBREVIATION LIST 60-3
ENGINE AND COOLING SYSTEM 60-9
INDEX 00 INDEX AND FOREWORD
00-8 PC45MR-5, PC55MR-5
MAINTENANCE STANDARD FOR PTO 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM 60-10
POWER TRAIN 60-11
MAINTENANCE STANDARD OF SWING CIRCLE 60-11
MAINTENANCE STANDARD OF SWING MACHINERY 60-12
MAINTENANCE STANDARD OF SPROCKET 60-14
UNDERCARRIAGE AND FRAME 60-15
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 60-15
MAINTENANCE STANDARD OF IDLER 60-16
MAINTENANCE STANDARD OF TRACK ROLLER 60-18
MAINTENANCE STANDARD OF CARRIER ROLLER 60-19
MAINTENANCE STANDARD OF TRACK SHOE 60-20
MAINTENANCE STANDARD OF TRIPLE SHOE 60-22
MAINTENANCE STANDARD OF ROAD LINER 60-23
MAINTENANCE STANDARD FOR RUBBER SHOE 60-24
HYDRAULIC SYSTEM 60-25
MAINTENANCE STANDARD OF HYDRAULIC TANK 60-25
MAINTENANCE STANDARD OF MAIN PUMP 60-26
MAINTENANCE STANDARD OF PC-EPC VALVE 60-28
MAINTENANCE STANDARD OF SWING MOTOR 60-29
MAINTENANCE STANDARD OF TRAVEL MOTOR 60-31
MAINTENANCE STANDARD OF CONTROL VALVE 60-32
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60-44
MAINTENANCE STANDARD OF BLADE PPC VALVE 60-47
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 60-49
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60-51
MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE 60-54
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60-56
WORK EQUIPMENT 60-57
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-57
MAINTENANCE STANDARD OF BOOM CYLINDER 60-68
MAINTENANCE STANDARD OF ARM CYLINDER 60-69
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-71
MAINTENANCE STANDARD OF BLADE CYLINDER 60-73
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 60-74
80 APPENDIX 80-1
CONTENTS 80-2
ABBREVIATION LIST 80-3
AIR CONDITIONER SYSTEM 80-9
PRECAUTIONS FOR REFRIGERANT 80-9
AIR CONDITIONER COMPONENT 80-10
SPECIFICATIONS OF AIR CONDITIONER 80-11
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-12
OUTLINE OF REFRIGERATION CYCLE 80-13
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-15
AIR CONDITIONER UNIT 80-15
COMPRESSOR 80-17
CONDENSER 80-19
RECEIVER DRIER 80-21
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-22
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-24
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-27
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 80-31
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL
SYSTEM) 80-34
00 INDEX AND FOREWORD INDEX
PC45MR-5, PC55MR-5 00-9
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL
SYSTEMS) 80-38
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 80-39
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 80-40
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 80-41
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-42
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-43
HANDLE COMPRESSOR OIL 80-45
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
ABBREVIATION LIST 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-9
HYDRAULIC CIRCUIT DIAGRAM 90-13
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS) (1/2) 90-15
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS) (2/2) 90-17
ELECTRICAL CIRCUIT DIAGRAM 90-19
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-19
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (1/5) 90-23
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (2/5) 90-25
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (3/5) 90-27
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (4/5) 90-29
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (5/5) 90-31
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(1/5) 90-33
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(2/5) 90-35
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(3/5) 90-37
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(4/5) 90-39
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(5/5) 90-41
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (1/6) 90-43
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (2/6) 90-45
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (3/6) 90-47
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (4/6) 90-49
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (5/6) 90-51
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (6/6) 90-53
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(1/6) 90-55
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(2/6) 90-57
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(3/6) 90-59
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(4/6) 90-61
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(5/6) 90-63
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(6/6) 90-65
INDEX 1

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