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Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOAD

Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOAD

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Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOAD

Language : English
Pages : 1118
Downloadable : Yes
File Type : PDF
Size: 44.5 MB

TABLE OF CONTENTS:

Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOAD

SERIAL NUMBERS

PC45MR-5M0 F50001 and upPC55MR-5M0 F60001 and upINDEX
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 01-12
SPECIFICATIONS 01-14
WEIGHT TABLE 01-21
TABLE OF FUEL, COOLANT, AND LUBRICANTS 01-24
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-5M0, PC55MR-5M0
HYDRAULIC SYSTEM 10-47
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-47
CLSS 10-49
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10-52
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-55
WORK EQUIPMENT SYSTEM 10-115
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-115
STRUCTURE OF VALVE CONTROL 10-119
PPC LOCK SYSTEM 10-121
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10-123
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10-124
HYDRAULIC QUICK COUPLER WORKING SYSTEM 10-126
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-128
SWING SYSTEM 10-143
LAYOUT DRAWING OF SWING SYSTEM 10-143
COMPONENT PARTS OF SWING SYSTEM 10-144
TRAVEL SYSTEM 10-153
LAYOUT DRAWING OF TRAVEL SYSTEM 10-153
TRAVEL CONTROL SYSTEM DIAGRAM 10-155
COMPONENT PARTS OF TRAVEL SYSTEM 10-157
UNDERCARRIAGE AND FRAME 10-168
LAYOUT DRAWING OF UNDERCARRIAGE 10-168
IDLER CUSHION 10-169
WORK EQUIPMENT 10-170
STRUCTURE OF WORK EQUIPMENT 10-170
FUNCTION OF WORK EQUIPMENT 10-171
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10-172
CAB AND ITS ATTACHMENTS 10-173
ROPS CAB 10-173
TILT TYPE FLOOR 10-174
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-5M0 20-9
STANDARD VALUE TABLE FOR ENGINE: PC55MR-5M0 20-11
STANDARD VALUE TABLE FOR MACHINE 20-13
STANDARD VALUE TABLE FOR MACHINE: PC45MR-5M0 20-13
STANDARD VALUE TABLE FOR MACHINE: PC55MR-5M0 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 30-14
ENGINE AND COOLING SYSTEM 30-16
TEST ENGINE SPEED 30-16
TEST EXHAUST GAS COLOR 30-17
TEST AND ADJUST VALVE CLEARANCE 30-19
TEST COMPRESSION PRESSURE 30-21
TEST ENGINE OIL PRESSURE 30-23
BLEED AIR FROM FUEL SYSTEM 30-25
TEST FUEL CIRCUIT FOR LEAKAGE 30-26
TEST AND ADJUST ALTERNATOR BELT TENSION 30-27
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 30-28
POWER TRAIN 30-30
TEST SWING CIRCLE BEARING CLEARANCE 30-30
00 INDEX AND FOREWORD INDEX
PC45MR-5M0, PC55MR-5M0 00-3
UNDERCARRIAGE AND FRAME 30-31
TEST AND ADJUST TRACK TENSION 30-31
HYDRAULIC SYSTEM 30-33
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-33
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS
30-39
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30-48
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 30-54
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30-58
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30-60
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-64
TEST PPC VALVE OUTLET PRESSURE 30-68
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30-74
TEST SWING PARKING BRAKE RELEASE PRESSURE 30-75
TEST AND ADJUST TRAVEL DEVIATION 30-77
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-79
TEST OIL LEAKAGE 30-81
BLEED AIR FROM HYDRAULIC CIRCUIT 30-84
PRESSURIZE HYDRAULIC TANK 30-87
CAB AND ITS ATTACHMENTS 30-88
METHOD FOR OPENING AND CLOSING FLOOR UNIT 30-88
ELECTRICAL SYSTEM 30-94
SET AND OPERATE MACHINE MONITOR 30-94
METHOD FOR STARTING UP KOMTRAX TERMINAL 30-137
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-142
TEST DIODES 30-143
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 40-18
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-44
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40-47
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-51
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-53
FUSE LOCATION TABLE 40-59
FAILURE CODES TABLE 40-61
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-67
FAILURE CODE [6AZ0ZG] 40-67
FAILURE CODE [989L00] 40-69
FAILURE CODE [989M00] 40-70
FAILURE CODE [989N00] 40-71
FAILURE CODE [B@BCNS] 40-72
FAILURE CODE [D19JKZ] 40-73
FAILURE CODE [D811MC] 40-76
FAILURE CODE [D862KA] 40-77
FAILURE CODE [D8ALKA] 40-78
FAILURE CODE [D8ALKB] 40-80
FAILURE CODE [D8AQKR] 40-82
FAILURE CODE [DAF0KT] 40-84
FAILURE CODE [DAF0MB] 40-85
FAILURE CODE [DAF0MC] 40-86
FAILURE CODE [DAF3KK] 40-87
FAILURE CODE [DAF9KQ] 40-89
INDEX 00 INDEX AND FOREWORD
00-4 PC45MR-5M0, PC55MR-5M0
FAILURE CODE [DAFGMC] 40-90
FAILURE CODE [DAFLKA] 40-91
FAILURE CODE [DAFLKB] 40-93
FAILURE CODE [DAFQKR] 40-95
FAILURE CODE [DB2QKR] 40-96
FAILURE CODE [DBH0MC] 40-100
FAILURE CODE [DBH2KK] 40-101
FAILURE CODE [DBH5KP] 40-104
FAILURE CODE [DBH9KQ] 40-107
FAILURE CODE [DBHLKA] 40-110
FAILURE CODE [DBHLKB] 40-112
FAILURE CODE [DBHQKR] 40-114
FAILURE CODE [DDNRKA] 40-119
FAILURE CODE [DDNRKY] 40-121
FAILURE CODE [DDNS00] 40-123
FAILURE CODE [DDWLKA] 40-125
FAILURE CODE [DDWLKB] 40-127
FAILURE CODE [DFB1KZ] 40-129
FAILURE CODE [DFB2KZ] 40-131
FAILURE CODE [DFB3L8] 40-133
FAILURE CODE [DFB4L8] 40-136
FAILURE CODE [DFB5KZ] 40-139
FAILURE CODE [DFB6KZ] 40-141
FAILURE CODE [DHS1MA] 40-143
FAILURE CODE [DHS5MA] 40-145
FAILURE CODE [DHX1MA] 40-147
FAILURE CODE [DKULKA] 40-149
FAILURE CODE [DKULKB] 40-151
FAILURE CODE [DKULKY] 40-153
FAILURE CODE [DV00KB] 40-155
FAILURE CODE [DV20KB] 40-156
FAILURE CODE [DV20KB] 40-158
FAILURE CODE [DV50KB] 40-160
FAILURE CODE [DV50KY] 40-162
FAILURE CODE [DW43KA] 40-164
FAILURE CODE [DW43KB] 40-166
FAILURE CODE [DW43KY] 40-168
FAILURE CODE [DW4CKY] 40-169
FAILURE CODE [DXA8KA] 40-171
FAILURE CODE [DXA8KB] 40-174
FAILURE CODE [DXE7KA] 40-176
FAILURE CODE [DXE7KB] 40-178
FAILURE CODE [DXE7KY] 40-180
FAILURE CODE [DXE8KA] 40-182
FAILURE CODE [DXE8KB] 40-184
FAILURE CODE [DXE8KY] 40-186
FAILURE CODE [DXE9KA] 40-188
FAILURE CODE [DXE9KB] 40-190
FAILURE CODE [DXE9KY] 40-192
FAILURE CODE [DXEAKA] 40-194
FAILURE CODE [DXEAKB] 40-196
FAILURE CODE [DXEAKY] 40-198
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-200
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-200
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 40-207
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-209
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-211
00 INDEX AND FOREWORD INDEX
PC45MR-5M0, PC55MR-5M0 00-5
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-214
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-215
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-216
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-217
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-218
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40-219
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 40-221
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM 40-222
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE 40-223
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40-224
E-15 FUNCTION SWITCH DOES NOT OPERATE 40-225
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 40-226
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED 40-227
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE 40-228
E-19 ALARM BUZZER DOES NOT SOUND 40-230
E-20 ALARM BUZZER CANNOT BE CANCELED 40-231
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-232
E-22 SERVICE MODE CANNOT BE SELECTED 40-233
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 40-234
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 40-236
E-25 ALARM DOES NOT SOUND DURING TRAVEL 40-238
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 40-240
E-27 HORN DOES NOT SOUND 40-241
E-28 HORN DOES NOT STOP SOUNDING 40-244
E-29 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP
40-246
E-30 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 40-250
E-31 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE
40-252
E-32 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-254
E-33 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 40-255
E-34 Work equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 40-256
E-35 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-258
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-259
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-259
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 40-260
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 40-261
H-3 TRAVEL OR BLADE DOES NOT OPERATE 40-262
H-4 SWING OR BLADE DOES NOT OPERATE 40-263
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 40-264
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 40-265
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 40-266
H-8 SWING AND BLADE SPEED OR POWER IS LOW 40-267
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40-268
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 40-269
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-270
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 40-272
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 40-273
H-14 BLADE DOES NOT OPERATE 40-274
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 40-275
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 40-276
INDEX 00 INDEX AND FOREWORD
00-6 PC45MR-5M0, PC55MR-5M0
H-17 SPEED OR POWER OF BOOM IS LOW 40-277
H-18 ARM SPEED OR POWER IS LOW 40-279
H-19 BUCKET SPEED OR POWER IS LOW 40-280
H-20 BLADE SPEED OR POWER IS LOW 40-281
H-21 BOOM SWING SPEED OR POWER IS LOW 40-283
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40-284
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE 40-285
H-24 HYDRAULIC DRIFT OF ARM IS LARGE 40-286
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-287
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 40-288
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 40-290
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER 40-291
H-29 MACHINE DOES NOT TRAVEL STRAIGHT 40-292
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 40-294
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 40-295
H-32 TRAVEL SPEED IS LOW 40-297
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE 40-299
H-34 ONE OF TRACKS DOES NOT RUN 40-300
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 40-302
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 40-303
H-37 SWINGS ONLY IN ONE DIRECTION 40-305
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) 40-307
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION 40-309
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT) 40-310
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT) 40-311
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 40-312
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 40-313
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 40-314
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40-315
TROUBLESHOOTING OF ENGINE (S-MODE) 40-316
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-316
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-317
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-318
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-319
S-4 ENGINE STARTABILITY IS POOR 40-320
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-322
S-6 ENGINE STOPS DURING OPERATION 40-323
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-324
S-8 ENGINE LACKS POWER 40-325
S-9 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-327
S-10 OIL BECOMES CONTAMINATED QUICKLY 40-328
S-11 FUEL CONSUMPTION IS EXCESSIVE 40-329
S-12 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-330
S-13 OIL PRESSURE DROPS 40-331
S-14 FUEL MIXES INTO ENGINE OIL 40-332
S-15 WATER MIXES INTO ENGINE OIL (MILKY) 40-333
S-16 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-334
S-17 UNUSUAL NOISE IS HEARD 40-335
S-18 VIBRATION IS EXCESSIVE 40-336
00 INDEX AND FOREWORD INDEX
PC45MR-5M0, PC55MR-5M0 00-7
S-19 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-337
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
ABBREVIATION LIST 50-4
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-10
HOW TO READ THIS MANUAL 50-10
COATING MATERIALS LIST 50-12
SPECIAL TOOLS LIST 50-16
SKETCHES OF SPECIAL TOOLS 50-21
ENGINE AND COOLING SYSTEM 50-22
REMOVE AND INSTALL STARTER ASSEMBLY 50-22
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-24
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-31
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-38
POWER TRAIN 50-43
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-43
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50-47
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 50-49
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 50-56
UNDERCARRIAGE AND FRAME 50-58
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 50-58
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 50-61
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-63
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-66
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 50-69
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 50-72
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-75
HYDRAULIC SYSTEM 50-82
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 50-82
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 50-86
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-89
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50-95
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50-98
WORK EQUIPMENT 50-101
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-101
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 50-105
CAB AND ITS ATTACHMENTS 50-114
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 50-114
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 50-121
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 50-131
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-134
REMOVE AND INSTALL OPERATOR’S SEAT 50-142
REMOVE AND INSTALL SEAT BELT 50-144
ELECTRICAL SYSTEM 50-145
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-145
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 50-147
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-150
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50-153
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ABBREVIATION LIST 60-3
ENGINE AND COOLING SYSTEM 60-9
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
INDEX 00 INDEX AND FOREWORD
00-8 PC45MR-5M0, PC55MR-5M0
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 60-42
MAINTENANCE STANDARD OF BLADE PPC VALVE 60-45
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 60-47
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60-49
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60-52
WORK EQUIPMENT 60-53
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-53
MAINTENANCE STANDARD OF BOOM CYLINDER 60-65
MAINTENANCE STANDARD OF ARM CYLINDER 60-66
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-68
MAINTENANCE STANDARD OF BLADE CYLINDER 60-70
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 60-71
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 80-20
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-21
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-23
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-26
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 80-30
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL
SYSTEM) 80-33
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL
SYSTEMS) 80-37
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 80-38
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 80-39
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 80-40
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-41
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-42
00 INDEX AND FOREWORD INDEX
PC45MR-5M0, PC55MR-5M0 00-9
HANDLE COMPRESSOR OIL 80-44
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 (1/2) 90-13
HYDRAULIC CIRCUIT DIAGRAM (2/2) 90-15
ELECTRICAL CIRCUIT DIAGRAM 90-17
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-17
ELECTRICAL CIRCUIT DIAGRAM (1/6) 90-21
ELECTRICAL CIRCUIT DIAGRAM (2/6) 90-23
ELECTRICAL CIRCUIT DIAGRAM (3/6) 90-25
ELECTRICAL CIRCUIT DIAGRAM (4/6) 90-27
ELECTRICAL CIRCUIT DIAGRAM (5/6) 90-29
ELECTRICAL CIRCUIT DIAGRAM (6/6) 90-31
INDEX 1

DESCRIPTION:

Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOAD

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.

IMAGES PREVIEW OF THE MANUAL:

  

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