Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC45MR, PC55MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC45MR-3, PC55MR-3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN04597-06 – Hydraulic Excavator PC45MR-3, PC55MR-3 Shop Manual.pdf
TEN00306-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual.pdf
TEN00390-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual.pdf
TEN00508-01 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,576 pages
File Format: PDF
Language: English
SEN04597-06 – Hydraulic Excavator PC45MR-3, PC55MR-3 Shop Manual…2
COVER…2
00 Index and foreword…0
100 Index…3
Composition of shop manual…4
Table of contents…6
200 Foreword and general information…13
Safety notice…14
How to read the shop manual…20
Explanation of terms for maintenance standard…22
Handling of electric equipment and hydraulic component…24
Handling of connectors newly used for engines…33
How to read electric wire code…36
Precautions when carrying out work…39
Method of disassembling and connecting push-pull type coupler…42
Standard tightening torque table…45
Conversion table…49
01 Specification…0
100 Specification and technical data…55
Specification dimension drawing…56
Working range drawing…57
Specifications…58
Weight table…64
Table of fuel, coolant and lubricants…68
10 Structure, function and maintenance standard…0
100 Engine and cooling system…71
PTO…72
Cooling system…74
200 Power train…77
Power train…78
Swing circle…79
Swing machinery…80
300 Undercarriage and frame…83
Track frame…84
Idler cushion…85
Idler…86
Track roller…88
Carrier roller…89
Sprocket…90
Track shoe…91
410 Hydraulic system, Part 1…95
Hydraulic components layout drawing…96
Hydraulic tank, filter…97
Center swivel joint…99
Travel motor…100
Hydraulic cylinder…108
Solenoid valve…112
Multi-control valve…117
420 Hydraulic system, Part 2…119
Hydraulic pump…120
Control valve…128
Anti-drop valve…142
430 Hydraulic system, Part 3…149
CLSS…150
Operation for each function and valve…154
Swing motor…176
PPC valve…183
500 Work equipment…197
Work equipment…198
Dimensions of each part of work equipment…202
600 Cab and its attachments…207
Floor…208
700 Electrical system…211
Engine control system…212
Electrical control system…216
Auto-deceleration function…222
Attachment proportional switch, breaker operation switch, work mode selection, flow control function…224
KOMTRAX system…232
Component parts of system…235
Monitor system…236
Sensors…239
20 Standard value table…0
100 Standard service value table…243
Standard service value table for engine related parts…244
Standard service value table for chassis related parts…246
30 Testing and adjusting…0
100 Testing and adjusting…263
Tools for testing, adjusting, and troubleshooting…265
Testing engine speed…268
Testing exhaust gas color…269
Testing and adjusting valve clearance…270
Testing compression pressure…272
Testing engine oil pressure…273
Testing and adjusting fuel injection timing…274
Testing and adjusting alternator belt tension…278
Testing and adjusting air conditioner compressor belt tension…279
Adjusting fuel control lever…280
Testing clearance in swing circle bearings…281
Testing and adjusting track shoe tension…282
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits…283
Testing and adjusting LS differential pressure…288
Adjusting PC valve…291
Testing and adjusting control pump circuit oil pressure…292
Testing solenoid valve output pressure…294
Testing PPC valve output pressure…295
Adjusting PPC valve…297
Testing swing holding brake release pressure…298
Testing and adjusting travel deviation…299
Testing oil leakage from work equipment cylinder…301
Bleeding air from each part…303
Releasing residual pressure from hydraulic circuit…305
Releasing residual pressure from hydraulic tank…306
Pressurizing hydraulic tank…306
How to open and close (tilt) floor…307
Inspection procedures for diode…312
Function and flow of operator and service mode…314
How to start operation of KOMTRAX terminal…338
Lamp display of KOMTRAX terminal…342
Removal and installation of KOMTRAX terminal…345
Preparation work for troubleshooting of electrical system…346
40 Troubleshooting…0
100 General information on troubleshooting…349
Points to remember when troubleshooting…350
Sequence of events in troubleshooting…351
Checks before troubleshooting…352
Classification and procedures of troubleshooting…353
Information contained in troubleshooting table…354
Connection table for connector pin numbers…358
T- branch box and T- branch adapter table…394
110 Failure code table and fuse locations…399
User code and failure code list…400
Fuse locations…401
120 General information on troubleshooting…405
Points to remember when troubleshooting…406
Sequence of events in troubleshooting…407
Checks before troubleshooting…408
Classification and procedures of troubleshooting…409
Information contained in troubleshooting table…410
Connection table for connector pin numbers…414
T- branch box and T- branch adapter table…450
130 Troubleshooting by failure code…455
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller…457
Failure code [DBH1KK] Unswitched power supply error…459
Failure code [DBH2KK] Solenoid power supply error…461
Failure code [DBH5KP] 5V sensor power supply output 0 error…463
Failure code [DBH6KP] 5V sensor power supply output 1 error…464
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit)…465
Failure code [DDWLKB] Breaker switch error (Hot short circuit)…466
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)…467
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)…468
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error…469
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault)…470
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit)…472
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)…474
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)…476
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)…478
Failure code [D1E0KB] Motor power supply relay error (Ground fault)…480
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)…482
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)…484
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)…486
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)…488
Failure code [DY10MA] Fuel control motor operation error…490
Failure code [D1E0KA] Fuel control motor power supply relay contactsticking (NC side)…492
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)…494
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection)…496
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)…498
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit)…499
200 Troubleshooting of electrical system (E-mode)…501
Before carrying out troubleshooting of electrical system…502
E-1 Engine does not start…504
E-2 Engine does not stop…512
E-3 When starting switch is turned ON, any item does not operate…514
E-4 When starting switch is turned ON, some items do not operate…516
E-5 Alarm buzzer is abnormal…517
E-6 Engine oil pressure caution is turned ON…519
E-7 Charge level caution is turned ON…520
E-8 Preheating system does not operate or preheater does not become hot…522
E-9 Coolant temperature gauge is abnormal…524
E-10 Fuel level gauge is abnormal…528
E-11 Service meter does not operate while engine is running…532
E-12 2nd travel speed is not selected…535
E-13 Working lamp does not light up…538
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves…540
E-15 Windshield wiper does not operate…542
E-16 Windshield washer does not operate…544
E-17 Defective air conditioner…546
E-18 KOMTRAX system does not operate normally…554
300 Troubleshooting of hydraulic and mechanical system (H-mode)…557
Information contained in troubleshooting table…559
H-1 Speed or power of whole work equipment, travel, swing, and blade is low…560
H-2 Engine speed lowers extremely or engine stalls…564
H-3 Whole work equipment, travel system, swing system, and blade do not work…565
H-4 Abnormal sound comes out from around hydraulic pump…569
H-5 Fine control performance or response is low…569
H-6 Speed or power of boom is low…570
H-7 Speed or power of arm is low…571
H-8 Speed or power of bucket is low…572
H-9 Speed or power of boom swing is low…573
H-10 Work equipment does not move singly…573
H-11 Work equipment hydraulic drift is large…574
H-12 Time lag of work equipment is large…576
H-13 In compound operation of work equipment, speed of part loaded more is low…576
H-14 Machine deviates during travel…577
H-15 Travel speed or travel power is low (while work equipment is normal)…579
H-16 Machine is not steered well or steering power is low…580
H-17 Travel speed does not change…581
H-18 Travel motor does not work…582
H-19 Speed or power of swing is low…584
H-20 Machine does not swing…586
H-21 Swing acceleration performance is low…588
H-22 Machine overruns when it stops swinging…590
H-23 Large shock is made when machine stops swinging…591
H-24 When upper structure stops swinging, it makes large sound…591
H-25 Hydraulic drift of swing is large…592
H-26 Speed or power of blade is low…593
H-27 Blade does not move…594
H-28 Hydraulic drift of blade is large…595
400 Troubleshooting of engine (S-mode)…597
Method of using troubleshooting charts…599
S-1 Starting performance is poor…602
S-2 Engine does not start…603
S-3 Engine does not pick up smoothly…606
S-4 Engine stops during operations…607
S-5 Engine does not rotate smoothly…608
S-6 Engine lacks output (or lacks power)…609
S-7 Exhaust smoke is black (incomplete combustion)…610
S-8 Oil consumption is excessive (or exhaust smoke is blue)…611
S-9 Oil becomes contaminated quickly…612
S-10 Fuel consumption is excessive…613
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…614
S-12 Oil pressure drops…615
S-13 Oil level rises (Entry of coolant/fuel)…616
S-14 Coolant temperature becomes too high (overheating)…617
S-15 Abnormal noise is made…618
S-16 Vibration is excessive…619
50 Disassembly and assembly…0
100 General information on disassembly and assembly…621
How to read this manual…622
Coating materials list…624
Special tool list…627
Sketches of special tools…630
200 Engine and cooling system…633
Removal and installation of fuel injection pump assembly…634
Removal and installation of radiator assembly…636
Removal and installation of hydraulic oil cooler assembly…638
Removal and installation of engine and hydraulic pump assembly…642
300 Power train…649
Removal and installation of swing motor and swing machinery assembly…650
Disassembly and assembly of swing motor and swing machinery assembly…651
Removal and installation of swing circle assembly…656
400 Undercarriage and frame…659
Removal and installation of track shoe assembly…660
Disassembly and assembly of idler assembly…661
Disassembly and assembly of recoil spring assembly…663
Disassembly and assembly of track roller assembly…666
Disassembly and assembly of carrier roller assembly…667
Removal and installation of revolving frame assembly…668
500 Hydraulic system…671
Removal and installation of center swivel joint assembly…672
Disassembly and assembly of center swivel joint assembly…674
Removal and installation of work equipment pump assembly…678
Disassembly and assembly of control valve assembly…680
Disassembly and assembly of hydraulic cylinder assembly…681
600 Work equipment…687
Removal and installation of work equipment assembly…688
700 Cab and its attachments…691
Removal and installation of operator’s cab glass (stuck glass)…692
Removal and installation of front window assembly…701
Removal and installation of floor frame assembly (Canopy specification)…702
Removal and installation of operator cab and floor frame assembly (Operator cab specification)…705
800 Electrical system…709
Removal and installation of air conditioner unit assembly (If equipped)…710
Removal and installation of KOMTRAX terminal…713
90 Diagrams and Drawings…0
100 Hydraulic diagrams and drawings…715
Hydraulic circuit diagram…717
200 Electrical diagrams and drawings…0
Electrical circuit diagram (1/3)…724
Electrical circuit diagram (2/3)…725
Electrical circuit diagram (3/3)…726
Connector list and stereogram…727
Related circuit diagram of proportional swithch…728
TEN00306-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual…732
COVER…732
FOREWORD…733
FOREWORD…734
SAFETY INFORMATION…735
INTRODUCTION…737
DIRECTIONS OF MACHINE…737
PRODUCT INFORMATION…738
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…738
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…738
EPA NAMEPLATE…739
SERVICE METER LOCATION…739
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…740
CONTENTS…741
SAFETY…745
SAFETY…746
SAFETY LABELS…748
LOCATION OF SAFETY LABELS…748
SAFETY LABELS…749
GENERAL PRECAUTIONS…754
SAFETY MACHINE OPERATION…763
STARTING ENGINE…763
OPERATION…766
TRANSPORTATION…772
BATTERY…773
TOWING…775
LIFTING OBJECTS WITH BUCKET…776
SAFETY MAINTENANCE INFORMATION…777
OPERATION…785
MACHINE VIEW ILLUSTRATIONS…786
OVERALL MACHINE VIEW…786
CONTROLS AND GAUGES…787
DETAILED CONTROLS AND GAUGES…788
MONITORING SYSTEM…788
SWITCHES…794
CONTROL LEVERS AND PEDALS…798
WINDSHIELD…804
SLIDING DOOR…808
SLIDING WINDOW…808
EMERGENCY ESCAPE HAMMER…809
COVER WITH LOCK…810
ENGINE REAR COVER…811
COOLING COVER…811
MUD COVER…812
METHOD OF OPENING (TILTING) FLOOR…813
AUXILIARY ELECTRIC POWER…819
FUSE…819
BLOCK FUSE…820
OPERATION MANUAL STORAGE…821
TOOL BOX…821
ASHTRAY…821
HANDLING MACHINES EQUIPPED WITH KOMTRAX…822
MACHINE OPERATIONS AND CONTROLS…823
BEFORE STARTING ENGINE…823
STARTING ENGINE…841
AFTER STARTING ENGINE…845
STOPPING THE ENGINE…848
MACHINE OPERATION…849
STEERING THE MACHINE…854
SWINGING…856
WORK EQUIPMENT CONTROLS AND OPERATIONS…857
PROHIBITED OPERATIONS…859
GENERAL OPERATION INFORMATION…861
TRAVELING ON SLOPES…863
ESCAPE FROM MUD…865
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…866
BUCKET REPLACEMENT…868
PARKING MACHINE…869
MACHINE INSPECTION AFTER DAILY WORK…870
LOCKING…871
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…872
TRANSPORTATION…877
TRANSPORTATION PROCEDURE…877
LOADING AND UNLOADING WITH TRAILER…878
LIFTING MACHINE…884
COLD WEATHER OPERATION…887
COLD WEATHER OPERATION INFORMATION…887
CAB HEATER IN COLD WEATHER…888
AFTER DAILY WORK COMPLETION…889
AFTER COLD WEATHER SEASON…889
LONG TERM STORAGE…890
BEFORE STORAGE…890
DURING STORAGE…890
AFTER STORAGE…890
TROUBLES AND ACTIONS…892
RUNNING OUT OF FUEL…892
PHENOMENA THAT ARE NOT FAILURES…892
TOWING THE MACHINE…893
SEVERE JOB CONDITION…893
DISCHARGED BATTERY…894
OTHER TROUBLE…898
MAINTENANCE…901
MAINTENANCE INFORMATION…902
OUTLINE OF SERVICE…904
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…904
ELECTRIC SYSTEM MAINTENANCE…908
HANDLING HYDRAULIC SYSTEM…908
WEAR PARTS…909
WEAR PARTS LIST…909
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…910
TIGHTENING TORQUE SPECIFICATIONS…913
TIGHTENING TORQUE LIST…913
SAFETY CRITICAL PARTS…914
SAFETY CRITICAL PARTS LIST…914
MAINTENANCE SCHEDULE…915
MAINTENANCE SCHEDULE CHART…915
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…916
MAINTENANCE PROCEDURE…917
WHEN REQUIRED…917
CHECK BEFORE STARTING…950
EVERY 500 HOURS MAINTENANCE…951
EVERY 1000 HOURS MAINTENANCE…959
EVERY 1500 HOURS MAINTENANCE…962
EVERY 2000 HOURS MAINTENANCE…963
SPECIFICATIONS…969
SPECIFICATIONS…970
ATTACHMENTS, OPTIONS…973
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…974
SAFETY FIRST…974
ATTACHMENT INSTALLATION…975
BUCKET WITH HOOK…976
HOOK CONDITION…976
PROHIBITED OPERATIONS…976
AIR CONDITIONER…977
CONTROL PANEL AND COMPONENTS…977
AIR CONDITIONER CONTROLS…978
PHENOMENA THAT ARE NOT FAILURES…979
AIR CONDITIONER MAINTENANCE…980
WINDSHIELD WASHER…985
WINDSHIELD WASHER OPERATION…985
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…985
MACHINE READY FOR ATTACHMENT…986
LOCATIONS…986
HYDRAULIC CIRCUIT…989
ATTACHMENT OPERATIONS…992
LONG TERM STORAGE…993
SPECIFICATIONS…994
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…995
CONTROL PATTERN CHANGE PROCEDURE…995
MACHINE CONTROL PATTERNS…996
ATTACHMENT GUIDE…997
ATTACHMENT COMBINATIONS…997
RECOMMENDED ATTACHMENT OPERATIONS…998
HYDRAULIC BREAKER…998
INDEX…1003
TEN00390-03 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual…1007
COVER…1007
FOREWORD…1008
FOREWORD…1009
SAFETY INFORMATION…1010
INTRODUCTION…1012
DIRECTIONS OF MACHINE…1012
PRODUCT INFORMATION…1013
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1013
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1013
EPA NAMEPLATE…1014
SERVICE METER LOCATION…1014
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1015
CONTENTS…1016
SAFETY…1020
SAFETY…1021
SAFETY LABELS…1023
LOCATION OF SAFETY LABELS…1023
SAFETY LABELS…1024
GENERAL PRECAUTIONS…1029
SAFETY MACHINE OPERATION…1038
OPERATION…1041
TRANSPORTATION…1047
BATTERY…1048
TOWING…1050
LIFTING OBJECTS WITH BUCKET…1051
SAFETY MAINTENANCE INFORMATION…1052
OPERATION…1060
MACHINE VIEW ILLUSTRATIONS…1061
OVERALL MACHINE VIEW…1061
CONTROLS AND GAUGES…1062
DETAILED CONTROLS AND GAUGES…1063
MONITORING SYSTEM…1063
SWITCHES…1069
CONTROL LEVERS AND PEDALS…1073
WINDSHIELD…1079
SLIDING DOOR…1082
SLIDING WINDOW…1082
EMERGENCY ESCAPE HAMMER…1083
COVER WITH LOCK…1084
ENGINE REAR COVER…1085
COOLING COVER…1085
MUD COVER…1086
METHOD OF OPENING (TILTING) FLOOR…1087
AUXILIARY ELECTRIC POWER…1093
FUSE…1093
BLOCK FUSE…1094
OPERATION MANUAL STORAGE…1095
TOOL BOX…1095
ASHTRAY…1095
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1096
MACHINE OPERATIONS AND CONTROLS…1097
BEFORE STARTING ENGINE…1097
STARTING ENGINE…1115
AFTER STARTING ENGINE…1119
STOPPING THE ENGINE…1122
MACHINE OPERATION…1123
STEERING THE MACHINE…1128
SWINGING…1130
WORK EQUIPMENT CONTROLS AND OPERATIONS…1131
PROHIBITED OPERATIONS…1133
GENERAL OPERATION INFORMATION…1135
TRAVELING ON SLOPES…1137
ESCAPE FROM MUD…1139
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1140
BUCKET REPLACEMENT…1142
PARKING MACHINE…1143
MACHINE INSPECTION AFTER DAILY WORK…1144
LOCKING…1145
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1146
TRANSPORTATION…1151
TRANSPORTATION PROCEDURE…1151
LOADING AND UNLOADING WITH TRAILER…1152
LIFTING MACHINE…1158
COLD WEATHER OPERATION…1161
COLD WEATHER OPERATION INFORMATION…1161
CAB HEATER IN COLD WEATHER…1162
AFTER DAILY WORK COMPLETION…1163
AFTER COLD WEATHER SEASON…1163
LONG TERM STORAGE…1164
BEFORE STORAGE…1164
DURING STORAGE…1164
AFTER STORAGE…1164
TROUBLES AND ACTIONS…1166
RUNNING OUT OF FUEL…1166
PHENOMENA THAT ARE NOT FAILURES…1166
TOWING THE MACHINE…1167
SEVERE JOB CONDITION…1167
DISCHARGED BATTERY…1168
OTHER TROUBLE…1172
MAINTENANCE…1176
MAINTENANCE INFORMATION…1177
OUTLINE OF SERVICE…1179
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1179
ELECTRIC SYSTEM MAINTENANCE…1183
HANDLING HYDRAULIC SYSTEM…1183
WEAR PARTS…1184
WEAR PARTS LIST…1184
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1185
TIGHTENING TORQUE SPECIFICATIONS…1188
TIGHTENING TORQUE LIST…1188
SAFETY CRITICAL PARTS…1189
SAFETY CRITICAL PARTS LIST…1189
MAINTENANCE SCHEDULE…1190
MAINTENANCE SCHEDULE CHART…1190
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1191
MAINTENANCE PROCEDURE…1192
WHEN REQUIRED…1192
CHECK BEFORE STARTING…1225
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1225
EVERY 500 HOURS MAINTENANCE…1226
EVERY 1000 HOURS MAINTENANCE…1234
EVERY 1500 HOURS MAINTENANCE…1237
EVERY 2000 HOURS MAINTENANCE…1238
SPECIFICATIONS…1244
SPECIFICATIONS…1245
ATTACHMENTS, OPTIONS…1248
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1249
SAFETY FIRST…1249
ATTACHMENT INSTALLATION…1250
BUCKET WITH HOOK…1251
HOOK CONDITION…1251
PROHIBITED OPERATIONS…1251
AIR CONDITIONER…1252
CONTROL PANEL AND COMPONENTS…1252
AIR CONDITIONER CONTROLS…1253
PHENOMENA THAT ARE NOT FAILURES…1254
AIR CONDITIONER MAINTENANCE…1255
WINDSHIELD WASHER…1260
WINDSHIELD WASHER OPERATION…1260
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1260
MACHINE READY FOR ATTACHMENT…1261
LOCATIONS…1261
HYDRAULIC CIRCUIT…1267
ATTACHMENT OPERATIONS…1269
LONG TERM STORAGE…1274
SPECIFICATIONS…1274
OTHER TROUBLE…1275
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1277
CONTROL PATTERN CHANGE PROCEDURE…1277
MACHINE CONTROL PATTERNS…1278
ATTACHMENT GUIDE…1279
ATTACHMENT COMBINATIONS…1279
RECOMMENDED ATTACHMENT OPERATIONS…1280
HYDRAULIC BREAKER…1280
INDEX…1286
TEN00508-01 – Hydraulic Excavator PC45MR-3, PC55MR-3 Operation & Maintenance Manual…1290
COVER…1290
FOREWORD…1291
FOREWORD…1292
SAFETY INFORMATION…1293
INTRODUCTION…1295
DIRECTIONS OF MACHINE…1295
PROTECTIVE STRUCTURE…1295
PRODUCT INFORMATION…1296
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1296
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1296
EPA NAMEPLATE…1297
SERVICE METER LOCATION…1297
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1298
CONTENTS…1299
SAFETY…1303
SAFETY…1304
SAFETY LABELS…1306
LOCATION OF SAFETY LABELS…1306
SAFETY LABELS…1307
GENERAL PRECAUTIONS…1313
SAFETY MACHINE OPERATION…1322
STARTING ENGINE…1322
OPERATION…1325
TRANSPORTATION…1331
BATTERY…1332
TOWING…1334
LIFTING OBJECTS WITH BUCKET…1335
SAFETY MAINTENANCE INFORMATION…1336
OPERATION…1345
MACHINE VIEW ILLUSTRATIONS…1346
OVERALL MACHINE VIEW…1346
CONTROLS AND GAUGES…1347
DETAILED CONTROLS AND GAUGES…1348
MONITORING SYSTEM…1348
SWITCHES…1354
CONTROL LEVERS AND PEDALS…1358
WINDSHIELD…1364
SLIDING DOOR…1367
SLIDING WINDOW…1367
EMERGENCY ESCAPE HAMMER…1368
COVER WITH LOCK…1369
ENGINE REAR COVER…1371
COOLING COVER…1371
MUD COVER…1372
METHOD OF OPENING (TILTING) FLOOR…1373
AUXILIARY ELECTRIC POWER…1379
FUSE…1379
BLOCK FUSE…1380
OPERATION MANUAL STORAGE…1381
TOOL BOX…1381
ASHTRAY…1381
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1382
MACHINE OPERATIONS AND CONTROLS…1383
BEFORE STARTING ENGINE…1383
STARTING ENGINE…1401
AFTER STARTING ENGINE…1405
STOPPING THE ENGINE…1408
MACHINE OPERATION…1409
STEERING THE MACHINE…1414
SWINGING…1416
WORK EQUIPMENT CONTROLS AND OPERATIONS…1417
PROHIBITED OPERATIONS…1419
GENERAL OPERATION INFORMATION…1421
TRAVELING ON SLOPES…1423
ESCAPE FROM MUD…1425
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1426
BUCKET REPLACEMENT…1428
PARKING MACHINE…1429
MACHINE INSPECTION AFTER DAILY WORK…1430
LOCKING…1431
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1432
TRANSPORTATION…1437
TRANSPORTATION PROCEDURE…1437
LOADING AND UNLOADING WITH TRAILER…1438
LIFTING MACHINE…1444
COLD WEATHER OPERATION…1447
COLD WEATHER OPERATION INFORMATION…1447
CAB HEATER IN COLD WEATHER…1448
AFTER DAILY WORK COMPLETION…1449
AFTER COLD WEATHER SEASON…1449
LONG TERM STORAGE…1450
BEFORE STORAGE…1450
DURING STORAGE…1450
AFTER STORAGE…1450
TROUBLES AND ACTIONS…1452
RUNNING OUT OF FUEL…1452
PHENOMENA THAT ARE NOT FAILURES…1452
TOWING THE MACHINE…1453
SEVERE JOB CONDITION…1453
DISCHARGED BATTERY…1454
OTHER TROUBLE…1458
MAINTENANCE…1461
MAINTENANCE INFORMATION…1462
OUTLINE OF SERVICE…1464
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1464
ELECTRIC SYSTEM MAINTENANCE…1468
HANDLING HYDRAULIC SYSTEM…1468
WEAR PARTS…1469
WEAR PARTS LIST…1469
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1470
TIGHTENING TORQUE SPECIFICATIONS…1473
TIGHTENING TORQUE LIST…1473
SAFETY CRITICAL PARTS…1474
SAFETY CRITICAL PARTS LIST…1474
MAINTENANCE SCHEDULE…1475
MAINTENANCE SCHEDULE CHART…1475
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1477
MAINTENANCE PROCEDURE…1478
WHEN REQUIRED…1478
CHECK BEFORE STARTING…1510
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1510
EVERY 100 HOURS MAINTENANCE…1511
EVERY 500 HOURS MAINTENANCE…1512
EVERY 1000 HOURS MAINTENANCE…1520
EVERY 1500 HOURS MAINTENANCE…1523
EVERY 2000 HOURS MAINTENANCE…1524
SPECIFICATIONS…1531
SPECIFICATIONS…1532
ATTACHMENTS, OPTIONS…1535
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1536
SAFETY FIRST…1536
ATTACHMENT INSTALLATION…1537
BUCKET WITH HOOK…1538
HOOK CONDITION…1538
PROHIBITED OPERATIONS…1538
AIR CONDITIONER…1539
CONTROL PANEL AND COMPONENTS…1539
AIR CONDITIONER CONTROLS…1540
PHENOMENA THAT ARE NOT FAILURES…1541
AIR CONDITIONER MAINTENANCE…1542
WINDSHIELD WASHER…1547
WINDSHIELD WASHER OPERATION…1547
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1547
MACHINE READY FOR ATTACHMENT…1548
LOCATIONS…1548
HYDRAULIC CIRCUIT…1554
ATTACHMENT OPERATIONS…1556
LONG TERM STORAGE…1561
SPECIFICATIONS…1561
OTHER TROUBLE…1562
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1564
CONTROL PATTERN CHANGE PROCEDURE…1564
MACHINE CONTROL PATTERNS…1565
ATTACHMENT GUIDE…1566
ATTACHMENT COMBINATIONS…1566
RECOMMENDED ATTACHMENT OPERATIONS…1567
HYDRAULIC BREAKER…1567
INDEX…1573
Komatsu Hydraulic Excavator PC45MR, PC55MR Repair Service Manuals