Komatsu PC45MR-3, PC55MR-3 Mini Excavator Service Manual
682 pages · Publication SEN04597-07 · PC45MR-3, PC55MR-3
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What's inside
From the manual's own table of contents: 46 sections, 265 entries. See sample pages (PDF, 658 KB)
Shop Manual, contents binder, binder label and tabs
Index and foreword
Index
Foreword and general information
Specification
Specification and technical data
Structure, function and maintenance standard
Engine and cooling system
Power train
Undercarriage and frame
Hydraulic system, Part 1
Hydraulic system, Part 2
Hydraulic system, Part 3
Work equipment
Cab and its attachments
Electrical system
Standrad value table
Standard service value table
Testing and adjusting
Troubuleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by faivlure code
Troubleshooting of electrical system (E-mode)
Show all 46 sections
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
Disassembly and assembly
General information on disassembly and assembly
Engine and cooling system
Power train
Undercarriage and frame
Hydraulic system
Work equipment
Cab and its attachments
Electrical system
Diagrams and drawings
Hydraulic diagrams and drawings
Electrical diagrams and drawings
Index and foreword11 topics
- Composition of shop manual
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
Specification5 topics
- Specification dimension drawing
- Working range drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
Structure, function and maintenance standard36 topics
- Cooling system
- Power train
- Swing circle
- Swing machinery
- Track frame
- Idler cushion
- Idler
- Track roller
- Carrier roller
- Sprocket
- Track shoe
- Hydraulic components layout drawing
- Hydraulic tank, filter
- Center swivel joint
- Travel motor
- Hydraulic cylinder
- Solenoid valve
- Multi-control valve
- Hydraulic pump
- Control valve
- Anti-drop valve
- CLSS
- Operation for each function and valve
- Swing motor
- PPC valve
- Work equipment
- Dimensions of each part of work equipment
- Floor
- Engine control system
- Electric control system
- Auto-deceleration function
- Attachment proportional switch, breaker operation switch, work mode selection, flow control function
- KOMTRAX system
- Component parts of system
- Monitor system
- Sensors
Standard value table2 topics
- Standard service value table for engine related parts
- Standard service value table for chassis related parts
Testing and adjusting33 topics
- Tools for testing, adjusting, and troubleshooting
- Testing engine speed
- Testing exhaust gas color
- Testing and adjusting valve clearance
- Testing compression pressure
- Testing engine oil pressure
- Testing and adjusting fuel injection timing
- Testing and adjusting alternator belt tension
- Testing and adjusting air conditioner compressor belt tension
- Adjusting fuel control lever
- Testing clearance in swing circle bearings
- Testing and adjusting track shoe tension
- Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits
- Testing and adjusting LS differential pressure
- Adjusting PC valve
- Testing and adjusting control pump circuit oil pressure
- Testing solenoid valve output pressure
- Testing PPC valve output pressure
- Adjusting PPC valve
- Testing swing holding brake release pressure
- Testing and adjusting travel deviation
- Testing oil leakage from work equipment cylinder
- Bleeding air from each part
- Releasing residual pressure from hydraulic circuit
- Releasing residual pressure from hydraulic tank
- Pressurizing hydraulic tank
- How to open and close (tilt) floor
- Inspection procedures for diode
- Function and flow of operator and service mode
- How to start operation of KOMTRAX terminal
- Lamp display of KOMTRAX terminal
- Removal and installation of KOMTRAX terminal
- Preparation work for troubleshooting of electrical system
Troubleshooting98 topics
- User code and failure code list
- Fuse locations
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Classification and procedures of troubleshooting
- Information contained in troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller
- Failure code [DBH1KK] Unswitched power supply error
- Failure code [DBH2KK] Solenoid power supply error
- Failure code [DBH5KP] 5V sensor power supply output 0 error
- Failure code [DBH6KP] 5V sensor power supply output 1 error
- Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit)
- Failure code [DDWLKB] Breaker switch error (Hot short circuit)
- Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)
- Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)
- Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error
- Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault)
- Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit)
- Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)
- Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)
- Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)
- Failure code [D1E0KB] Motor power supply relay error (Ground fault)
- Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)
- Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)
- Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)
- Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)
- Failure code [DY10MA] Fuel control motor operation error
- Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side)
- Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)
- Failure code [DXEAKA] EPC valve (port A side) error (Disconnection)
- Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)
- Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit)
- Before carrying out troubleshooting of electrical system
- E-1 Engine does not start
- E-2 Engine does not stop
- E-3 When starting switch is turned ON, any item does not operate
- E-4 When starting switch is turned ON, some items do not operate
- E-5 Alarm buzzer is abnormal
- E-6 Engine oil pressure caution is turned ON
- E-7 Charge level caution is turned ON
- E-8 Preheating system does not operate or preheater does not become hot
- E-9 Coolant temperature gauge is abnormal
- E-10 Fuel level gauge is abnormal
- E-11 Service meter does not operate while engine is running
- E-12 2nd travel speed is not selected
- E-13 Working lamp does not light up
- E-15 Windshield wiper does not operate
- E-16 Windshield washer does not operate
- E-17 Defective air conditioner
- E-18 KOMTRAX system does not operate normally
- H-1 Speed or power of whole work equipment, travel, swing, and blade is low
- H-2 Engine speed lowers extremely or engine stalls
- H-3 Whole work equipment, travel system, swing system, and blade do not work
- H-4 Abnormal sound comes out from around hydraulic pump
- H-5 Fine control performance or response is low
- H-6 Speed or power of boom is low
- H-7 Speed or power of arm is low
- H-8 Speed or power of bucket is low
- H-9 Speed or power of boom swing is low
- H-10 Work equipment does not move singly
- H-11 Work equipment hydraulic drift is large
- H-12 Time lag of work equipment is large
- H-13 In compound operation of work equipment, speed of part loaded more is low
- H-14 Machine deviates during travel
- H-15 Travel speed or travel power is low (while work equipment is normal)
- H-16 Machine is not steered well or steering power is low
- H-17 Travel speed does not change
- H-18 Travel motor does not work
- H-19 Speed or power of swing is low
- H-20 Machine does not swing
- H-21 Swing acceleration performance is low
- H-22 Machine overruns when it stops swinging
- H-23 Large shock is made when machine stops swinging
- H-24 When upper structure stops swinging, it makes large sound
- H-25 Hydraulic drift of swing is large
- H-26 Speed or power of blade is low
- H-27 Blade does not move
- H-28 Hydraulic drift of blade is large
- Method of using troubleshooting charts
- S-1 Starting performance is poor
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly
- S-6 Engine lacks output (or lacks power)
- S-7 Exhaust smoke is black (incomplete combustion)
- S-8 Oil consumption is excessive (or exhaust smoke is blue)
- S-9 Oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
- S-12 Oil pressure drops
- S-13 Oil level rises (Entry of coolant/fuel)
- S-14 Coolant temperature becomes too high (overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
Disassembly and assembly28 topics
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- Removal and installation of fuel injection pump assembly
- Removal and installation of radiator assembly
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of engine and hydraulic pump assembly
- Removal and installation of swing motor and swing machinery assembly
- Disassembly and assembly of swing motor and swing machinery assembly
- Removal and installation of swing circle assembly
- Removal and installation of track shoe assembly
- Disassembly and assembly of idler assembly
- Disassembly and assembly of recoil spring assembly
- Disassembly and assembly of track roller assembly
- Disassembly and assembly of carrier roller assembly
- Removal and installation of revolving frame assembly
- Removal and installation of center swivel joint assembly
- Disassembly and assembly of center swivel joint assembly
- Removal and installation of work equipment pump assembly
- Disassembly and assembly of control valve assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Removal and installation of work equipment assembly
- Removal and installation of operator’s cab glass (stuck glass)
- Removal and installation of front window assembly
- Removal and installation of floor frame assembly (Canopy specification)
- Removal and installation of operator cab and floor frame assembly (Operator cab specification)
- Removal and installation of air conditioner unit assembly (If equipped)
Diagrams and drawings6 topics
- Hydraulic circuit diagram
- Electrical circuit diagram (1/3)
- Electrical circuit diagram (2/3)
- Electrical circuit diagram (3/3)
- Connector list and stereogram
- Related circuit diagram of proportional switch
Inside this manual
Real pages from this service manual (682 pages). Open the sample pages (PDF, 658 KB)
- Specifications, page 60: Specifications
- Troubleshooting, page 410: PC45MR-3,PC55MR-3
- Diagram, page 460: 200 Troubleshooting of electrical system (E-mode)
- Foldout diagram: Electrical circuit diagram (1/3)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC45MR-3, PC55MR-3 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual SEN04597-07$69.65
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 682 pages
Quantity one is the manual described above.
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Binder not included
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