SM PC45MR-3

SEN04597-03
HYDRAULIC PC45MR -3
EXCAVATOR
PC55MR -3
PC45MR- 5001
SERIAL NUMBERS and up
PC55MR- 15001
SEN04599-03
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC45MR-3,
PC55MR-3
Machine model Serial number

PC45MR-3 5001 and up
00 Index and foreword 00

100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC45MR-3, PC55MR-3 00-100 1

100 Index
SEN04599-03 Composition of shop manual
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04597-03
00 Index and foreword .................................................................................................................... SEN04598-03

100 Index .................................................................................................................................. SEN04599-03 q
200 Foreword and general information ..................................................................................... SEN04600-01 q
01 Specification ............................................................................................................................... SEN04601-00

100 Specification and technical data......................................................................................... SEN04602-00
10 Structure, function and maintenance standard........................................................................... SEN04603-01

100 Engine and cooling system ................................................................................................ SEN04604-00
200 Power train......................................................................................................................... SEN04605-00
300 Undercarriage and frame ................................................................................................... SEN04606-00
410 Hydraulic system, Part 1 .................................................................................................... SEN04607-01 q
420 Hydraulic system, Part 2 .................................................................................................... SEN04608-00
430 Hydraulic system, Part 3 .................................................................................................... SEN04609-00
500 Work equipment................................................................................................................. SEN04610-00
600 Cab and its attachments .................................................................................................... SEN04611-00
700 Electrical system ................................................................................................................ SEN04612-01 q
20 Standrad value table................................................................................................................... SEN04613-00

100 Standard service value table.............................................................................................. SEN04648-00
30 Testing and adjusting ................................................................................................................. SEN04614-00

100 Testing and adjusting ......................................................................................................... SEN04649-00
40 Troubuleshooting........................................................................................................................ SEN04615-00
100 General information on troubleshooting............................................................................. SEN04650-00
200 Troubleshooting of electrical system (E-mode).................................................................. SEN04651-00
300 Troubleshooting of hydraulic and mechanical system (H-mode) ....................................... SEN04652-00
400 Troubleshooting of engine (S-mode).................................................................................. SEN04653-00
50 Disassembly and assembly........................................................................................................ SEN04616-00

100 General information on disassembly and assembly .......................................................... SEN04654-00
200 Engine and cooling system ................................................................................................ SEN04655-00
300 Power train......................................................................................................................... SEN04656-00
00-100 2 PC45MR-3, PC55MR-3

100 Index
Composition of shop manual SEN04599-03
400 Undercarriage and frame ...................................................................................................SEN04657-00

500 Hydraulic system ................................................................................................................SEN04658-00
600 Work equipment .................................................................................................................SEN04659-00
700 Cab and its attachments.....................................................................................................SEN04660-00
800 Electrical system ................................................................................................................SEN04661-00
90 Diagrams and drawings..............................................................................................................SEN04617-02

100 Hydraulic diagrams and drawings ......................................................................................SEN04618-01 q
200 Electrical diagrams and drawings.......................................................................................SEN04619-02 q
PC45MR-3, PC55MR-3 00-100 3

100 Index
SEN04599-03 Table of contents
Table of contents 1
00 Index and foreword
100 Index SEN04599-03
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN04600-01
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 8
Explanation of terms for maintenance standard............................................................................................ 10
Handling of electric equipment and hydraulic component............................................................................. 12
Handling of connectors newly used for engines............................................................................................ 21
How to read electric wire code ...................................................................................................................... 24
Precautions when carrying out work ............................................................................................................. 27
Method of disassembling and connecting push-pull type coupler................................................................. 30
Standard tightening torque table ................................................................................................................... 33
Conversion table ........................................................................................................................................... 37
01 Specification
100 Specification and technical data SEN04602-00
Specification dimension drawing ................................................................................................................... 2
Working range drawing ................................................................................................................................. 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 10
Table of fuel, coolant and lubricants.............................................................................................................. 14
10 Structure, function and maintenance standard

100 Engine and cooling system SEN04604-00
PTO............................................................................................................................................................... 2
Cooling system.............................................................................................................................................. 4
200 Power train SEN04605-00
Power train .................................................................................................................................................... 2
Swing circle ................................................................................................................................................... 3
Swing machinery........................................................................................................................................... 4
300 Undercarriage and frame SEN04606-00
Track frame ................................................................................................................................................... 2
Idler cushion.................................................................................................................................................. 3
Idler ............................................................................................................................................................... 4
Track roller .................................................................................................................................................... 6
Carrier roller .................................................................................................................................................. 7
Sprocket ........................................................................................................................................................ 8
Track shoe..................................................................................................................................................... 9
410 Hydraulic system, Part 1 SEN04607-01
Hydraulic components layout drawing .......................................................................................................... 2
Hydraulic tank, filter....................................................................................................................................... 3
Center swivel joint ......................................................................................................................................... 5
Travel motor .................................................................................................................................................. 6
Hydraulic cylinder.......................................................................................................................................... 14
Solenoid valve............................................................................................................................................... 18
Multi-control valve ......................................................................................................................................... 23
Hydraulic pump ............................................................................................................................................. 2
Control valve ................................................................................................................................................. 10
00-100 4 PC45MR-3, PC55MR-3

100 Index
Table of contents SEN04599-03

CLSS ............................................................................................................................................................. 2
Operation for each function and valve........................................................................................................... 6
Swing motor................................................................................................................................................... 28
PPC valve...................................................................................................................................................... 35
500 Work equipment SEN04610-00
Work equipment ............................................................................................................................................ 2
Dimensions of each part of work equipment ................................................................................................. 6
600 Cab and its attachments SEN04611-00
Floor .............................................................................................................................................................. 2
700 Electrical system SEN04612-01
Engine control system ................................................................................................................................... 2
Electrical control system................................................................................................................................ 6
Auto-deceleration function............................................................................................................................. 12
Attachment proportional switch, breaker operation switch, work mode selection, flow control function........ 14
KOMTRAX system ........................................................................................................................................ 21
Component parts of system........................................................................................................................... 24
Monitor system .............................................................................................................................................. 25
Sensors ......................................................................................................................................................... 28
20 Standard value table

100 Standard service value table SEN04648-00
Standard service value table for engine related parts.................................................................................... 2
Standard service value table for chassis related parts .................................................................................. 4
30 Testing and adjusting

100 Testing and adjusting SEN04649-00
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Testing engine speed..................................................................................................................................... 6
Testing exhaust gas color .............................................................................................................................. 7
Testing and adjusting valve clearance........................................................................................................... 8
Testing compression pressure....................................................................................................................... 10
Testing engine oil pressure............................................................................................................................ 11
Testing and adjusting fuel injection timing ..................................................................................................... 12
Testing and adjusting alternator belt tension ................................................................................................. 16
Testing and adjusting air conditioner compressor belt tension ...................................................................... 17
Adjusting fuel control lever ............................................................................................................................ 18
Testing clearance in swing circle bearings .................................................................................................... 19
Testing and adjusting track shoe tension....................................................................................................... 20
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits ........ 21
Testing and adjusting LS differential pressure............................................................................................... 26
Adjusting PC valve ........................................................................................................................................ 29
Testing and adjusting control pump circuit oil pressure ................................................................................. 30
Testing solenoid valve output pressure ......................................................................................................... 32
Testing PPC valve output pressure ............................................................................................................... 33
Adjusting PPC valve ...................................................................................................................................... 35
Testing swing holding brake release pressure............................................................................................... 36
Testing and adjusting travel deviation............................................................................................................ 37
Testing oil leakage from work equipment cylinder ......................................................................................... 39
Bleeding air from each part ........................................................................................................................... 41
Releasing residual pressure from hydraulic circuit ........................................................................................ 43
Releasing residual pressure from hydraulic tank........................................................................................... 44
Pressurizing hydraulic tank............................................................................................................................ 44
How to open and close (tilt) floor ................................................................................................................... 45
Inspection procedures for diode .................................................................................................................... 50
How to start operation of KOMTRAX terminal............................................................................................... 51
Lamp display of KOMTRAX terminal............................................................................................................. 55
PC45MR-3, PC55MR-3 00-100 5

100 Index
Removal and installation of KOMTRAX terminal .......................................................................................... 58

Preparation work for troubleshooting of electrical system............................................................................. 59
40 Troubleshooting
100 General information on troubleshooting SEN04650-00
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Checks before troubleshooting ..................................................................................................................... 4
Classification and procedures of troubleshooting ......................................................................................... 5
Information contained in troubleshooting table ............................................................................................. 6
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
200 Troubleshooting of electrical system (E-mode) SEN04651-00
Before carrying out troubleshooting of electrical system............................................................................... 2
E-1 Engine does not start.............................................................................................................................. 4
E-2 Engine does not stop.............................................................................................................................. 12
E-3 When starting switch is turned ON, any item does not operate.............................................................. 14
E-4 When starting switch is turned ON, some items do not operate............................................................. 16
E-5 Alarm buzzer is abnormal....................................................................................................................... 17
E-6 Engine oil pressure caution is turned ON............................................................................................... 19
E-7 Charge level caution is turned ON.......................................................................................................... 20
E-8 Preheating system does not operate or preheater does not become hot............................................... 22
E-9 Coolant temperature gauge is abnormal ................................................................................................ 24
E-10 Fuel level gauge is abnormal................................................................................................................ 28
E-11 Service meter does not operate while engine is running ...................................................................... 32
E-12 2nd travel speed is not selected ........................................................................................................... 35
E-13 Working lamp does not light up ............................................................................................................ 38
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK,
work equipment still moves.................................................................................................................. 40
E-15 Windshield wiper does not operate ...................................................................................................... 42
E-16 Windshield washer does not operate ................................................................................................... 44
E-17 Defective air conditioner ....................................................................................................................... 46
E-18 KOMTRAX system does not operate normally..................................................................................... 54
300 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04652-00
Information contained in troubleshooting table ............................................................................................. 3
H-1 Speed or power of whole work equipment, travel, swing, and blade is low............................................ 4
H-2 Engine speed lowers extremely or engine stalls .................................................................................... 8
H-3 Whole work equipment, travel system, swing system, and blade do not work....................................... 9
H-4 Abnormal sound comes out from around hydraulic pump...................................................................... 13
H-5 Fine control performance or response is low ......................................................................................... 13
H-6 Speed or power of boom is low .............................................................................................................. 14
H-7 Speed or power of arm is low ................................................................................................................. 15
H-8 Speed or power of bucket is low............................................................................................................. 16
H-9 Speed or power of boom swing is low .................................................................................................... 17
H-10 Work equipment does not move singly ................................................................................................ 17
H-11 Work equipment hydraulic drift is large................................................................................................. 18
H-12 Time lag of work equipment is large..................................................................................................... 20
H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 20
H-14 Machine deviates during travel............................................................................................................. 21
H-15 Travel speed or travel power is low (while work equipment is normal) ................................................ 23
H-16 Machine is not steered well or steering power is low ........................................................................... 24
H-17 Travel speed does not change ............................................................................................................. 25
H-18 Travel motor does not work.................................................................................................................. 26
H-19 Speed or power of swing is low ............................................................................................................ 28
H-20 Machine does not swing....................................................................................................................... 30
H-21 Swing acceleration performance is low ................................................................................................ 32
H-22 Machine overruns when it stops swinging............................................................................................ 34
00-100 6 PC45MR-3, PC55MR-3

100 Index
H-23 Large shock is made when machine stops swinging............................................................................ 35

H-24 When upper structure stops swinging, it makes large sound ............................................................... 35
H-25 Hydraulic drift of swing is large ............................................................................................................. 36
H-26 Speed or power of blade is low............................................................................................................. 37
H-27 Blade does not move ............................................................................................................................ 38
H-28 Hydraulic drift of blade is large ............................................................................................................. 39
400 Troubleshooting of engine (S-mode) SEN04653-00
Method of using troubleshooting charts......................................................................................................... 3
S-1 Starting performance is poor................................................................................................................... 6
S-2 Engine does not start .............................................................................................................................. 7
S-3 Engine does not pick up smoothly .......................................................................................................... 10
S-4 Engine stops during operations .............................................................................................................. 11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ...................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) .................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive ............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................... 18
S-12 Oil pressure drops................................................................................................................................. 19
S-13 Oil level rises (Entry of coolant/fuel) ..................................................................................................... 20
S-14 Coolant temperature becomes too high (overheating).......................................................................... 21
S-15 Abnormal noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
50 Disassembly and assembly

100 General information on disassembly and assembly SEN04654-00
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools ............................................................................................................................... 10
200 Engine and cooling system SEN04655-00
Removal and installation of fuel injection pump assembly ............................................................................ 2
Removal and installation of radiator assembly .............................................................................................. 4
Removal and installation of hydraulic oil cooler assembly ............................................................................ 6
Removal and installation of engine and hydraulic pump assembly ............................................................... 10
300 Power train SEN04656-00
Removal and installation of swing motor and swing machinery assembly .................................................... 2
Disassembly and assembly of swing motor and swing machinery assembly................................................ 3
Removal and installation of swing circle assembly........................................................................................ 8
400 Undercarriage and frame SEN04657-00
Removal and installation of track shoe assembly.......................................................................................... 2
Disassembly and assembly of idler assembly ............................................................................................... 3
Disassembly and assembly of recoil spring assembly .................................................................................. 5
Disassembly and assembly of track roller assembly ..................................................................................... 8
Disassembly and assembly of carrier roller assembly................................................................................... 9
Removal and installation of revolving frame assembly.................................................................................. 10
500 Hydraulic system SEN04658-00
Removal and installation of center swivel joint assembly.............................................................................. 2
Disassembly and assembly of center swivel joint assembly ......................................................................... 4
Removal and installation of work equipment pump assembly....................................................................... 8
Disassembly and assembly of control valve assembly.................................................................................. 10
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 11
600 Work equipment SEN04659-00
Removal and installation of work equipment assembly................................................................................. 2
700 Cab and its attachments SEN04660-00
Removal and installation of operator’s cab glass (stuck glass) ..................................................................... 2
PC45MR-3, PC55MR-3 00-100 7

100 Index
Removal and installation of front window assembly...................................................................................... 11

Removal and installation of floor frame assembly (Canopy specification) .................................................... 12
Removal and installation of operator cab and floor frame assembly (Operator cab specification) ............... 15
800Electrical system SEN04661-00
Removal and installation of air conditioner unit assembly (If equipped) ....................................................... 2
90 Diagrams and drawings

100 Hydraulic diagrams and drawings SEN04618-01
Hydraulic circuit diagram............................................................................................................................... 3
200 Electrical diagrams and drawings SEN04619-02
Electrical circuit diagram (1/3)....................................................................................................................... 3
Connector list and stereogram ...................................................................................................................... 9
00-100 8 PC45MR-3, PC55MR-3

100 Index
PC45MR-3, PC55MR-3 00-100 9

SEN04599-03
PC45MR-3, PC55MR-3 Hydraulic excavator

Form No. SEN04599-03
©2009 KOMATSU
All Rights Reserved
Printed in Japan 07-09
00-100 10
SEN04600-01
PC45MR-3,PC55MR-3
SEN04600-01
HYDRAULIC EXCAVATOR
Shop Manual
PC45MR-3
PC55MR-3

00 Index and Foreword

200 Foreword and general information
Safety notice - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
How to read the shop manual- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Explanation of terms for maintenance standard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Handling of electric equipment and hydraulic component - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Handling of connectors newly used for engines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
How to read electric wire code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Precautions when carrying out work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Method of disassembling and connecting push-pull type coupler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
Standard tightening torque table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
Conversion table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
PC45MR-3,PC55MR-3 00-200 1
SEN04600-01 Safety notice
Safety notice
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific pur-
pose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
1. General precautions
k Mistakes in operation are extremely dan- 7) If welding repairs are needed, always have a
gerous. Read the Operation and Mainte- trained and experienced welder carry out the
nance Manual carefully before operating work. When carrying out welding work,
the machine. In addition, read this manu- always wear welding gloves, apron, shielding
al and understand its contents before goggles, cap and other clothes suited for
starting the work. welding work.
1) Before carrying out any greasing or repairs, 8) Before starting work, warm up your body
read all the safety labels stuck to the thoroughly to start work under good condi-
machine. For the locations of the safety tion.
labels and detailed explanation of precau- 9) Avoid continuing work for long hours and
tions, see the Operation and Maintenance take rests at proper intervals to keep your
Manual. body in good condition.
2) Decide a place in the repair workshop to Take rests in specified safe places.
keep tools and removed parts. Always keep
the tools and parts in their correct places. Safety points
Always keep the work area clean and make 1 Good arrangement
sure that there is no dirt, water, or oil on the 2 Correct work clothes
floor. Smoke only in the areas provided for 3 Following work standard
smoking. Never smoke while working. 4 Making and checking signals
Prohibition of operation and handling by unli-
3) When carrying out any operation, always 5
censed workers
wear safety shoes and helmet. Do not wear 6 Safety check before starting work
loose work clothes, or clothes with buttons Wearing protective goggles(for cleaning or grind-
missing. 7
ing work)
q Always wear safety glasses when hitting Wearing shielding goggles and protectors(for
8
parts with a hammer. welding work)
q Always wear safety glasses when grind- 9 Good physical condition and preparation
ing parts with a grinder, etc. Precautions against work which you are not used
10
to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the operating
procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5) Only qualified workers must carry out work
and operation which require license or quali-
fication.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones of them. Before starting work, thor-
oughly check the tools, machine, forklift,
service car, etc.
00-200 2 PC45MR-3,PC55MR-3
Safety notice SEN04600-01
2. Preparation work 5) When raising a heavy component (heavier

1) Before adding oil or making any repairs, park than 25kg), use a hoist or crane. Before
the machine on a hard and level ground, and starting work, check that the slings (wire
apply the parking brake and block the wheels ropes, chains, and hooks) are free from
or tracks to prevent the machine from damage. Always use slings which have
moving. ample capacity and install them to proper
2) Before starting work, lower the work equip- places. Operate the hoist or crane slowly to
ment (blade, ripper, bucket, etc.) to the prevent the component from hitting any other
ground. If this is not possible, insert the lock part. Do not work with any part still raised by
pin or use blocks to prevent the work equip- the hoist or crane.
ment from falling. In addition, be sure to lock 6) When removing a cover which is under
all the control levers and hang warning tag on internal pressure or under pressure from a
them. spring, always leave 2 bolts in diagonal posi-
3) When disassembling or assembling, support tions. Loosen those bolts gradually and alter-
the machine with blocks, jacks, or stands nately to release the pressure, and then
before starting work. remove the cover.
4) Remove all mud and oil from the steps or 7) When removing components, be careful not
other places used to get on and off the to break or damage the electrical wiring.
machine. Always use the handrails, ladders Damaged wiring may cause electrical fires.
or steps when getting on or off the machine. 8) When removing piping, stop the fuel or oil
Never jump on or off the machine. If it is from spilling out. If any fuel or oil drips onto
impossible to use the handrails, ladders or the floor, wipe it up immediately. Fuel or oil
steps, use a stand to provide safe footing. on the floor can cause you to slip and can
even start fires.
3. Precautions during work 9) As a general rule, do not use gasoline to
1) Before disconnecting or removing compo- wash parts. Do not use it to clean electrical
nents of the oil, water, or air circuits, first parts, in particular.
release the pressure completely from the 10)Be sure to assemble all parts again in their
circuit. When removing the oil filler cap, a original places. Replace any damaged parts
drain plug, or an oil pressure pickup and parts which must not be reused with new
plug,loosen it slowly to prevent the oil from parts. When installing hoses and wires, be
spurting out. sure that they will not be damaged by contact
2) The coolant and oil in the circuits are hot with other parts when the machine is oper-
when the engine is stopped, so be careful not ated.
to get scalded. Wait for the oil and coolant to 11)When installing high pressure hoses and
cool before carrying out any work on the oil or tubes, make sure that they are not twisted.
water circuits. Damaged hoses and tubes are dangerous,
3) Before starting work, stop the engine. When so be extremely careful when installing
working on or around a rotating part, in partic- hoses and tubes for high pressure circuits. In
ular, stop the engine. When checking the addition, check that connections of them are
machine without stopping the engine correct.
(measuring oil pressure, revolving speed, 12)When assembling or installing parts, always
temperature, etc.), take extreme care not to tighten them to the specified torques. When
get or caught in rotating parts or moving installing protective parts such as guards, or
parts. parts which vibrate violently or rotate at high
4) Before starting work, remove the leads from speeds, be particularly careful to check that
the battery. Always remove the lead from the they are installed correctly.
negative (–) terminal first. 13)When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14)When measuring hydraulic pressure, check
that the measuring tools are correctly
installed.
PC45MR-3,PC55MR-3 00-200 3
15)Take care when removing or installing the

tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
16)If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
00-200 4 PC45MR-3,PC55MR-3
4. Precautions for sling work and making signals

1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.) 8) When installing wire ropes to an angular
4) Measure the weight of the load by the eye load, apply pads to protect the wire ropes. If
and check its center of gravity. the load is slippery, apply proper material to
5) Use proper sling according to the weight of prevent the wire rope from slipping.
the load and method of slinging. If too thick 9) Use the specified eyebolts and fix wire ropes,
wire ropes are used to sling a light load, the chains, etc. to them with shackles, etc.
load may slip and fall. 10)Apply wire ropes to the middle portion of the
6) Do not sling a load with 1 wire rope alone. If hook.
it is slung so, it may rotate and may slip out of q Slinging near the tip of the hook may
the rope. Install 2 or more wire ropes cause the rope to slip off the hook during
symmetrically. hoisting. The hook has the maximum
k Slinging with 1 rope may cause turn- strength at the middle portion.
ing of the load during hoisting, un-
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 °, as a rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with 2 ropes,
each of which is allowed to sling up to 9.8kN 11)Do not use twisted or kinked wire ropes.
{1,000kg} vertically, at various hanging
12)When lifting up a load, observe the following.
angles. When the 2 ropes sling a load verti-
q Wind in the crane slowly until wire ropes
cally, up to 19.6kN {2,000kg} of total weight
are stretched. When settling the wire
can be suspended. This weight is reduced to
ropes with the hand, do not grasp them
9.8kN {1,000kg} when the 2 ropes make a
but press them from above. If you grasp
hanging angle of 120 °. If the 2 ropes sling a
them, your fingers may be caught.
19.6kN {2,000kg } load at a lifting angle of
q After the wire ropes are stretched, stop
150 ° , each of them is subjected to a force as
the crane and check the condition of the
large as 39.2kN {4,000kg}.
slung load, wire ropes, and pads.
PC45MR-3,PC55MR-3 00-200 5
qIf the load is unstable or the wire rope or 13)If the hoist stops because of a power failure,
chains are twisted, lower the load and lift turn the power switch OFF. When turning on
it up again. a switch which was turned OFF by the
q Do not lift up the load at an angle. ground fault circuit interrupter, check that the
13)When lowering a load, observe the following. devices related to that switch are not in oper-
q When lowering a load, stop it temporarily ation state.
at 30cm above the floor, and then lower it 14)If you find an obstacle around the hoist, stop
slowly. the operation.
q Check that the load is stable, and then re- 15)After finishing the work, stop the hoist at the
move the sling. specified position and raise the hook to at
q Remove kinks and dirt from the wire least 2mabove the floor. Do not leave the
ropes and chains used for the sling work, sling installed to the hook.
and put them in the specified place.
7. Selecting wire ropes
5. Precautions for using mobile crane 1) Select adequate ropes depending on the
a Read the Operation and Maintenance Manu- weight of parts to be hoisted, referring to the
al of the crane carefully in advance and oper- table below.
ate the crane safely. Wire ropes
(Standard "Z" twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
kWhen raising a heavy part (heavier than 25 Nominal diameter
Allowable load
kg), use a hoist, etc. In Disassembly and of rope
assembly, the weight of a part heavier mm kN ton
than 25 kg is indicated after the mark of 10 8.8 0.9
4.
12 12.7 1.3
14 17.3 1.7
1) Before starting work, inspect the wire ropes, 16 22.6 2.3
brake, clutch, controller, rails, over wind stop 18 28.6 2.9
device, ground fault circuit interrupter, crane 20 35.3 3.6
collision prevention device, and power appli- 25 55.3 5.6
cation warning lamp, and check safety. 30 79.6 8.1
40 141.6 14.4
2) Observe the signals for sling work. 50 221.6 22.6
3) Operate the hoist at a safe place. 60 318.3 32.4
4) Check the direction indicator plates (east, a The allowable load is one-sixth of the
west, south, and north) and the directions of breaking strength of the rope used (Safe-
the control buttons without fail. ty coefficient: 6).
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch on a position where
it will not be an obstacle to work and
passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
00-200 6 PC45MR-3,PC55MR-3
8. Precautions for disconnecting and

connecting hoses and tubes in air condi-
tioner circuit
1) Disconnection
k For the environment, the air condition-
er of this machine uses the refrigerant
(air conditioner gas: R134a) which has
fewer factors of the depletion of the
ozone layer. However, it does not
mean that you may discharge the re-
frigerant into the atmosphere as it is.
Be sure to recover the refrigerant
when disconnecting the refrigerant
gas circuit and then reuse it. a For tightening torque, see the precau-
a Ask professional traders for collecting tions for installation in each section of
and filling operation of refrigerant "Disassembly and assembly".
(R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight and your skin may be fro-
zen. Accordingly, put on safety glass-
es, safety gloves and safety clothes
when recovering or adding the refrig-
erant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that each O-ring (1) is not
damaged or deteriorated.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings (1).
a Example of O-ring (Fitted to every
joint of hoses and tubes)
PC45MR-3,PC55MR-3 00-200 7
SEN04600-01 How to read the shop manual
How to read the shop manual
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.
Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section contains table of contents, and safety and basic information. If any revision of the shop man-
ual is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and meth-
od of adjusting each part. The standard values and judgment criteria for testing and adjusting are ex-
plained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard

This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.
80. Appendix
The section explains the equipment which can not be included in the other sections. This section explains
the structure, function, testing, adjusting, and troubleshooting fo the equipment.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
00-200 8 PC45MR-3,PC55MR-3
How to read the shop manual SEN04600-01
This section explains the method of remanufacturing and repairing engine and replacing parts.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.
q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (1),(2),(3)...)
q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving standards are

a Caution
necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when selecting hoisting
Weight
wire, or when working posture is important, etc.
3 Tightening torque Places that require special attention for tightening torque during assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5 Oil, coolant Places where oil, etc. must be added, and capacity.
6 Drain Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, convention-
ally used Gravitational System of units is indicated in parentheses { }.
PC45MR-3,PC55MR-3 00-200 9
SEN04600-01 Explanation of terms for maintenance standard
Explanation of terms for maintenance standard

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a tempo-
rary standard size is set and an allowable dif-
ference from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference
from the standard size is called the "toler-
ance".
q The tolerance with the symbols of + or – is in-
dicated on the right side of the standard size.
Example:
Standard size Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of the

shaft to be fitted to that hole are indicated by
the same standard size and different toler-
ances of the hole and shaft. The tightness of
fit is decided by the tolerance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
-0.030 +0.046
60
-0.076 0
00-200 10 PC45MR-3,PC55MR-3
Explanation of terms for maintenance standard SEN04600-01
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are as- q Parts can be used until the clearance be-
sembled is called the "standard clearance", tween them is increased to a certain limit.
which is indicated by the range from the min- The limit at which those parts cannot be used
imum clearance to the maximum clearance. is called the "clearance limit".
q When some parts are repaired, the clearance q If the clearance between the parts exceeds
is generally adjusted to the standard clear- the clearance limit, they must be replaced or
ance. repaired.
q A value of performance and function of new
products or equivalent is called the "standard 6. Interference limit
value", which is indicated by a range or a tar- q The allowable maximum interference be-
get value. tween the hole of a part and the shaft of an-
q When some parts are repaired, the value of other part to be assembled is called the
performance/function is set to the standard "interference limit".
value. q The interference limit shows the repair limit of
the part of smaller tolerance.
3. Standard interference q If the interference between the parts exceeds
q When the diameter of a hole of a part shown the interference limit, they must be replaced
in the given standard size and tolerance table or repaired.
is smaller than that of the mating shaft, the
difference between those diameters is called
the "interference".
q The range (A – B) from the difference (A) be-
tween the minimum size of the shaft and the
maximum size of the hole to the difference
(B) between the maximum size of the shaft
and the minimum size of the hole is the "stan-
dard interference".
q After repairing or replacing some parts, mea-
sure the size of their hole and shaft and
check that the interference is in the standard
range.
4. Repair limit and allowable value or allowable

dimension
q The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the "repair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product is worn to the allowable value, it
must be checked or repaired. Since the per-
missible value is estimated from various tests
or experiences in most cases, however, it
must be judged after considering the operat-
ing condition and customer's requirement.
PC45MR-3,PC55MR-3 00-200 11
SEN04600-01 Handling of electric equipment and hydraulic component
Handling of electric equipment and hydraulic component
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Han-
dling hydraulic equipment" (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about 10 times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are connected to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated to cause defective
contact or the wire is broken.
00-200 12 PC45MR-3,PC55MR-3
Handling of electric equipment and hydraulic component SEN04600-01
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering
may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to splash water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface
between the male and female pins, the oil will
not let the electricity pass, so there will be
defective contact. If there is oil or grease
stuck to the connector, wipe it off with a dry
cloth or blow it dry with compressed air and
spray it with a contact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.
PC45MR-3,PC55MR-3 00-200 13
3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.
2] When removing from clips
q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.
q When removing a connector from a

clip, pull the connector in a parallel di-
rection to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the housing
may break.
3] Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust, dirt,
oil, or water from getting in the connector
portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
00-200 14 PC45MR-3,PC55MR-3
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or water a If there is any damage or breakage,
stuck to the connector pins (mating replace the connector.
portion).
Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
2] Fix the connector securely.

Align the position of the connector
correctly, and then insert it securely. For
connectors with the lock stopper, push in
the connector until the stopper clicks into
position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp has been re-
moved, be sure to return it to its origi-
nal position. Check also that there are
no loose clamps.
PC45MR-3,PC55MR-3 00-200 15
3) Heavy duty wire connector (DT 8-pole, 12-pole)

Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing both sides of locks (a) and incomplete setting of
(b), pull out female connector (2). ((a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a),(b): Locks
00-200 16 PC45MR-3,PC55MR-3
4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact,
so remove all oil and water from the
compressed air before blowing with
air.
2] Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.
3] Carry out a continuity test on the connector.

After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
PC45MR-3,PC55MR-3 00-200 17
4. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand.
6) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the controller. Fit an arc
welding ground close to the welding point.
5. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related con-
nectors several times to check.
3) Always connect any disconnected connec-
tors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary ab-
normality displays will be generated.
4) When carrying out troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), move the related wiring and
connectors several times and check that
there is no change in the reading of the
tester.
a If there is any change, there is probably
defective contact in that circuit.
00-200 18 PC45MR-3,PC55MR-3
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to check the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be checked with special test equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
4. Do not let any dirt or dust get in during refilling operations

Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
PC45MR-3,PC55MR-3 00-200 19
5. Change hydraulic oil when the temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment is used to remove the ultra
fine (about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-200 20 PC45MR-3,PC55MR-3
Handling of connectors newly used for engines SEN04600-01
Handling of connectors newly used for engines

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
Slide lock type Pull lock type (PACKARD-2)

(FRAMATOME-3,FRAMATOME-2) q 95–170,12V140 engines
q 95–170,12V140 engines q Various temperature sensors
q Various pressure sensors and NE speed Examples)
sensor Intake air temperature sensor in intake mani-
Examples) fold: TIM
Intake air pressure sensor in intake manifold: Fuel temperature sensor: TFUEL
PIM(125,170,12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor:POIL(125,170,12V140 Coolant temperature sensor: TWTR, etc.
engines)
Oil pressure switch(95,107,114 engines) Disconnect
Ne speed sensor of flywheel housing: Disconnect the connector by pulling lock (B) (on the
NE(95-170,12V140 engines) wiring harness side) of connector (2) outward.
Ambient pressure sensor:
PAMB(125,170,12V140 engines)
Disconnect
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector(1)
toward you.
a Even if lock L2 is pressed, connector(1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A
with a small screwdriver while press lock
L2 , and then pull out connector(1) toward
you.
Connect
Insert the connector straight until it "clicks".
Connect
PC45MR-3,PC55MR-3 00-200 21
SEN04600-01 Handling of connectors newly used for engines
Push lock type (1)

q 95, 107, 114 engines While pressing up lock (C)of the connector with
Example) Fuel pressure sensor in common rail flat-head screwdriver [1], pull out connector (3) in
(BOSCH-03) the direction of the arrow.
Disconnect
While pressing lock (C), pull out connector (3) in the
direction of the arrow.
q 114 engine
Connect
Push lock type (2)

q 107, 114 engines
Example) Intake air pressure/temperature
q 107 engine sensor in intake manifold(SUMITOMO-04)
Disconnect
While pressing lock (D), pull out connector (4) in the
direction of the arrow.
a If the lock is on the underside, use flat-head

screwdriver[1]since you cannot insert your fin-
gers.
Connect
00-200 22 PC45MR-3,PC55MR-3
Handling of connectors newly used for engines SEN04600-01
Push lock type (3) Turn-housing type (Round green connector)

q 95, 125 – 170, 12V140 engines q 140 engine
Example) Intake air pressure sensor in intake
Disconnect manifold.
While pressing lock (E) of the connector, pull out (CANNON-04): PIM etc.
connector (5) in the direction of the arrow.
Disconnect
Example) Fuel pressure sensor in common rail: 1) Turn housing (H1) in the direction of the
PFUEL etc. (AMP-3) arrow.
a When connector is unlocked, housing
(H1)becomes heavy to turn.
2) Pull out housing (H1)in the direction of the
arrow.
a Housing (H1)is left on the wiring harness
side.
Example) Injection pressure control valve of fuel

supply pump: PCV (SUMITOMO-2)
Connect
1) Insert the connector to the end, while setting
its groove.
2) Turn housing (H1)in the direction of the arrow
until it "clicks".
Examples) Speed sensor of fuel supply pump:G

(SUMITOMO-3)
a Pull the connector straight up.
Connect
PC45MR-3,PC55MR-3 00-200 23
SEN04600-01 How to read electric wire code
How to read electric wire code

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal
No. of 0.85
Indicates color of wire by color code.

Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their
symbols are not indicated on the diagram.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thick-
ness and outside diameter and different from AV and AVS in material of the cover.
(Table 1)
Using tem-
Type Symbol Material perature Example of use
range (°C)
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above.)
bile Insulator Soft polyvinyl chloride
-30 to +60
Thin-cover Conductor
appliance General wiring
low-voltage wire AVS
(nominal No. 3 and below.)
for automobile Insulator Soft polyvinyl chloride
Heat-resistant Conductor General wiring in extremely cold
appliance
low-voltage wire AEX -50 to +110 district, wiring at high ambient tem-
Heat-resistant crosslinked
for automobile Insulator perature place
polyethylene
00-200 24 PC45MR-3,PC55MR-3
How to read electric wire code SEN04600-01
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -

Cov-
AV Standard - - - - - - - 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
"f" of nominal No. denotes "flexible".
PC45MR-3,PC55MR-3 00-200 25
SEN04600-01 How to read electric wire code
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - D -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of cir-
Br BrW BrR BrY BrB - - -
cuit
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
00-200 26 PC45MR-3,PC55MR-3
Precautions when carrying out work SEN04600-01
Precautions when carrying out work
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the work.
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 00210
03 07376-70315 02789 - 00315
04 07376 - 70422 02789 - 00422
05 07376 - 70522 02789 - 00522
06 07376 - 70628 02789 - 00628
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 22.5 22.5 34
PC45MR-3,PC55MR-3 00-200 27
SEN04600-01 Precautions when carrying out work
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) .
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with liquid gasket.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, hydraulic pumps
and other hydraulic component removed for repair, always bleed the air as follows:
1] Start the engine and run at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder100 mm from the end of its stroke.
3] Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4] After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing work

1) Refilling with coolant, oil and grease
q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run
the engine to circulate the coolant through the system . Then check the coolant level again.
q If the hydraulic component has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
q If the piping or hydraulic component have been removed, always bleed the air from the system after
reassembling the parts.
a For details, see Testing and adjusting, "Bleeding air".
q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2) Checking cylinder head and manifolds for looseness

Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see "Disassembly and assembly" .
00-200 28 PC45MR-3,PC55MR-3
Precautions when carrying out work SEN04600-01
3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
PC45MR-3,PC55MR-3 00-200 29
SEN04600-01 Method of disassembling and connecting push-pull type coupler
Method of disassembling and connecting push-pull type coupler
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3) . (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.
00-200 30 PC45MR-3,PC55MR-3
Method of disassembling and connecting push-pull type coupler SEN04600-01
Type 2
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
PC45MR-3,PC55MR-3 00-200 31
SEN04600-01 Method of disassembling and connecting push-pull type coupler
Type 3
1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until the sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
00-200 32 PC45MR-3,PC55MR-3
Standard tightening torque table SEN04600-01
Standard tightening torque table

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.

Thread diameter of bolt Width across flats Tightening torque
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 –20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 –608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Figure A a Figure B
Remarks: The widths across flats by thread diameter of flanged bolts (marked with "*") in Fig. A are the
ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
PC45MR-3,PC55MR-3 00-200 33
SEN04600-01 Standard tightening torque table
2. Table of tightening torques for split flanged bolts

a Unless there are special instructions, tighten split flanged bolts to the torque below.
mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}
Nominal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03,04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
Varies depending on
05,06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of connector.
10,12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}
Nominal No.
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-200 34 PC45MR-3,PC55MR-3
Standard tightening torque table SEN04600-01
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
No. of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16 – 18UNF 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal
diameter across Nominal No. –Number
Thread diameter (mm)
of pipe flats Range Target of threads, type of
(Reference)
(mm) (mm) thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1 – 14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in( ) are slso used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine
series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 - -
PC45MR-3,PC55MR-3 00-200 35
SEN04600-01 Standard tightening torque table
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine se-
ries to the torque below.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 en-
gine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
00-200 36 PC45MR-3,PC55MR-3
Conversion table SEN04600-01
Conversion table
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PC45MR-3,PC55MR-3 00-200 37
SEN04600-01 Conversion table
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 5 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-200 38 PC45MR-3,PC55MR-3
Liters to U.K. Gallons

1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
PC45MR-3,PC55MR-3 00-200 39
SEN04600-01 Conversion table
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-200 40 PC45MR-3,PC55MR-3
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 47 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 68 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 69 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
PC45MR-3,PC55MR-3 00-200 41
SEN04600-01
©2009 KOMATSU
All Rights Reserved
00-200 42
SEN04602-00
HYDRAULIC EXCAVATOR
PC45MR-3,
PC55MR-3

01 Specification 1
100 Specification and technical data
Specification dimension drawing..................................................................................................................... 2
Working range drawing ................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................. 10
Table of fuel, coolant and lubricants.............................................................................................................. 14
PC45MR-3, PC55MR-3 01-100 1

SEN04602-00 Specification dimension drawing
Specification dimension drawing1
Item Unit PC45MR-3 PC55MR-3
Operating Canopy specification 4,795 5,160

kg
weight Cab specification 4,915 5,280
3
Bucket capacity m 0.14 0.16
Komatsu Komatsu
Engine model — 4D88E-6 4D88E-6
Diesel engine Diesel engine
Rated engine output kW{HP}/rpm 28.5 {38.2} / 2,400 28.5 {38.2} / 2,400
A Overall length mm 5,330 5,550
B Overall height mm 2,550 2,550
C Overall width mm 1,960 1,960
D Shoe width mm 400 400
Tail swing Canopy specification 1,060 1,060

E radius mm
Cab specification 1,060 1,060
F Overall length of track mm 2,520 2,520
G Distance between tumbler centers mm 2,000 2,000
Minimum ground clearance mm 290 290
Travel speed (Low / High) km/h 2.8 / 4.6 2.8 / 4.6
Continuous swing speed rpm 9.0 9.0
01-100 2 PC45MR-3, PC55MR-3

Working range drawing SEN04602-00
Working range drawing 1
Working range (mm) PC45MR-3 PC55MR-3
A Max. digging radius 6,040 6,220

B Max. digging depth 3,670 3,800
C Max. digging height 5,730 5,945
D Max. vertical wall depth 3,060 3,020
E Max. dumping height 4,060 4,230
Swing radius of work equipment 2,410 2,270
F
<Values in ( ) are boom swing radii> (1,830) (1,740)
G Max. reach at ground level 5,885 6,070
H Blade lifting height 430 430
I Blade lowering depth 330 330
PC45MR-3, PC55MR-3 01-100 3

SEN04602-00 Specifications
Specifications 1
PC45MR-3
Machine model
Canopy specification Cab specification
Serial number 5001 and up

Bucket capacity m3 0.14 0.14
Operating weight kg 4,795 4,915

[4,860] [4,980]
Max. digging depth mm 3,670 3,670
Max. vertical wall depth mm 3,060 3,060
Max. digging reach mm 6,040 6,040
Working ranges
Max. reach at ground level mm 5,885 5,885

Max. digging height mm 5,730 5,730
Max. dumping height mm 4,060 4,060
Performance
Bucket offset mm 630 / 880 630 / 880

Max. blade lifting height mm 430 430
Max. blade lowering depth mm 330 330
Max. digging force (bucket) kN {kg} 33.9 {3,460} 33.9 {3,460}
Swing max. slope angle deg. 19.0 19.0
Travel speed km/h 2.8 / 4.6 2.8 / 4.6
Gradeability deg. 30 30
24.9 {0.25} 25.9 {0.26}
Ground pressure kPa {kg/cm2} [25.9 {0.26}] [26.9 {0.27}]
Overall length (for transport) mm 5,330 5,330
Overall width mm 1,960 1,960
Overall height (for transport) mm 2,550 2,550
Ground clearance of conterweight mm 608 608
Min. ground clearance mm 290 290
Tail swing radius mm 1,060 1,060
Dimensions
Min. swing radius of work equipment

(at boom swing) mm 2,410 (1,830) 2,410 (1,830)
Height of work equipment at min. swing
radius mm 4,140 4,140
Overall width of crawler mm 1,960 1,960

Overall length of crawler mm 2,520 2,520
Distance between tumbler centers mm 2,000 2,000
Track gauge mm 1,560 1,560
Machine cab height mm 1,395 1,395
Blade width x height mm 1,960 × 355 1,960 × 355
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe
specification are shown.)
a Values in [ ] are for steel shoe specification.
a Operating weight of machine with full tank of fuel and a 75 kg operator (ISO 6016).
01-100 4 PC45MR-3, PC55MR-3

Specifications SEN04602-00
PC45MR-3
Machine model

Model 4D88E-6
Type 4-cycle, water cooled, in-line direct injection type
No. of cylinders – bore x stroke mm 4 – 88 × 90
Piston displacement l {cc} 2.189 {2,189}
Flywheel horsepower kW/rpm {HP/rpm} 28.5 / 2,400 {38.2 / 2,400}
Performance
Maximum torque Nm/rpm {kgm/rpm} 137 / 1,440 {14.0 / 1,440}

Engine
High idle speed rpm 2,550

Low idle speed rpm 1,175
Starting motor 12 V, 2.3 kW
Alternator 12 V, 40 A
Battery (*1) 12 V, 72 Ah × 1 (115D31L)
Radiator
• Core type CF68-4
Carrier roller 1 on each side
Undercarriage
Track roller 4 on each side

Track shoe (Rubber shoe) Unit-type rubber crawler
Track shoe (Steel shoe) Assembly-type double grouser: 39 each side
Type x no. Variable displacement piston type × 1, gear type × 1
Hydraulic pump
Theoretical capacity cm /rev

3
22.3 × 2 + 14.1 + 5.2
Set pressure
For travel, work equipment MPa {kg/cm2} 26.5 {270}
For swing MPa {kg/cm2} 18.6 {190}
For blade MPa {kg/cm2} 21.6 {220}
Hydraulic system
Control
Type x no. 9-spool type × 1

valve
Control method Hydraulic assist type

Variable-displacement piston motor (with counter-
Travel motor
Hydraulic
balance valve, parking brake) × 2

motor
Fixed-displacement piston motor (with brake

Swing motor
valve, swing shaft brake) × 1
Hydraulic tank Box-shaped, open type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)
*1: The battery capacity (Ah) is based on 5-hour rate.
PC45MR-3, PC55MR-3 01-100 5

PC45MR-3
Machine model

Cylinder type Double acting piston
Boom cylinder
Inside diameter of cylinder mm 90

Outside diameter of piston rod mm 50
Stroke mm 696
Max. distance between pins mm 1,739
Min. distance between pins mm 1,043
Arm cylinder

Stroke mm 649
Min. distance between pins mm 982
Work equipment cylinder

Hydraulic system
Bucket cylinder

Stroke mm 580
Boom swing cylinder

Stroke mm 630
Max. distance between pins mm 1,573.5
Min. distance between pins mm 943.5
Blade cylinder

Stroke mm 140
Max. distance between pins mm 642.5
01-100 6 PC45MR-3, PC55MR-3

PC55MR-3
Machine model

Bucket capacity m3 0.16 0.16
Operating weight kg 5,160 5,280

[5,225] [5,345]
Max. digging depth mm 3,800 3,800
Max. vertical wall depth mm 3,020 3,020
Max. digging reach mm 6,220 6,220
Working ranges
Max. reach at ground level mm 6,070 6,070

Max. digging height mm 5,945 5,945
Max. dumping height mm 4,230 4,230
Performance
Bucket offset mm 630 / 880 630 / 880

Max. blade lifting height mm 430 430
Max. blade lowering depth mm 330 330
Max. digging force (bucket) kN {kg} 39.0 {3,980} 39.0 {3,980}
Swing max. slope angle deg. 19.0 19.0
Travel speed km/h 2.8 / 4.6 2.8 / 4.6
Gradeability deg. 30 30
30.0 {0.31} 36.3 {0.37}
Ground pressure kPa {kg/cm2} [31.1 {0.32}] [37.3 {0.38}]
Overall length (for transport) mm 5,550 5,550
Overall width mm 1,960 1,960
Overall height (for transport) mm 2,550 2,550
Ground clearance of conterweight mm 608 608
Min. ground clearance mm 290 290
Tail swing radius mm 1,060 1,060
Dimensions
Min. swing radius of work equipment

(at boom swing) mm 2,270 (1,740) 2,270 (1,740)
Height of work equipment at min. swing
radius mm 4,475 4,475
Overall width of crawler mm 1,960 1,960

Overall length of crawler mm 2,520 2,520
Distance between tumbler centers mm 2,000 2,000
Track gauge mm 1,560 1,560
Machine cab height mm 1,395 1,395
Blade width x height mm 1,960 × 355 1,960 × 355
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specifi-
cation are shown.)
a Values in [ ] are for the steel shoe specification.
a Operating weight of machine with full tank of fuel and a 75 kg operator (ISO 6016).
PC45MR-3, PC55MR-3 01-100 7

PC55MR-3
Machine model

Model 4D88E-6
Type 4-cycle, water cooled, in-line direct injection type
No. of cylinders – bore x stroke mm 4 – 88 × 90
Piston displacement l {cc} 2.189 {2,189}
Flywheel horsepower kW/rpm {HP/rpm} 28.5 / 2,400 {38.2 / 2,400}
Performance
Maximum torque Nm/rpm {kgm/rpm} 137 / 1,440 {14.0 / 1,440}

Engine
High idle speed rpm 2,550

Low idle speed rpm 1,175
Starting motor 12 V, 2.3 kW
Alternator 12 V, 40 A
Battery (*1) 12 V, 72 Ah × 1 (115D31L)
Radiator
• Core type CF68-4
Carrier roller 1 on each side
Undercarriage
Track roller 4 on each side

Track shoe (Rubber shoe) Unit-type rubber crawler
Track shoe (Steel shoe) Assembly-type double grouser: 39 each side
Type x no. Variable displacement piston type × 1, gear type × 1
Hydraulic pump
Theoretical capacity cm /rev

3
22.3 × 2 + 14.1 + 5.2
Set pressure
For travel, work equipment MPa {kg/cm2} 26.5 {270}
For swing MPa {kg/cm2} 18.6 {190}
For blade MPa {kg/cm2} 21.6 {220}
Hydraulic system
Control
Type x no. 9-spool type × 1

valve
Control method Hydraulic assist type

Variable-displacement piston motor (with counter-
Travel motor
Hydraulic
balance valve, parking brake) × 2

motor
Fixed-displacement piston motor (with brake

Swing motor
valve, swing shaft brake) × 1
Hydraulic tank Box-shaped, open type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)
01-100 8 PC45MR-3, PC55MR-3

PC55MR-3
Machine model

Boom cylinder

Stroke mm 696
Arm cylinder

Stroke mm 733
Work equipment cylinder

Hydraulic system
Bucket cylinder

Stroke mm 580
Boom swing cylinder

Stroke mm 630
Max. distance between pins mm 1,573.5
Blade cylinder

Stroke mm 140
Max. distance between pins mm 642.5
PC45MR-3, PC55MR-3 01-100 9

SEN04602-00 Weight table
Weight table 1
k This weight table is a guide for use when transporting or handing components.
Unit: kg
PC45MR-3
Machine model
Canopy Cab specification
specification
Engine assembly (without oil, coolant) 242 242
• Engine 195 195
• Engine mount 8 8
• PTO 10 10
• Hydraulic pump 29 29
Cooling assembly (excluding coolant and oil) 33 33
Battery 24 24
Revolving frame 518 518
Floor frame 153 —
Canopy assembly 114 —
Handrail 8 —
Operator's cab (with floor frame) — 396
Operator's seat 23 23
Fuel tank (without fuel) 6 6
Hydraulic tank (without hydraulic oil) 39 39
Control valve 42 42
Counterweight 687 687
Swing motor (with brake valve) 15 15
Swing machinery 26 26
Track frame assembly (without track shoe) 920 920
• Track frame 513 513
• Idler assembly 36 × 2 36 × 2
• Recoil spring assembly 18 × 2 18 × 2
• Carrier roller assembly 3×2 3×2
• Track roller assembly 10 × 8 10 × 8
• Travel motor (with reduction gear) 56 × 2 56 × 2
• Sprocket 12 × 2 12 × 2
• Swing circle 59 59
• Center swivel joint 18 18
01-100 10 PC45MR-3, PC55MR-3

Weight table SEN04602-00
Unit: kg
PC55MR-3

specification
15001 and up
242 242
195 195
8 8
10 10
29 29
33 33
24 24
518 518
153 —
114 —
8 —
— 396
23 23
6 6
39 39
42 42
957 957
15 15
26 26
958 958
551 551
36 × 2 36 × 2
18 × 2 18 × 2
3×2 3×2
10 × 8 10 × 8
56 × 2 56 × 2
12 × 2 12 × 2
59 59
18 18
PC45MR-3, PC55MR-3 01-100 11

SEN04602-00 Weight table
Unit: kg
PC45MR-3
Machine model
specification
Track shoe assembly
• Rubber shoe (350 mm) 242 × 2 242 × 2
• Triple grouser shoe (350 mm) 274 × 2 274 × 2
Boom swing bracket assembly 101 101
Boom assembly 160 160
Arm assembly 96 96
Bucket link assembly 28 28
Bucket assembly (with side cutter) 105 105
Blade assembly 210 210
Boom cylinder assembly 41 41
Arm cylinder assembly 36 36
Bucket cylinder assembly 25 25
Boom swing cylinder assembly 35 35
Blade cylinder assembly 29 29
01-100 12 PC45MR-3, PC55MR-3

Weight table SEN04602-00
Unit: kg
PC55MR-3

specification
15001 and up
242 × 2 242 × 2
274 × 2 274 × 2
101 101
176 176
102 102
28 28
121 121
210 210
41 41
46 46
29 29
39 39
29 29
PC45MR-3, PC55MR-3 01-100 13

SEN04602-00 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1

a For details of notes (Notes 1 and 2 ...) in the table, see "Operation and Maintenance Manual".
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 8.1 7.5
Final drive case (each) 0.8 0.8
Hydraulic system 55 20
Fuel tank 65 —
Cooling system 8.5 —
01-100 14 PC45MR-3, PC55MR-3

Table of fuel, coolant and lubricants SEN04602-00
PC45MR-3, PC55MR-3 01-100 15

SEN04602-00
PC45MR, PC55MR-3 Hydraulic excavator

©2008 KOMATSU
All Rights Reserved
Printed in Japan 05-08 (01)
01-100 16
SEN04604-00
HYDRAULIC EXCAVATOR
PC45MR-3,
PC55MR-3

10 Structure, function and

maintenance standard 1
100 Engine and cooling system
PTO................................................................................................................................................................. 2
Cooling system ............................................................................................................................................... 4
PC45MR-3, PC55MR-3 10-100 1

SEN04604-00 PTO
PTO 1
1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump
10-100 2 PC45MR-3, PC55MR-3

PTO SEN04604-00
PC45MR-3, PC55MR-3 10-100 3

SEN04604-00 Cooling system
Cooling system 1
1. Radiator cap 7. Oil cooler outlet

2. Oil cooler inlet 8. Radiator inlet hose
3. Fan guard 9. Reservoir tank
4. Radiator 10. Fuel cooler
5. Oil cooler 11. Drain valve
6. Shroud 12. Radiator outlet hose
10-100 4 PC45MR-3, PC55MR-3

Cooling system SEN04604-00
Specifications
Radiator Oil cooler Fuel cooler
Core type CF68-4 CF40-1 Drawn-cup
Fin pitch (mm) 3.5 / 2 3.5 / 2 3.0 / 2
Total heat dissipation surface (m2) 13.61 3.70 0.2
Pressure valve cracking pressure 88.3 ± 14.7 — —

(kPa {kg/cm2}) {0.9 ± 0.15}
Vacuum valve cracking pressure 0 – 4.9 — —
(kPa {kg/cm2}) {0 – 0.05}
PC45MR-3, PC55MR-3 10-100 5

SEN04604-00

©2008 KOMATSU
All Rights Reserved
10-100 6
SEN04605-00
HYDRAULIC EXCAVATOR
PC45MR-3,
PC55MR-3


200 Power train
Power train...................................................................................................................................................... 2
Swing circle..................................................................................................................................................... 3
Swing machinery............................................................................................................................................. 4
PC45MR-3, PC55MR-3 10-200 1

200 Power train
SEN04605-00 Power train
Power train 1
1. Idler 8. Hydraulic pump (For pilot)

2. Swing motor 9. Left travel motor
3. Center swivel joint 10. Control valve
4. Right travel motor 11. Travel Hi-Lo speed selector valve
5. Engine 12. PPC lock solenoid valve
6. Hydraulic pump (For work equipment and travel) 13. Swing machinery
7. Hydraulic pump (For swing and blade) 14. Swing circle
10-200 2 PC45MR-3, PC55MR-3

200 Power train
Swing circle SEN04605-00
Swing circle 1
Unit: mm
No. Check item Criteria Remedy
Standard clearance Repair limit

1 Clearance between bearing Replace
0.20 – 0.70 1.7
1. Swing circle bearing lubricator a. Inner race soft zone position

2. Swing circle pinion lubricator b. Outer race soft zone position
3. Outer race
4. Inner race Specifications
5. Ball Reduction ratio: 90 / 10 = 9.00
6. Seal Grease: G2-LI
PC45MR-3, PC55MR-3 10-200 3

200 Power train
SEN04605-00 Swing machinery
Swing machinery 1
1. Swing motor Specifications

2. No.1 sun gear (No. of teeth: 21)
3. No.1 planetary gear (No. of teeth: 33) Reduction ratio (21+87) / 21 × (21+87) / 21 = 26.45
4. Swing machinery case (No. of teeth: 87) Swing reduction ratio 26.45 × 9.00 = 238.04
5. No. 2 planetary gear (No. of teeth: 33)
Swing speed (rpm) 9.0
6. No. 2 sun gear (No. of teeth: 21)
7. Swing pinion (No. of teeth: 10) Lubrication oil SAE10W
8. Taper roller bearing
Oil amount (l) 1.3
9. No. 2 planetary carrier
10. No. 1 planetary carrier
10-200 4 PC45MR-3, PC55MR-3

200 Power train
Swing machinery SEN04605-00
Unit: mm
Backlash between swing motor shaft Standard clearance Repair limit

1
and No. 1 sun gear 0.04 – 0.11 —
Backlash between No. 1 sun gear
2 0.12 – 0.28 0.6
and No. 1 planetary gear
Backlash between No. 1 planetary
3 0.14 – 0.38 0.6
gear and swing machinery case
4 0.10 – 0.26 —
gear and No. 2 sun gear Replace
Backlash between No. 2 sun gear
5 0.12 – 0.28 0.6
and No. 2 planetary gear
6 0.14 – 0.38 0.6
gear and swing machinery case
7 0.016 – 0.097 —
carrier and swing pinion
Backlash between swing pinion
8 0.14 – 0.73 2.0
and swing circle
Standard size Tolerance Repair limit Repair by hard
Wear of oil seal sliding surface of
9 0 chromium plat-
swing pinion 55 54.8
–0.073 ing or replace
PC45MR-3, PC55MR-3 10-200 5

SEN04605-00

©2008 KOMATSU
All Rights Reserved
10-200 6
SEN04606-00
HYDRAULIC EXCAVATOR
PC45MR-3,
PC55MR-3


300 Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Idler cushion.................................................................................................................................................... 3
Idler ................................................................................................................................................................. 4
Track roller ...................................................................................................................................................... 6
Carrier roller .................................................................................................................................................... 7
Sprocket .......................................................................................................................................................... 8
Track shoe ...................................................................................................................................................... 9
PC45MR-3, PC55MR-3 10-300 1

SEN04606-00 Track frame
Track frame 1
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier roller 8. Idler cushion
4. Travel motor 9. Idler guard
5. Sprocket (Steel shoe spec.)
10-300 2 PC45MR-3, PC55MR-3

Idler cushion SEN04606-00
Idler cushion 1
a The following figure shows the rubber shoe specification.
1. Rod
2. Cylinder
3. Recoil spring
4. Rear support
5. Nut
6. Lubricator
Specifications
Grease: G2-LI
Amount of grease (ml): 120
Unit: mm

Free Installed Installed Free Installed
Recoil spring
length length load length load
(Rubber shoe spec.)
7 42.4 kN 39.0 kN Replace
302 202.2 294
{4,326 kg} {3,980 kg}
Recoil spring 27.0 kN 24.0 kN
302 238.2 294
(Steel shoe spec.) {2,748 kg} {2,446 kg}
PC45MR-3, PC55MR-3 10-300 3

SEN04606-00 Idler
Idler 1
10-300 4 PC45MR-3, PC55MR-3

Idler SEN04606-00
Unit: mm
Standard size Repair limit

Outside diameter of projec-
1
tion 377 —
2 Outside diameter of tread 335 327

Repair by over-
3 Depth of tread 21 25 laying welding
or replace
4 Thickness of tread 10.3 6.3
5 Width of tread 18 22
6 Total width 75 —
Standard Tolerance Standard Clearance

Clearance between shaft size Shaft Hole clearance limit
7
and bushing
– 0.025 + 0.142 0.105 –
35 —
– 0.064 + 0.080 0.206
Replace
Clearance between shaft – 0.025 + 0.060 0.025 –
8 35 —
and support – 0.064 0 0.124
Standard clearance Clearance limit
Play of shaft in axial
9
direction 0.25 —
Track frame 120 124

Repair by over-
10 Height of idler guide
Idler laying welding
support 118 114
Track frame 161 165 Repair by over-

11 Width of idler guide laying welding
Idler shaft 160 155 or replace
PC45MR-3, PC55MR-3 10-300 5

SEN04606-00 Track roller
Track roller 1
Unit: mm

1 Outside diameter of flange
123 —
2 Outside diameter of tread 95 87
Repair by over-
3 Thickness of tread 26.5 22.5
laying welding
or replace
4 Width of flange 41 35
5 Width of tread 34.5 —
6 Total width 110 —

7
and bushing
– 0.025 + 0.142 0.105 –
35 —
– 0.050 + 0.080 0.192
Clearance between shaft – 0.025 + 0.039 0.025 – Replace
8 35 —
and collar – 0.050 0 0.089
Standard clearance Clearance limit
Play of roller in axial direc-
9
tion 0.17 – 0.40 —
10-300 6 PC45MR-3, PC55MR-3

Carrier roller SEN04606-00
Carrier roller 1
Unit: mm

1 Outside diameter of tread
70 65
Repair by over-
laying welding
2 Thickness of tread 9 6.5 or replace
3 Width of tread 100 —

4
and support
– 0.050 + 0.210 0.050 –
30 —
– 0.100 0 0.310
Replace
Standard Tolerance Standard Interference
Interference between shaft size Shaft Hole interference limit
5
and seal
0 – 0.200 0.148 –
30 —
– 0.052 – 0.400 0.400
PC45MR-3, PC55MR-3 10-300 7

SEN04606-00 Sprocket
Sprocket 1
Unit: mm
Standard size Tolerance Repair limit

1 Wear of root circle diameter + 1.0
380.37 368
– 2.0
2 0
Wear of tip circle diameter 423.99 412
– 3.0 Repair by over-
laying welding or
3 Wear of tip width 26 — 24 replace
4 + 0.5
Wear of bottom width 33 30
– 1.0
5 + 0.492
Thickness of bottom 75.185 69
– 1.075
10-300 8 PC45MR-3, PC55MR-3

Track shoe SEN04606-00
Track shoe 1
Rubber shoe
Unit: mm

1 Wear of lug height
25 5
2 Wear of roller guide 47 60

Replace
Wear of meshing parts of
3 2 –3
sprocket
4 Wear of roller tread height 25 19
PC45MR-3, PC55MR-3 10-300 9

SEN04606-00 Track shoe
Triple grouser shoe

(If equipped)
10-300 10 PC45MR-3, PC55MR-3

Track shoe SEN04606-00
Unit: mm
Standard size Turning limit Repair limit The pin and bush-
1 Link pitch ing are able to use
135 138 143 in reverse until
reach to reverse
limit.
If these had
2 Outside diameter of bushing 35 32 29 exceeded the repair
limit, replace pin,
bushing or link
3 Thickness of bushing 6.05 4.55 3.05 assembly.

4 Height of link Repair by over-
65 59
laying welding or
replace
Thickness of link
5 18.075 12.075
(Bushing fitting part)
Standard Tolerance Standard Interference

Interference between size Shaft Hole interference limit
6
bushing and link
Shaft 35 + 0.030 + 0.040 0.110 –
—
Hole 34.85 0 0 0.180
Interference between Shaft 22.5 + 0.060 + 0.052 0.148 –
7 —
regular pin and link Hole 22.3 0 0 0.260
Interference between Shaft 22.5 – 0.030 + 0.052 0.078 –
8 — Replace
master pin and link Hole 22.3 – 0.070 0 0.170

Clearance between regular size Shaft Hole clearance limit
9
pin and bushing
Shaft 22.5 + 0.060 0.140 –
± 0.2 —
Hole 22.9 0 0.600
Clearance between master Shaft 22.5 – 0.200 0.400 –
10 ± 0.2 —
pin and bushing Hole 22.9 – 0.400 1.000
Standard clearance Standard clearance Standard clearance
Clearance of link mating (Each side) (Both sides) (Each side)
11
face
0.7 – 1.4 1.4 – 2.8 —
Adjust
12 Projection of regular pin 1.5
13 Projection of master pin 3.25
Standard size Repair limit Repair by over-

Height of
14 laying welding or
grouser • Triple 14 10 replace
Thickness of Repair by overlay-

15 • Triple 20 16 ing welding or re-
grouser place
Tightening torque of shoe
16 137 ± 19.6 Nm {14 ± 2 kgm} Retighten
bolt
PC45MR-3, PC55MR-3 10-300 11

SEN04606-00

©2008 KOMATSU
All Rights Reserved
10-300 12
SEN04607-01
PC45MR-3,PC55MR-3
SEN04607-01
HYDRAULIC EXCAVATOR
Shop Manual
PC45MR-3
PC55MR-3

10 Structure,function and
maintenance standard
410 Hydraulic system, Part 1
Hydraulic components layout drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Hydraulic tank, filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Center swivel joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Travel motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Hydraulic cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Multi-control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
PC45MR-3,PC55MR-3 10-410 1
SEN04607-01 Hydraulic components layout drawing
Hydraulic components layout drawing
1. Boom swing PPC valve 12. Control valve

2. Swing motor 13. Multi-control valve (If equipped)
3. Boom swing cylinder 14. Attachment PPC valve (If equipped)
4. R.H. work equipment PPC valve 15. Travel PPC valve
5. Hydraulic tank 16. 2-spool solenoid valve
6. Blade PPC valve 17. Arm cylinder
7. Oil cooler 18. Boom cylinder
8. R.H. travel motor 19. Center swivel joint
9. L.H. travel motor 20. Blade cylinder
10. Hydraulic pump 21. Bucket cylinder
11. L.H. work equipment PPC valve
10-410 2 PC45MR-3,PC55MR-3
Hydraulic tank, filter SEN04607-01
Hydraulic tank, filter
1. Filler cap Specifications

2. Hydraulic tank Tank capacity (l) 33
3. Drain plug Oil amount (l) 20
4. Sight gauge Bypass valve set pressure 150 ± 30
5. Bypass valve (kPa {kg/cm2}) {1.53 ± 0.31}
6. Filter element Pressure valve cracking presure 38 ± 15
7. Cyclone assembly (MPa {kg/cm2}) {0.39 ± 0.15}
8. Strainer Vacuum valve cracking pressure 0–5
(kPa {kg/cm2}) {0 – 0.05}
PC45MR-3,PC55MR-3 10-410 3
SEN04607-01 Hydraulic tank, filter
Operation of cyclone assembly
q The hydraulic oil returning from each actuator

flows through the filter to block (1) of the cyclone
assembly.
q When the hydraulic oil flows from block (1) into
the cylindrical part of cyclone (2), it swirls and its
speed is increased.
q Since the hydraulic oil swirls, a centrifugal force
is generated and bubbles of low specific gravity
gather to the center.
q The bubbles gathering to the center are dis-
charged through the upper center of block (1)
and outlet (a) on the side of cyclone (2) into the
hydraulic oil in the tank. The hydraulic oil and air
are separated in this way.
q The hydraulic oil containing no bubbles is dis-
charged through outlet (b) at the bottom of cy-
clone (2), and then it flows through the strainer
into the pump again.
10-410 4 PC45MR-3,PC55MR-3
Center swivel joint SEN04607-01
Center swivel joint
A1: From L.H. travel control valve F2: To blade cylinder head
A2: To L.H. travel motor G1: From blade control valve
B1: From L.H. travel control valve G2: To blade cylinder bottom
B2: To L.H. travel motor T1: To hydraulic tank
C1: From R.H. travel control valve T2: From travel motor drain port
C2: To R.H. travel motor
D1: From R.H. travel control valve 1. Shaft
D2: To R.H. travel motor 2. Rotor
E1: From travel Hi-Lo speed selector valve 3. Slipper seal
E2: To travel Hi-Lo speed selector valve 4. Cover
F1: From blade control valve
Unit: mm

Standard size Standard clearance Clearance limit
5 Clearance between rotor and shaft Replace
60 0.055 – 0.085 0.090
PC45MR-3,PC55MR-3 10-410 5
SEN04607-01 Travel motor
Travel motor
A : From travel control valve

B : From travel control valve
PP : From travel Hi-Lo speed selector valve
DR1: To tank (left side)
Plug (right side)
DR2: Plug (left side)
To tank (right side)
Specification
Type PHV-4B-60B-PT-8882A
Hi 19.11
Theoretical delivery (cm3/rev) Lo 33.08
Hi 2,820
Rated speed (rpm)
Lo 1,630
Brake cracking pressure 0.76
(MPa {kg/cm2}) {7.8}
Speed changing pressure 0.86
2}) {8.8}
(MPa {kg/cm
Automatic speed changing pressure HioLo 23.1{236}
(MPa {kg/cm2}) LooHi 21.6{221}
Reduction ratio 47.53
10-410 6 PC45MR-3,PC55MR-3
Travel motor SEN04607-01
1. Oil filler plug 14. Disc

2. Cover 15. Shaft
3. No. 2 planetary gear 16. Rocker cam
4. No. 2 sun gear 17. Control piston
5. Ring gear 18. No. 1 planetary gear
6. Ball 19. No. 1 sun gear
7. Housing 20. No.2 planetary carrier
8. Piston 21. Drain plug
9. Cylinder 22. Oil level plug
10. Valve plate 23. Check valve
11. Brake valve 24. Counterbalance valve
12. Brake piston 25. Check valve
13. Plate 26. Automatic speed changing valve
PC45MR-3,PC55MR-3 10-410 7
Outline
q Swash plate (1) has two rear faces (x) and (y),
and is supported by ball (2).
q The travel speed is switched by pressurized oil
from control chamber (a) acting on control piston
(3).This switches the angle of swash plate (1)
between the maximum angle and minimum an-
gle to determine the travel speed.
10-410 8 PC45MR-3,PC55MR-3
Operation of motor
At low speed (When motor swash plate angle is at maximum)
q Since 2nd travel speed selector solenoid valve

(1) is turned OFF, the hydraulic oil from the con-
trol pump does not flow to port (PP).
q Since automatic speed changing valve (2) is
pressed down by spring (3), the circuit to control
chamber (a) is shut off.
q Since control chamber (a) is connected to the
drain port, swash plate (6) is pressed to the right
by the reaction force of center spring (7).
q Accordingly, swash plate (6) leans around ball
(8) toward the maximum swash plate angle side
and the motor capacity becomes maximum and
the travel speed decreases.
PC45MR-3,PC55MR-3 10-410 9
At high speed (When motor swash plate angle is at minimum)
q When 2nd travel speed selector solenoid valve

(1) is turned ON, the pilot pressure from the con-
trol pump flows to port (PP).
q Automatic speed changing valve (2) compress-
es spring (3) and moves up to open the circuit to
control chamber (a).
q The main hydraulic oil from the control valve
flows from automatic speed changing valve (2)
through check valve (4) to control chamber (a) to
press control piston (5) to the left.
q Accordingly, swash plate (6) leans around ball
(8) against center spring (7) toward the minimum
swash plate angle side and the motor capacity
becomes minimum and the travel speed increas-
es.
a The automatic travel speed changing function

works only while the travel speed selector switch
is set in the high speed position.
See "Automatic speed changing valve".
a While the arm crane (if equipped) is used, the
travel speed is kept low.
10-410 10 PC45MR-3,PC55MR-3
Operation of automatic speed changing valve
Automatic change of travel speed from high speed (High) to low speed (Low)
q While the travel speed selector switch is set in

the high speed position, motor drive pressure
(PC) is led into chambers (a) and (b) of automat-
ic speed changing valve (1).
q If motor drive pressure (PC) rises, the total of
force (F1) generated by the difference of the
pressure receiving area between chambers a
and (b) (a>b) and reaction force (F2) of spring
(2) becomes larger than force (F3) generated by
pilot pressure (PP).
(F3<F1+F2)
q As a result, automatic speed changing valve (1)
moves to the left and shuts off motor drive pres-
sure (A) flowing into control chamber (c).
q At the same time, port (DR) opens and the oil in
control chamber (c) is drained and control piston
(3) moves to the left.
q Accordingly, the swash plate of motor (4) leans
toward the maximum swash plate angle side and
the travel speed decreases.
PC45MR-3,PC55MR-3 10-410 11
Automatic change of travel speed from low speed (Low) to high speed (High)
q If the machine travels at low speed while the

travel speed selector switch is set in the high
speed position, the motor drive pressure (PC) is
led to chamber (a) of automatic speed changing
valve (1). (Chamber (b) is connected to port
(DR).)
q If the motor drive pressure (PC) lowers, the total
of force (F1) generated in chamber (a) by the
motor drive pressure (PC) and spring tension (2)
becomes less than force (F2) generated by the
pilot pressure (PP).
(F3>F1+F2)
q As a result, automatic speed changing valve (1)
moves to the right and motor drive pressure (A)
flows into control chamber (c).
q At the same time, port (DR) closes and control
chamber (c) is filled with oil and control piston (3)
moves to the right.
q Accordingly, the swash plate of motor (4) leans
toward the minimum swash plate angle side and
the travel speed increases.
10-410 12 PC45MR-3,PC55MR-3
Operation of counterbalance valve Operation of parking brake
Operation when pressurized oil is supplied When travel lever is operated

q When the travel lever is operated, the pressur- q If the travel lever is operated, the hydraulic oil
ized oil from the control valve is supplied to port from the pump flows in chamber (A) of brake pis-
(A). It pushes open check valve (1) and flows ton (1) and pushes brake piston (2) to the right.
from motor inlet port (MA) to motor outlet port As a result, the pressing force of spring (4)
(MB). against plate (2) and disc (3) is lost, and then
q The pressurized oil at the supply side flows from plate (2) and disc (3) are separated and the
orifice (C) to chamber (D). When the pressure in braking force is released.
chamber (D) goes above the spring (2), spool (3)
is pushed to the right direction.
As a result, port (MB) and port (B) are
connected, the outlet port side of the motor is
opened, and the motor starts to rotate.
When travel lever is in neutral

q If the travel lever is set in neutral, the hydraulic
oil in chamber (A) of brake piston (1) is shut off
and piston (1) is pressed to the left by spring (4).
As a result, plate (2) and disc (3) are pressed
Operation when pressure oil is shut off and the brake operates.
q If the travel lever is returned to the neutral posi-
tion, the pressure oil from the control valve is
shut off and spool (3) is pushed back to the left
by the force of spring (2).
q At this time, the oil flows in port (A) through ori-
fice (C) in chamber (D). The throttle effect of ori-
fice (C) generates back pressure to restrict the
speed of spool (3) returning to the left.
q Even if the pressure oil flowing in port (A) is shut
off, the motor continues revolution because of its
inertia.
q At this time, the changing speed of spool (3) and
the shape of the cut reduce the returning oil
gradually to stop the motor smoothly.
PC45MR-3,PC55MR-3 10-410 13
SEN04607-01 Hydraulic cylinder
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
10-410 14 PC45MR-3,PC55MR-3
Hydraulic cylinder SEN04607-01
Boom swing cylinder
Bucket cylinder
PC45MR-3,PC55MR-3 10-410 15
SEN04607-01 Hydraulic cylinder
PC45MR-3
Unit: mm

Cylinder name
size Shaft Hole clearance limit Replace cylinder
-0.025 +0.039 0.025 - head
Boom 50 0.403
-0.064 0 0.103
Clearance -0.025 +0.164 0.032 -
Arm 50 0.528
1 between piston -0.064 +0.007 0.228
rod and bushing Bucket -0.025 +0.152 0.032 -
45 0.539
-0.087 +0.007 0.239
Replace bushing
-0.025 +0.164 0.032 -
Boom swing 50 0.528
-0.064 +0.007 0.228
-0.025 +0.167 0.032 -
Blade 50 0.528
-0.064 +0.007 0.228
-0.147 +0.142
Boom 50 0.227– 0.351 1.0
-0.209 +0.080
-0.025 +0.142 0.105 -
Clearance Arm 45 1.0
-0.064 +0.080 0.206
between piston
-0.170 -0.011 0.105 -
2 rod supporting Bucket 45 1.0
-0.230 -0.065 0.219
shaft and bush-
-0.025 +0.142 0.105 -
ing Boom swing 50 1.0
-0.064 +0.080 0.206
-0.030 +0.174 0.130 -
Blade 55 1.0
-0.076 +0.100 0.250 Replace pin and
-0.025 +0.142 0.105 - bushing
Boom 50 1.0
-0.087 +0.080 0.229
-0.025 +0.142 0.105 -
-0.087 +0.080 0.229
between cylin-
-0.025 +0.142 0.105 -
3 der bottom sup- Bucket 45 1.0
-0.064 +0.080 0.206
porting shaft and
-0.025 +0.142 0.105 -
bushing Boom swing 50 1.0
-0.064 +0.080 0.206
-0.030 +0.174 0.130 -
Blade 55 1.0
-0.076 +0.100 0.250
Boom 736 ± 73.6 Nm{75±7.5kgm}
Arm 785±78.5Nm{80±8.0kgm}
Tightening
4 torque of cylinder Bucket 785±78.5Nm{80 ± 8.0 kgm}
head
Boom swing 676.2 ± 67.6Nm {69 ± 6.9 kgm}
Blade 931 ± 93.1 Nm {95 ± 9.5 kgm}

Retighten
Boom 1.25 ± 0.13 kNm {127 ± 12.7 kgm}
Arm 1.67 ± 0.17 kNm{170 ± 17.0 kgm}

Tightening
5 torque of cylinder Bucket 1.08 ± 0.11 kNm {110 ± 11.0 kgm}
piston
Boom swing 1.42 ± 0.14 kNm{145 ± 14.5 kgm}
Blade 1.42 ± 0.14 kNm{145 ± 14.5 kgm}
10-410 16 PC45MR-3,PC55MR-3
Hydraulic cylinder SEN04607-01
PC55MR-3
Unit: mm

Cylinder name
size Shaft Hole clearance limit Replace cylinder
-0.025 +0.039 0.025 - head
Boom 50 0.403
-0.064 0 0.103
Clearance -0.030 +0.163 0.036 -
Arm 55 0.539
1 between piston -0.076 +0.006 0.239
rod and bushing Bucket -0.025 +0.164 0.032 -
50 0.528
-0.064 +0.007 0.228
Replace bushing
-0.025 +0.164
Boom swing 50 0.032– 0.251 0.551
-0.087 +0.007
-0.025 +0.164 0.032 -
Blade 50 0.528
-0.064 +0.007 0.228
-0.147 +0.142 0.227 -
Boom 50 1.0
-0.209 +0.080 0.351
-0.025 +0.142 0.105 -
-0.064 +0.080 0.206
between piston
-0.170 -0.011 0.105 -
2 rod supporting Bucket 45 1.0
-0.230 -0.065 0.219
shaft and bush-
-0.025 +0.142 0.105 -
ing Boom swing 50 1.0
-0.064 +0.080 0.206
-0.030 +0.174 0.130 -
Blade 55 1.0
-0.076 +0.100 0.250 Replace pin and
-0.025 +0.142 0.105 - bushing
Boom 50 1.0
-0.087 +0.080 0.229
-0.025 +0.142 0.105 -
-0.087 +0.080 0.229
between cylin-
-0.025 +0.142 0.105 -
3 der bottom sup- Bucket 45 1.0
-0.064 +0.080 0.206
porting shaft and
-0.025 +0.142 0.105 -
bushing Boom swing 50 1.0
-0.064 +0.080 0.206
-0.030 +0.174 0.130 -
Blade 55 1.0
-0.076 +0.100 0.250
Boom 736 ± 73.6 Nm {75 ± 7.5 kgm}
Arm 961 ± 96.1 Nm {98 ± 9.8 kgm}

Tightening
4 torque of cylinder Bucket 863 ± 86.3 Nm {88 ± 8.8 kgm}
head
Boom swing 735 ± 73.5 Nm {75 ± 7.5 kgm}
Blade 931 ± 93.1 Nm {95 ± 9.5 kgm}

Retighten
Boom 1.25 ± 0.13 kNm {127 ± 12.7 kgm}
Arm 2.30 ± 0.23 kNm {235 ± 23.5 kgm}

Tightening
5 torque of cylinder Bucket 1.08 ± 0.11 kNm {110 ± 11.0 kgm}
piston
Boom swing 1.42 ± 0.14 kNm {145 ± 14.5 kgm}
Blade 1.42 ± 0.14 kNm {145 ±14.5 kgm}
PC45MR-3,PC55MR-3 10-410 17
SEN04607-01 Solenoid valve
Solenoid valve
2-spool solenoid valve
A: To PPC valve
B: To 2nd travel speed selector valve
P: From hydraulic pump
T: To hydraulic tank
1. PPC lock solenoid valve

2. 2nd travel speed select solenoid valve
3. Control relief valve
Solenoid valve Control relief valve

4. Coil (ON/OFF type) 9. Adjustment screw
5. Push pin 10. Locknut
6. Valve spool 11. Plug
7. Return spring 12. Return spring
8. Valve body 13. Cover
14. Plunger
10-410 18 PC45MR-3,PC55MR-3
Solenoid valve SEN04607-01
2nd travel speed selector solenoid valve

PPC lock solenoid valve
Operation
When solenoid is turned OFF When solenoid is turned ON
(When circuit is shut off) (When circuit is connected)
q While the signal current is not flowing from the q While the signal current is flowing from the PPC
PPC lock solenoid valve or travel speed selector lock solenoid valve or travel speed selector
switch, solenoid (1) is turned OFF. switch to solenoid (1), solenoid (1) is turned ON.
Accordingly, spool (2) is pressed up by spring q Accordingly, spool (2) is pressed down by push
(3). pin (4).
q As a result, ports (P) and (A) are shut off from q As a result, ports (P) and (A) are connected to
each other and the pilot pressure does not flow each other and the pilot pressure flows into the
into the actuator. actuator.
At the same time, the oil from the actuator flows At the same time, port (T) is closed and the oil
through ports (A) and (T) to the hydraulic tank. does not flow to the hydraulic tank.
PC45MR-3,PC55MR-3 10-410 19
Control relief valve
Operation
q If the oil pressure from the hydraulic pump in-
creases, the oil in port (P) pushes plunger (1)
and its reaction force compresses spring (2) and
moves up plunger (1), and then the oil is relieved
through ports (P) and (T).
Set pressure: 3.14MPa {32 kg/cm2}
10-410 20 PC45MR-3,PC55MR-3
Solenoid valve SEN04607-01
2-spool EPC valve

(Attachment switch specification)
A1: From 2-spool solenoid valve

B1: To control valve (attachment port PB)
B2: To control valve (attachment port PA)
T : To hydraulic tank
1. Oil flow adjuster EPC valve for attachment (b)

2. Oil flow adjuster EPC valve for attachment (a)
EPC valve
3. Coil (proportional type)
4. Push pin
5. Valve spool
6. Guide
7. Return spring
PC45MR-3,PC55MR-3 10-410 21
Attachment control EPC valve
Operation
When signal current is maximum When signal current is reduced
(When coil is energized and circuit pressure is (When coil is energized and circuit pressure is
maximum) low)
q If the signal current flows from the controller into q If the signal current flowing from the controller
coil (1), coil (1) is energized. At this time, the into coil (1) is reduced, coil (1) is still energized
thrust of coil (1) is maximum. but its thrust is lowered in proportion to the signal
q As a result, spool (2) is pushed down by push pin current.
(3). q As a result, push pin (3) pushes down spool (2)
q Accordingly, all the pressurized oil from the PPC and the pressurized oil from port (A) flows to port
lock solenoid valve flows through port (A), spool (B).
(2), and port (B) to the control valve. At this time, q If the pressure in port (B) increases and the force
port (T) is closed and no oil flows into the tank. applied to face "a" of spool (2) becomes larger
than the thrust of coil (1), spool (2) is pushed up
and port (A) is disconnected from port (B) and
connected to port (T).
q Accordingly, spool (2) moves up and down so
that the thrust of coil (1) will be balanced with the
pressure in port (B).
q As a result, the circuit pressure between the
PPC lock solenoid valve and control valve is
controlled in proportion to the signal current.
10-410 22 PC45MR-3,PC55MR-3
Multi-control valve SEN04607-01
Multi-control valve
(1) ISO pattern

(2) Backhoe pattern
Operation pattern selection drawing (The port names correspond to the symbols in the drawing).
PC45MR-3,PC55MR-3 10-410 23
SEN04607-01
©2009 KOMATSU
All Rights Reserved
10-410 24
SEN04608-00
PC45MR-3,
PC55MR-3


Hydraulic pump ............................................................................................................................................... 2
Control valve ................................................................................................................................................. 10
PC45MR-3, PC55MR-3 10-420 1

SEN04608-00 Hydraulic pump
Hydraulic pump 1
Type: LPD25 + 25 + DNP21-14.1 + 5.2
Main pump
P1 : Pump discharge port 1. Main pump (Piston pump)

P2 : Pump discharge port 2. Servo valve
P3 : Gear pump discharge port 3. Gear pump
P4 : Pilot pump pressure output port
PS : Pump suction port
P1L : Pump pressure input port
P1T : Travel deviation adjustment orifice
P2T : Travel deviation adjustment orifice
PLS : LS pressure input port
10-420 2 PC45MR-3, PC55MR-3

Hydraulic pump SEN04608-00
1. Shaft 7. Cylinder block

2. Oil seal 8. Valve plate
3. Case 9. Spring (In servo piston)
4. Rocker cam 10. Servo piston
5. Shoe 11. Ball (For supporting rocker cam)
6. Piston
PC45MR-3, PC55MR-3 10-420 3

Function Structure
q The engine rotation and torque transmitted to q Cylinder block (7) is supported to shaft (1) by
the pump shaft is converted into hydraulic spline (a), and shaft (1) is supported by the
energy, and pressurized oil is discharged front and rear bearings.
according to the load. q The tip of piston (6) is a concave ball, and shoe
q It is possible to change the pump delivery by (5) is caulked to it to form one unit. Piston (6)
changing the swash plate angle. and shoe (5) form a spherical bearing.
q It has two discharge ports and it enables to q Rocker cam (4) has flat surface (A). Shoe (5)
supply the pressure individually to each one. is kept pressed against the flat surface (A) and
it slides circularly on flat surface (A). Rocker
cam (4) slides around ball (11).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) seals the pressure oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
der block (7) is sucked in and discharged
through valve plate (8).
q Hole number of cylinder block (7) is an even
number. So, it is fitted to two grooves of valve
plate (8) alternately.
10-420 4 PC45MR-3, PC55MR-3

Operations q When the center line (X) of the rocker cam (4)
becomes in line with the axial direction of the
Operation of pump cylinder block (7) (swash plate angle = 0), the
q Shaft (1) and cylinder block (7) rotate together difference between capacities of (E) and (F)
and shoe (5) slides on the flat surface (A). inside the cylinder block (7) becomes 0, so the
Since the rocker cam (4) leans around ball (11) pump does not carry out any suction or dis-
at this time, the angle (a) between the center charge action of oil. (In actual fact, the swash
line (X) of rocker cam (4) and axis of cylinder plate angle never becomes 0.)
block (7) changes. The angle (a) is called the q In other words, discharge amount of the pump
swash plate angle. is directly proportional to the swash plate angle
q When the center line (X) of the rocker cam (4) (a).
maintains the swash plate angle (a) in relation
to the axial direction of the cylinder block (7),
the flat surface (A) acts as a cam for the shoe
(5).
q By this, the piston (6) slides on the inside of the
cylinder block (7), creates a difference
between capacities (E) and (F), then suction
and discharge of oil for the amount of this dif-
ference (F) – (E) will be carried out.
q In other words, oil is discharged as the capac-
ity of the chamber (E) decreases when the cyl-
inder block (7) rotates.
In the meantime, the capacity of the chamber
(F) increases, and the oil is sucked at this pro-
cess.
[The figure shows the state of the pump when
suction of the chamber (F) and discharge of
the chamber (E) have completed.]
PC45MR-3, PC55MR-3 10-420 5

q As the swash plate angle (a) becomes larger,

difference between the capacities (E) and (F)
becomes larger, so the pump delivery (Q)
increases.
The swash plate angle (a) is changed by the
servo piston (10).
q Servo piston (10) is reciprocated straight by
the signal pressure of the PC and LS valves.
This reciprocation is transferred to rocker cam
(4). Rocker cam (4) supported on ball (11)
rocks around ball (11).
q The output pressure of the LS valve is applied
to the pressure chamber of servo piston (10).
q As output pressure rises, rocker cam (4)
moves to reduce the swash plate angle (a), so
the pump delivery (Q) decreases.
10-420 6 PC45MR-3, PC55MR-3

Operation as double pump When the single pump system is used

q The number of the holes of cylinder block (7) is When the machine travels straight:
even. The ports on the face in contact with valve q Right pressure 9.80 MPa {100 kg/cm2} × Right
plate (8) are connected to every second long flow rate (50.0 l/min) + Left pressure 9.80 MPa
oval port on the periphery of valve plate (8). {100 kg/cm2} × Left flow rate (50.0 l/min) = 8.10
q The two long oval ports of valve plate (8) are kW {11.0 HP} + 8.10 kW {11.0 HP} = 16.2 kW
equivalent to the two discharge ports of the {22.0 HP}
pump, and the pump operates as a double When the machine is steered:
pump. q Right pressure 19.6 MPa {200 kg/cm2} × Right
q While the machine is not traveling, the oil flows flow rate (50.0 l/min) + Left pressure 9.80 MPa
are merged inside the control valve and the {100 kg/cm2} × Left flow rate (40.0 l/min) = 16.2
pump operates as a single pump (Merging kW {22.0 HP} + 6.60 kW {9.0 HP} = 22.8 kW
mode). {31.0 HP}
q When the machine travels, the two discharge Since the pump input horsepower is larger than the
ports of the pump are connected respectively engine horsepower, the PC control starts (to pre-
to the right and left travel ports (Separation vent the engine from stalling).
mode). q Right pressure 19.6 MPa {200 kg/cm2} × Right
q While the machine is traveling straight, the flow rate (30.0 l/min) + Left pressure 19.6 MPa
pump is in the separation mode described {200 kg/cm2} × Left flow rate (20.0 l/min) = 9.60
above. Since the travel pressures on both kW {13.0 HP} + 6.60 kW {9.0 HP} = 16.2 kW
sides are the same basically, the pump oper- {22.0 HP}
ates as a single pump. (If the work equipment The average flow rate of both sides is reduced
is operated while the machine is traveling, the from 50.0 l/min to 25.0 l/min (Reduction by
pump is set in the merging mode.) 50%).
q When the machine steers during travel, how- When the double pump system is used
ever, the pump generates two pressures; One When the machine travels straight:
pressure rises for the outer track and the other q Right pressure 9.80 MPa {100 kg/cm2} × Right
lowers for the inner track. (For example, the flow rate (50.0 l/min) + Left pressure 9.80 MPa
higher pressure is applied to the even cylinder {100 kg/cm 2 } × Left flow rate (50.0 l/min) =
block ports and the lower pressure is applied to 8.10 kW {11.0 HP} + 8.10 kW {11.0 HP} = 16.2
the odd ports.) kW {22.0 HP}
q As explained above, the oil flow is separated When the machine is steered:
and pressure difference is generated only q Right pressure 19.6 MPa {200 kg/cm2} × Right
when the machine is steered during travel. flow rate (50.0 l/min) + Left pressure 4.90 MPa
q The PC control is carried out with the average {50 kg/cm2} × Left flow rate (40.0 l/min) = 16.2
of the above 2 pump pressures. kW {22.0 HP} + 2.90 kW {4.0 HP} = 19.1 kW
{26.0 HP}
Superiority of double pump system Since the pump input horsepower is larger than the
q Usually, when the machine having a double engine horsepower, the PC control starts (to pre-
pump system is steered during travel, the vent the engine from stalling).
motor pressure on the drive side (outside) rises q Right pressure 19.6 MPa {200 kg/cm2} × Right
and that on the driven side (inside) lowers. flow rate (43.0 l/min) + Left pressure 4.90 MPa
q In the case of an ordinary single pump system, {50.0 kg/cm 2 } × Left flow rate (33.0 l/min) =
the pressure compensation valve in the control 14.0 kW {19.0 HP} + 2.20 kW {3.0 HP} = 16.2
valve operates according to the characteristics kW {22.0 HP}
of the system, then the motor pressure on the The average flow rate of both sides is reduced from
driven side becomes the same as that on the 50.0 l/min to 38.0 l/min (Reduction by 24.0%).
drive side.
q In short, the pressure compensation valve on When the machine having the ordinary single pump
the driven side is closed and the pressure in system is steered, the flow rate is reduced by 50%.
the circuit on the driven side and that on the If the double pump system is used, however, the
drive side are increased by the same degree. reduction of the flow rate is only 24%.
q In the case of the double pump system, on the
other hand, the motor pressure on the driven
side is kept low, thus lowering of the oil flow
rate in the motor on the drive side is restricted.
Accordingly, the engine power is used as
shown below;
PC45MR-3, PC55MR-3 10-420 7

Servo valve
GH : Gear pump HI signal port (a2) 1. Lever

GL : Gear pump LO signal port (b2) 2. Spool
P1 : Pump signal pressure port 3. Plug
P1L : Pump pressure input port 4. Seat
PAVE : Pump average pressure port 5. Piston
PE : Control piston pressure port 6. Sleeve
PH : Pump shuttle pressure port 7. Plug
PLS : LS pressure input port 8. Locknut
T : Drain port 9. Spring
10. Spool
11. PC valve
12. LS valve
10-420 8 PC45MR-3, PC55MR-3

Function
LS valve
q The LS valve controls the pump discharge
according to the stroke of the control lever, or
the flow rate required by the actuator.
q This valve determines the flow rate required by
the actuator from differential pressure (dPLS)
between main pump discharge pressure (P1L)
and control valve outlet pressure (PLS), then
controls main pump delivery (Q).
[(P1L) is called the pump pressure, (PLS) LS
pressure, and (dPLS) LS differential pressure.]
q To put it concretely, the LS valve senses the
pressure loss [= LS differential pressure PC valve
(dPLS)] caused by the flow of oil from the
q When pump discharge pressure (P1)/(PAVE)
pump through the opening of the control valve
rises, the stroke of the control valve spool is
spool, then controls pump discharge (Q) so
increased and the opening area is increased
that this pressure loss will be constant. Conse-
and pump delivery (Q) is increased. At this
quently, the LS valve supplies the oil according
time, the PC valve limits pump delivery (Q)
to the demand of the control valve.
according to discharge pressure (P1)/(PAVE)
q In the range of fine control, etc. where the oil
so that the pump absorption horsepower will
flow rate does not exceed the pump capacity,
not exceed the engine horsepower. In other
the pump discharge is kept constant even if the
words, the PC valve performs approximate
engine speed is low or full, since the LS valve
constant-horsepower control.
always secures the oil flow rate required by the
q That is, if the load on the actuator is increased
control valve. To solve this problem, the LS
and pump discharge pressure (P1)/(PAVE)
differential pressure is automatically set low to
rises during operation, the PC valve reduces
reduce the discharge when the engine speed
pump delivery (Q). If the pump discharge pres-
is low.
sure lowers, the PC valve increases pump
q The engine speed is sensed by checking pres-
delivery (Q).
sures (GH) and (GL) before and after the fixed
q The relationship between pump discharge
throttle (metering throttle) of the discharge pas-
pressure (P1)/(PAVE) and pump delivery (Q) is
sage of the swing gear pump, and those pres-
shown below.
sures are applied to the third and fourth pressure
q When the machine swings, since the swing
receiving chambers (a2) and (b2) in the LS valve
pump and main pump are installed tandem, the
to change the setting of the LS valve.
torque absorbed in the main pump is lowered
q When the engine speed is low, the swing pump
by the part absorbed in the swing pump.
discharge is reduced and pressures (GH) and
q When the swing pump operates, the total of
(GL) before and after the metering throttle are
the main pump absorption torque and swing
almost the same [the metering differential
pump absorption torque is the total absorption
pressure calculated by (GH) – (HL) is low]. On
torque (100%)
the other hand, when the engine is running at
the full speed, the swing pump discharge is
increased and the metering differential pres-
sure becomes high.
q When the metering differential pressure is high
(the engine speed is high), the LS pressure is
set higher than the normal value. When the
metering differential pressure is low (the
engine speed is low), the LS pressure is set
lower than the normal value.
q The LS valve receives pump pressure (P1L),
LS pressure (PLS), and pressures (GH) and
(GL) before and after the metering throttle of
the swing gear pump. The relationship
between LS differential pressure (dPLS) and
pump discharge (Q) is shown at upper right.
PC45MR-3, PC55MR-3 10-420 9

SEN04608-00 Control valve
Control valve 1
Outline
a The control valve is an add-on type where one

service valve each can be added, so it is possi-
ble to add valves or remove valves if neces-
sary.
a The service valve is installed additionally
between the top cover and lower valve.
a As for the 10-spool valve, only the parts differ-
ent from the 9-spool valve are shown.
A1 : To L.H. travel motor PA5 : From bucket DUMP PPC valve

A2 : To R.H. travel motor PA6 : From boom swing PPC valve
A3 : To boom cylinder head PA7 : From blade PPC valve
A4 : To arm cylinder head PA8 : From swing R.H. PPC valve
A5 : To bucket cylinder head PA9 : From attachment PPC valve
A6 : To boom swing cylinder head PB1 : From L.H. travel REVERSE PPC valve
A7 : To blade cylinder head PB2 : From R.H. travel REVERSE PPC valve
A8 : To swing motor port (MA) PB3 : From boom RAISE PPC valve
A9 : To attachment actuator PB4 : From arm IN PPC valve
B1 : To L.H. travel motor PB5 : From bucket CURL PPC valve
B2 : To R.H. travel motor PB6 : From boom swing PPC valve
B3 : To boom cylinder bottom PB7 : From blade PPC valve
B4 : To arm cylinder bottom PB8 : From swing L.H. PPC valve
B5 : To bucket cylinder bottom PB9 : From attachment PPC valve
B6 : To boom swing cylinder bottom PP1 : (P1) pump pressure
B7 : To blade cylinder bottom PP2 : (P2) pump pressure
B8 : To swing motor port (MB) PP3 : Pump pressure on work equipment side
B9 : To attachment actuator PLS1 : L.H. travel LS pressure
C : To oil cooler PLS2 : R.H. travel LS pressure
LS : To pump LS valve PLS3 : Work equipment LS pressure
P1 : From main pump (Variable pump) PTR : Travel pressure switch mounting port
P2 : From main pump (Variable pump) PS : To swing motor port (B)
P3 : From main pump (Gear pump) S : To swing motor port (S)
PA1 : From L.H. travel FORWARD PPC valve T : To tank
PA2 : From R.H. travel FORWARD PPC valve TS : To tank
PA3 : From boom LOWER PPC valve
PA4 : From arm OUT PPC valve
10-420 10 PC45MR-3, PC55MR-3

Control valve SEN04608-00
9-spool valve
General view
(For KUK)
PC45MR-3, PC55MR-3 10-420 11

Sectional view
(1/4)
10-420 12 PC45MR-3, PC55MR-3

1. Suction valve (L.H. travel)

2. Suction valve (R.H. travel)
3. Suction valve (Boom)
4. Suction valve (Arm)
5. Suction valve (Bucket)
6. Suction valve (Blade)
7. Suction valve (Attachment)
8. Safety valve
9. Suction valve (Attachment)
10. Suction valve (Blade)
11. Suction valve (Boom swing)
12. Suction valve (Bucket)
13. Suction valve (Arm)
14. Suction valve (Boom)
15. Main relief valve
16. Suction valve (R.H. travel)
17. Suction valve (L.H. travel)
18. Spool (L.H. travel)
19. Spool (R.H. travel)
20. Spool (Boom)
21. Spool (Arm)
22. Spool (Bucket)
23. Spool (Boom swing)
24. Spool (Blade)
25. Spool (Swing)
26. Spool (Attachment)
27. Unload valve
Unit: mm

Free length
Installed Installed Free Installed
28 Suction valve spring × Outside
length load length load
diameter
5.10 N 4.12 N
39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
Replace spring
181 N 144 N
29 Spool return spring 29 × 17.5 25 — if damaged or
{18.42 kg} {14.7 kg}
deformed
126 N 100 N
30 Spool return spring 27.24 × 16.6 25 —
{12.8 kg} {10.2 kg}
176 N 140 N
31 Spool return spring 29 × 17.5 25 —
{17.9 kg} {14.3 kg}
55.4 N 44.3 N
32 Unload valve spring 37.2 × 12.5 30.5 —
{5.65 kg} {4.52 kg}
PC45MR-3, PC55MR-3 10-420 13

(2/4)
10-420 14 PC45MR-3, PC55MR-3

1. Lift check valve

2. Pressure compensation valve F (L.H. travel)
3. Pressure compensation valve F (R.H. travel)
4. Spool (Pump merge-divider valve)
5. Pressure compensation valve F (Boom)
6. Pressure compensation valve F (Arm)
7. Pressure compensation valve F (Bucket)
8. Pressure compensation valve F (Boom swing)
9. Pressure compensation valve F (Attachment)
10. Pressure compensation valve R (Attachment)
11. Swing relief valve (For gear pump)
12. Pressure compensation valve R (Boom swing)
13. Pressure compensation valve R (Bucket)
14. Pressure compensation valve R (Arm)
15. Pressure compensation valve R (Boom)
16. LS bypass valve (LS2)
17. Pressure compensation valve R (R.H. travel)
18. Pressure compensation valve R (L.H. travel)
19. Oil cooler bypass valve
20. Spool (L.H. travel)
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Free length
Back pressure check valve × Outside
21 length load length load
spring diameter
10.9 N 8.73 N
29.06 × 13.3 21 —
{1.11 kg} {0.89 kg}
Pump merge-divider valve 44.3 N 35.5 N
22 41.07 × 13.8 22 —
spring {4.52 kg} {3.62 kg}
Replace spring
78.8 N 63.1 N
23 Cooler check valve spring 27.2 × 13.2 21 — if damaged or
{8.04 kg} {6.43 kg}
deformed
Pressure compensation 6.86 N 5.49 N
24 20 × 8.4 12 —
valve spring {0.7 kg} {0.56 kg}
25 22.75 × 8.4 17 —
26 21.55 × 8.4 17 —
27 15.4 × 6 13 —
PC45MR-3, PC55MR-3 10-420 15

(3/4)
10-420 16 PC45MR-3, PC55MR-3

1. Pressure compensation valve R (R.H. travel)

2. Pressure compensation valve F (R.H. travel)
3. Spool (R.H. travel)
4. Suction valve
5. Suction valve
6. Unload valve
7. Check valve
9. Unload valve
10. LS bypass valve (LS2)
11. Spool (Pump merge-divider valve)
12. Unload valve
13. Check valve
14. Unload valve
15. Pressure compensation valve F (Boom)
16. Spool (Boom)
17. Suction valve
18. Boom hydraulic drift prevention valve
19. Check valve
20. Check valve
21. Suction valve
22. Pressure compensation valve R (Boom)
23. Pressure compensation valve F (Arm)
24. Spool (Arm)
25. Suction valve
26. Check valve
27. Suction valve
28. Pressure compensation valve R (Arm)

Unit: mm

Free length
29 Check valve spring × Outside
diameter
1.96 N 1.57 N
13.0 × 6.5 9.5 — Replace spring
{0.2 kg} {0.16 kg}
if damaged or
1.96 N 1.57 N deformed
30 Check valve spring 16.4 × 7.5 9.8 —
{0.2 kg} {0.16 kg}
1.96 N 1.57 N
31 Check valve spring 21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
5.49 N 4.41 N
32 Logic valve spring 10.98 × 6.2 9.5 —
{0.56 kg} {0.45 kg}
PC45MR-3, PC55MR-3 10-420 17

(4/4)
10-420 18 PC45MR-3, PC55MR-3

1. Pressure compensation valve F (Bucket)

2. Spool (Bucket)
3. Suction valve
4. Check valve
5. Suction valve
6. Pressure compensation valve R (Bucket)
7. Pressure compensation valve F (Boom swing)
8. Spool (Boom swing)
9. Check valve
10. Suction valve
11. Pressure compensation valve R (Boom swing)
12. Spool (Blade)
13. Suction valve
14. Check valve
15. Suction valve
16. Spool (Swing)
17. Swing relief valve (For gear pump)
20. Suction valve
21. Suction valve
23. Safety valve
24. Air bleeding plug

Unit: mm

Free length Replace spring
25 Check valve spring × Outside if damaged or
diameter deformed
1.96 N 1.57 N
21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
PC45MR-3, PC55MR-3 10-420 19

(For North America)
a These are the 9-spool valves of PC45MR-3

and PC55MR-3 (For North America), the
shapes of which, except section AB-AB, are
the same as those of the 9-spool valves of
PC45MR-3 and PC55MR-3 (For KUK) respec-
tively.
10-420 20 PC45MR-3, PC55MR-3

A9 : To stop valve
B9 : To stop valve
PA9 : To attachment PPC valve
PB9 : To attachment PPC valve

4. Port relief valve

R: Pressure reducivng valve
Unit: mm

Free length
5 Spool return spring × Outside
diameter
Replace spring
181 N 144 N
29 × 17.5 25 — if damaged or
{18.42 kg} {14.7 kg}
deformed
6 20 × 8.4 12 —
7 15.4 × 6 13 —
PC45MR-3, PC55MR-3 10-420 21

10-spool valve
(For North America)
a These are the 10-spool valves of PC45MR-3

and PC55MR-3 (For North America), the
shapes of which, except section AC-AC, are
the same as those of the 9-spool valves of
PC45MR-3 and PC55MR-3 (For North Amer-
ica) respectively.
10-420 22 PC45MR-3, PC55MR-3

A10 : To angle cylinder bottom

B10 : To angle cylinder head
PA10 : From PA PPC valve
PB10 : From PA PPC valve
1. Pressure compensation valve F (PA)

2. Pressure compensation valve R (PA)
3. Spool (PA)

Unit: mm

Free length
5 Spool return spring × Outside
diameter
Replace spring
181 N 144 N
29 × 17.5 25 — if damaged or
{18.42 kg} {14.7 kg}
deformed
6 20 × 8.4 12 —
7 15.4 × 6 13 —
PC45MR-3, PC55MR-3 10-420 23

SEN04608-00

©2008 KOMATSU
All Rights Reserved
10-420 24
SEN04609-00
PC45MR-3,
PC55MR-3


CLSS............................................................................................................................................................... 2
Operation for each function and valve ............................................................................................................ 6
Swing motor .................................................................................................................................................. 28
PPC valve ..................................................................................................................................................... 35
PC45MR-3, PC55MR-3 10-430 1

SEN04609-00 CLSS
CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a variable capacity pis-
tem, and has the following features. ton pump, control valve, and actuators.
q Fine control not influenced by load q The hydraulic pump consists of the pump body,
q Control enabling digging even with fine control PC valve and LS valve.
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
10-430 2 PC45MR-3, PC55MR-3

CLSS SEN04609-00
Basic principle q If LS differential pressure (dPLS) becomes

Control of pump swash plate angle lower than the set pressure of the LS valve
q The pump swash plate angle (pump delivery) (when the actuator load pressure is high), the
is controlled so that LS differential pressure pump swash plate moves towards the maxi-
(dPLS) [the difference between pump dis- mum position.
charge pressure (PP) and control valve outlet q If the set pressure becomes higher than the set
port LS pressure (PLS) (load pressure of actu- pressure of the LS valve (when the actuator
ator)] is constant. load pressure is low), the pump swash plate
q [LS differential pressure (dPLS) = Pump dis- moves towards the minimum position.
charge pressure (PP) – LS pressure (PLS)]
LS differential pressure (dPLS) and pump
swash plate angle
a For details of the operation, see “Hydraulic

pump”.
PC45MR-3, PC55MR-3 10-430 3

SEN04609-00 CLSS
Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve spool to
balance the load.
q When two actuators are operated together, this
valve acts to make pressure difference (dP)
between the upstream (inlet port) and down-
stream (outlet port) the same, regardless of the
size of the load (pressure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve when it is oper-
ated.
10-430 4 PC45MR-3, PC55MR-3

CLSS SEN04609-00
PC45MR-3, PC55MR-3 10-430 5

SEN04609-00 Operation for each function and valve
Operation for each function and valve 1

Hydraulic circuit diagram and name of valve
9-spool valve
(For KUK)
10-430 6 PC45MR-3, PC55MR-3

Operation for each function and valve SEN04609-00
1. Unload valve
Set pressure:
LS pressure + 2.45 MPa {25.0 kg/cm2}
2. Safety valve
Set pressure: 28.9 MPa {295 kg/cm2}
4. Pump merge-divider valve
5. Logic valve
6. Pressure compensation valve
7. Suction valve
8. Pilot pressure check valve
9. Check valve
10. Back pressure check valve
Set pressure: 0.34 MPa {3.5 kg/cm2}
11. Oil cooler bypass valve
Set pressure: 0.39 MPa {4.0 kg/cm2}
12. Swing relief valve (for gear pump)
13. Boom lock valve
PC45MR-3, PC55MR-3 10-430 7

(For North America)
a As for the hydraulic circuits of the 9-spool

valves (For North America) of PC45MR-3 and
PC55MR-3, only the parts different from the 9-
spool valves (For KUK) of PC45MR-3 and
PC55MR-3, are shown respectively.

10-430 8 PC45MR-3, PC55MR-3

10-spool valve
(For North America)
a As for the hydraulic circuits of the 10-spool

valves (For North America) of PC45MR-3 and
PC55MR-3, only the parts different from the 9-
spool valves (For North America) of PC45MR-3
and PC55MR-3, are shown respectively.


PC45MR-3, PC55MR-3 10-430 9

When control valve is at neutral
PP1, PP2 : Pump circuit

PLS1, PLS2 : LS circuit
T : Tank circuit
1. Spool
2. Spring
Function Operation
q When the control valve is at neutral, pump q Pump discharge pressure (PP1), (PP2) is act-
delivery (Q) discharged by the minimum swash ing on the left end of spool (1), and LS pres-
plate angle is released to the tank circuit. sure (PLS1), (PLS2) is acting on the right end.
When this happens, pump discharge pressure q When the control valve is at neutral, LS pres-
(PP1), (PP2) is set at 2.45 MPa {25.0 kg/cm2} sure (PLS1), (PLS2) is 0, so only pump dis-
by spring (2) inside the valve. [LS pressure charge pressure (PP1), (PP2) has any effect,
(PLS1), (PLS2): 0 MPa {0 kg/cm2}] and (PP1), (PP2) is set only by the load of
spring (2).
q As pump discharge pressure (PP1), (PP2)
rises and reaches the load of spring (2) (2.45
MPa {25.0 kg/cm2}), spool (1) is moved to the
right in the direction of the arrow. Pump dis-
charge pressure (PP1), (PP2) then passes
through the notch (a) in spool (1) and is con-
nected to tank circuit (T).
q In this way, pump discharge pressure (PP1),
(PP2) is set to 2.45 MPa {25.0 kg/cm2}.
10-430 10 PC45MR-3, PC55MR-3

When control valve is in fine control

T : Tank circuit
1. Spool
2. Spring
Function Operation
q When the control valve is in the fine control q When fine control is carried out on the control
mode, if the demand flow for actuator is less valve, LS pressure (PLS1), (PLS2) is gener-
than the value corresponding to the minimum ated and acts on the right end of spool (1).
swash plate angle of the pump, pump pressure When this happens, the area of the opening of
(PP1), (PP2) is set to LS pressure (PLS1), the control valve spool is small, so there is a
(PLS2) + 2.45 MPa {25.0 kg/cm2}. If the differ- big difference between LS pressure (PLS1),
ential pressure between pump pressure (PP1), (PLS2) and pump discharge pressure (PP1),
( PP2 ) an d LS pr essu re (PL S1), (PL S2) (PP2).
becomes equal to the load of spring (2) (2.45 q When the differential pressure between pump
MPa {25.0 kg/cm2}), the unload valve opens. discharge pressure (PP1), (PP2) and LS pres-
Accordingly, LS differential pressure (PLS) is sure (PLS1), (PLS2) reaches the load of spring
2.45 MPa {25.0 kg/cm2} at this time. (2) (2.45 MPa {25.0 kg/cm2}, spool (1) moves
to the right in the direction of the arrow, and
pump circuit (PP1), (PP2) and tank circuit (T)
are connected.
q In other words, pump discharge pressure
(PP1), (PP2) is set to a pressure equal to the
spring force (2.45 MPa {25.0 kg/cm 2 }) + LS
pressure (PLS1), (PLS2) and LS differential
pressure (dPLS) becomes 2.45 MPa {25.0 kg/
cm2}.
PC45MR-3, PC55MR-3 10-430 11

When control valve is being operated

(work equipment)

T : Tank circuit
1. Spool
2. Spring
Function Operation
q When the control valve is operated, if the q When the control valve is operated to a bigger
demand flow for actuator exceeds the value stroke, LS pressure (PLS1), (PLS2) is gener-
corresponding to the minimum swash plate ated and acts on the right end of spool (1).
angle of the pump, the outflow to tank circuit When this happens, the area of the opening of
(T) is shut off and all of pump delivery (Q1), the control valve spool is large, so the differ-
(Q2) is sent to the actuator circuit. ence between LS pressure (PLS1), (PLS2)
and pump discharge pressure (PP1), (PP2) is
small.
q For this reason, the differential pressure
between pump discharge pressure (PP1),
(PP2) and LS pressure (PLS1), (PLS2) does
not reach the load of spring (2) (2.45 MPa
{25.0 kg/cm2}), so spool (1) is pushed to the
left by spring (2).
q As a result, pump circuit (PP1), (PP2) and tank
circuit (T) are shut off, and all the pump deliv-
ery (Q1), (Q2) flows to the actuator circuit.
10-430 12 PC45MR-3, PC55MR-3

When travel control valve is operated (singly)

T : Tank circuit
1. Spool
2. Spring
Function
q When the machine travels, the swash plate
angle of the pump becomes maximum. At this
time, the oil flow is controlled according to the
opening rate of the spool (1).
Operation
q When the travel control valve is operated sin-
gly, the control valve is separated by the pump
merge-divider valve.
q As a result, the unload valves on (PP1) and
(PP2) sides operate according to the opening
rate of the travel spools (1) on both sides.
PC45MR-3, PC55MR-3 10-430 13

Introduction of LS pressure
Work equipment valve (Boom, arm, bucket, boom swing)
Function q At the same time, reducing valve (3) also

q The LS pressure is the actuator load pressure moves to the right, so pump pressure (PP3) is
at the outlet port end of the control valve. reduced by the pressure loss at notch (c). It
q With the control valve, it actually reduces goes to LS circuit (PLS3), and then goes to
pump pressure (PP3) at reducing valve (3) of spring chamber (PLS').
the pressure compensation valve to the same q When this happens, LS circuit (PLS3) is con-
pressure as actuation circuit pressure (A), and nected to tank circuit (T) from LS bypass valve
sends it to the LS circuit (PLS3). (4) (see the section on the LS bypass valve).
q The actuator circuit pressure (A) acts on the
Operation left end of reducing valve (3). The reduced
q When spool (1) is operated, pump pressure pump pressure (PP3) acts on at the other end.
(PP3) flows from flow control valve (2) and q As a result, reducing valve (3) is balanced at a
notch (a) in the spool through bridge passage position where actuator circuit pressure (A)
(b) to actuator circuit (A). and the pressure of spring chamber (PLS') are
the same. Pump pressure (PP3) reduced at
notch (a) becomes actuator circuit pressure (A)
and is taken to LS circuit (PLS3).
10-430 14 PC45MR-3, PC55MR-3

LS bypass valve
Function
q This releases the residual pressure of LS pres-
sure.
q It makes the speed of the rise in pressure of LS
pressure more gentle. In addition, with this dis-
carded throttled flow, it creates a pressure loss
in the throttled flow of the spool or shuttle
valve, and increases the stability by lowering
the effective LS differential pressure.
Operation
q The oil in LS circuit flows through filter (a) and
orifice (b) to the tank circuit.
PC45MR-3, PC55MR-3 10-430 15

Pressure compensation valve
Function q Flow control valve (2) and reducing valve (1)

q During compound operations, if the load pres- are balanced in position where the difference
sure becomes lower than the other actuator in pressure between (PLS) and (PA) acting on
and the oil flow tries to increase, compensation both ends of reducing valve (1) and the pres-
is received. sure loss between (PP) and (PPA) on both
[When this happens, the other actuator being sides of flow control valve (2) are the same.
used for compound operation (right side) is at q In this way, the pressure difference between
a higher load than the actuator on this side (left upstream pressure (PPA) and downstream
side).] pressure (PA) of both spools used during com-
pound operations is the same, so the pump
Operation flow is divided in proportion to the area of
q If the load pressure of the other actuator (right opening of notch (a) of each spool.
side) becomes higher during compound opera-
tions, the oil flow in actuator circuit (A) on this
side (left side) tries to increase.
q If this happens, the LS pressure (PLS) of the
other actuator acts on spring chamber (PLS'),
and reducing valve (1) and flow control valve
(2) are pushed to the left.
q Flow control valve (2) throttles the area of
opening between pump circuit (PP) and spool
upstream (PPA), and pressure loss is gener-
ated between (PP) and (PPA).
10-430 16 PC45MR-3, PC55MR-3

Area ratio of pressure compensation valve
Function Area ratio (S2) : (S1) and compensation charac-

q The pressure compensation valve determines teristics
the compensation characteristics by carrying q When ratio is 1.00:
out fine adjustment of the area ratio (S2) : (S1) [Pump pressure (PP) – spool notch upstream
between area (S2) of reducing valve (1) and pressure (PPB)] C [LS circuit pressure (PLS) –
area (S1) of flow control valve (2) to match the actuator circuit pressure (PA) = (A)] and oil flow
characteristics of each actuator. is divided in proportion to area of opening of
spool.
S1: Area of flow control valve (2) q When ratio is more than 1.00:
– area of piston (3) (PP) – (PPB) > (PLS) – (PA) = (A) and oil flow
S2: Area of reducing valve (1) is divided in a proportion less than area of
– area of piston (3) opening of spool.
q When ratio is less than 1.00:
(PP) – (PPB) < (PLS) – (PA) = (A) and oil flow
is divided in a proportion more than area of
opening of spool.
PC45MR-3, PC55MR-3 10-430 17

LS receiving throttle of pressure compensation valve
Function Operation
q If the other actuator is relieved during com- q If the other actuator (right side) is relieved dur-
pound operations, LS introduction throttle (b) ing compound operations, each circuit pres-
of reducing valve (1) divides the flow and sure (PPA), (PA) of the other actuator becomes
sends more oil to the side receiving compen- the same as the pump circuit pressure [(PP) =
sation. relief pressure].
q In this case, spring chamber (PLSA) of the
other actuator becomes the same as pump cir-
cuit pressure (PP) because of the balance of
reducing valve (1).
q (PLSB) passes through LS introduction throttle
(b) of reducing valve (1) and becomes (PLS).
(PLS) is connected to the tank circuit (T) from
LS bypass plug (4), so pressure loss is gener-
ated at LS introduction throttle (b) [the condi-
tion becomes (PLS) < (PLSB)].
q As a result, even if the other actuator is
relieved, a pressure difference is created
between (PP) and (PLS), so more oil flows to
actuator circuit (A) on this side (left side).
10-430 18 PC45MR-3, PC55MR-3

L.H., R.H. travel junction circuit

During straight travel
Function
q An interconnection circuit is installed to correct
the flow error in both travel circuits during
straight travel.
q With this circuit, the flow rates in both travel
motors become almost the same during
straight travel to reduce travel deviation.
q Dampers (b) are installed to ease the transient
characteristics of sudden opening and closing
of the interconnection circuit when the machine
is steered and the spools are operated sharply.
Operation
q Bridge circuits (PA) of both travel circuits are
connected to each other by interconnection cir-
cuit (L). Accordingly, if there is difference
between the oil flow rates in both travel motors,
it is corrected to reduce the travel deviation.
PC45MR-3, PC55MR-3 10-430 19

Steering when traveling
Operation
q When the right travel spool (Right 1) is
returned to the neutral position to steer the
machine in the straight travel state, the load
pressures in both travel actuator circuits (PA)
become different (Left A) > (Right A).
q Since the main pump is separated at this time,
oil flows in both travel motors according to the
opening area of the spool.
10-430 20 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 10-430 21

Swing and blade valve
10-430 22 PC45MR-3, PC55MR-3

Structure
q The swing and blade sections are the open
center valves of the gear pump. They are
arranged tandem, with the swing section
ahead of the blade section.
Operation
Swing section
q If pressure is applied from the PPC valve to the
port (PA8), the spool moves to the left and oil
flows in the port (A8).
port (PB8), the spool moves to the right and oil
flows in the port (B8).
q Load check valve (2) is installed in each spool,
corresponding to ports (A) and (B) of each
valve.
q Relief valve (1) for the gear pump is installed to
the swing section.
Blade section
port (PA7), the spool moves to the left and oil
flows in the port (A7).
port (PB7), the spool moves to the right and oil
flows in the port (B7).
q Load check valve (2) is installed in each spool,
corresponding to ports (A) and (B) of each
valve.
PC45MR-3, PC55MR-3 10-430 23

Swing holding brake cancel system
Operation
q The left and right swing PPC pressure and the
arm IN PPC pressure each pass through
check valve inside spring case, are output to
port (BR) from port (PS), and the swing holding
brake is canceled. [The highest pressure is
output to port (BR).]
q The arm and swing are connected by the pilot
circuit inside the control valve.
10-430 24 PC45MR-3, PC55MR-3

Logic valve
Function
q This valve changes the pilot pressure to
change the merge-divider valve.
Operation
When divided
q If only the travel PPC pressure is applied to
port (b), it is applied to output port (c) of the
pump merge-divider valve as it is. This pres-
sure sets the pump merge-divider valve in the
division mode.
When merged
q If the work equipment PPC pressure (exclud-
ing the swing pressure) is applied to port (a),
the pressure in output port (c) of the pump
merge-divider valve is connected through
spool (1) to spring chamber (d) and used as
seal drain pressure.
q Accordingly, the pump merge-divider valve is
not changed but kept in the merging mode.
Even if the travel PPC pressure is applied
under this condition, spool (1) is kept pressed
and the valve is kept in the merging mode.
PC45MR-3, PC55MR-3 10-430 25

Merge-divider valve
When machine travels singly
Function
q When the machine travels singly, the merge-
divider valve spool separates pump pressures
(PP1) and (PP2).
Operation
q When the machine travels singly, the travel
port pressure is applied through the logic valve
spool to the right side of merge-divider valve
spool (1). If this pressure exceeds the force of
spring (2), merge-divider valve spool (1) is
pushed to the right and left to separate pump
pressures (PP1), (PP2) and (PP3).
q At this time, LS pressures (PLS1), (PLS2) and
(PLS3) are also separated from each other.
The pump pressure is output to output pres-
sure (PLS) applied to the pump LS valve.
10-430 26 PC45MR-3, PC55MR-3

When "work equipment is operated" and when "machine travels and work equipment is operated
simultaneously"
Function Operation
q When the work equipment is operated and q When the work equipment is operated, the out-
when the machine travels and the work equip- put of the logic valve spool becomes seal drain
ment is operated simultaneously, the merge- and the oil for changing the pump merge-
divider valve spool merges pump (discharge) divider valve is drained into the tank.
pressures (PP1) and (PP2). q Accordingly, merge-divider valve spool (1) is
pressed to the right by the force of spring (2)
and pump pressures (PP1), (PP2) and (PP3)
are merged. At this time, LS pressures
(PLS1), (PLS2) and (PLS3) are merged, too.
q When the machine travels and the work equip-
ment is operated simultaneously, the travel
port pressure is not applied to the pump
merge-divider valve, since the logic valve
spool is changed. Since the oil for changing
the pump merge-divider valve is drained into
the tank, the oils are merged.
q When the control lever is in neutral, the spring
force of the pump merge-divider valve spool is
larger because of the valve changing force
made by the travel PPC pressure. Accord-
ingly, the oils are merged.
PC45MR-3, PC55MR-3 10-430 27

SEN04609-00 Swing motor
Swing motor 1
Type: LMF16
B: From control valve T : To tank MB: From control valve

S: From tank MA: From control valve
Specifications
Type : LMF16
Theoretical discharge : 16.1 cm3/rev
Rated speed : 2,100 rpm
Rated delivery : 34 l/min
Suction valve cracking pressure: 0.04 MPa
{0.45 kg/cm2}
Safety valve set pressure : 18.6 MPa
{190 kg/cm2}
10-430 28 PC45MR-3, PC55MR-3

Swing motor SEN04609-00
1. Output shaft 7. Disc 13. Check valve

2. Housing 8. Plate 14. Safety valve
3. Shoe 9. Cylinder 15. Brake ring
4. Piston 10. Brake piston
5. Center spring 11. Swash plate
6. Valve plate 12. Brake spring
Unit: mm

Free length Replace spring
16 Check valve spring × Outside if damaged or
diameter deformed
3.43 N 2.75 N
13.0 × 6.5 7 —
{0.35 kg} {0.28 kg}
PC45MR-3, PC55MR-3 10-430 29

Hydraulic motor portion
Function
q This hydraulic motor is a swash plate type axial
piston motor, which converts the hydraulic
force sent from the hydraulic pump to a rotat-
ing movement.
Principle of operation
q The oil sent from the hydraulic pump goes from
valve plate (7) and enters cylinder block (5).
The structure of the motor takes in the oil at
one side only of the (Y – Y) line joining the top
and bottom dead centers of the stroke of piston
(4).
q The pressure oil entering one side of cylinder
block (5) generates force F1 [(F1 (N {kg}) = P
(MPa {kg/cm2}) × x/4 D2 (cm2)] pushing each
piston (4) (3 or 4 pistons).
q This force acts on thrust plate (2), but thrust
plate (2) is secured at a certain angle (a) to
output shaft (1), so the force is divided into
force (F2) and (F3).
q Of the divided forces, the radial force (F3) gen-
erates the torque (T = F3 x ri) for line (Y – Y)
joining the top and bottom dead centers.
q The combined force of this torque {T = Σ (F3 x
ri)} goes as a rotating force through the piston
(4) to rotate cylinder block (5).
q Cylinder block (5) is joined to the output shaft
by a spline, so the output shaft rotates and
transmits the torque.
10-430 30 PC45MR-3, PC55MR-3

Swing brake When swing and arm control levers are oper-
ated
Operation q The PPC output pressure flows through port
When swing and arm control levers are in neu- (B) into brake chamber (a). The oil in chamber
tral (a) presses down brake spring (13). As a
q Since the PPC output pressure is 0 MPa {0 kg/ result, brake piston (12) moves down and disc
cm2}, brake piston (12) is pushed up by brake (14) and plate (15) are separated, thus the
spring (13). As a result, disc (14) and plate brake is released.
(15) are pressed and the brake works.
PC45MR-3, PC55MR-3 10-430 31

Actuation of hydraulic timer

q The hydraulic timer acts to delay the start of
the swing brake effect in order to ensure
smooth deceleration and to prevent damage to
the parts of the motor when the swing motor
stops and the swing brake is applied suddenly.
q When the PPC lever is actuated, PPC output
pressure is applied to chamber (a) and the
swing brake is released. In this condition, if
the PPC lever is set in neutral, the supply of
pressure oil to port (B) stops and the pressure
in chamber (a) drops. As a result, the oil in
chamber (a) is pushed out by brake spring
(13).
q There is a check valve in the control valve on
the port (B) side, so the oil does not flow
through but flows out to passage (c). However,
the passage of the oil is throttled by orifice (f)
(φ0.5) in the brake piston (10), so the oil in
chamber (a) flows out only slowly, and this
delays the actuation of the swing brake by the
determined amount.
10-430 32 PC45MR-3, PC55MR-3

Brake valve When machine stops swinging

q If the swing control lever is returned to the neu-
Outline tral position, oil is not supplied from the pump
q The brake valve consists of a check valve and to port (MB) any more. Since the return circuit
a safety valve. for the oil from the motor outlet to the tank is
closed by control valve (1), the pressure in port
Function (MA) rises and revolution resistance is gener-
q When the machine stops swinging, control ated in the motor, then the motor is braked.
valve (1) closes the outlet circuit of the motor. q The pressure in port (MA) rises to the set pres-
Since the motor continues revolving because sure of the safety valve. As a result, high brak-
of the inertia, the motor output pressure rises ing torque is generated in the motor, then the
abnormally to break the motor. Accordingly, motor stops.
the abnormally high pressure is released q While the safety valve is operating, the oil dis-
through the port (S) from outlet (high pressure charged from the safety valve and the oil from
side) of the motor to protect the motor. port (S) are supplied through check valve (CB)
to port (MB) so that cavitation will not occur in
Operation port (MB).
When machine starts swinging
q When the swing control lever is operated to
swing to the left, the hydraulic oil from the
pump flows through control valve (1) into port
(MB). As a result, the pressure in port (MB)
rises and the starting torque is generated in the
motor and the motor starts revolution. The oil
from the motor outlet returns from port (MA)
through control valve (1) to the tank.
PC45MR-3, PC55MR-3 10-430 33

Modulating relief valve
Function
The relief valve for the swing motor prevents the
relief pressure from rising sharply to reduce shocks
when the machine starts and stops swinging.
Modulating relief valve

Ordinary relief valve
Operation
When circuit pressure is P0
q The relief valve does not operate.
When circuit pressure rises sharply

q When circuit pressure rises to (P1), the
hydraulic pressure acts on the area difference
between (D1) and (D3) (D1 > D3) and pushes
spring (4) to open valve (3).
q At this time, pressure acts on the area differ-
ence between (D1) and (D2) (D2 > D1), so
seat (1) follows valve (3).
q As seat (1) moves, the passage for the pres-
surized oil in chamber (a) to flow into port (S) is
narrowed by ball (2). Accordingly, seat (1)
does not move so fast as valve (3).
q As a result, the relief pressure rises gradually
from (P1) to (P2) while seat (1) is moving to
sleeve (5).
10-430 34 PC45MR-3, PC55MR-3

PPC valve SEN04609-00
PPC valve 1
Work equipment and swing PPC valve
P : From pilot pump through solenoid valve P4 : L.H. PPC valve: swing LEFT port/
P1 : L.H. PPC valve: arm IN port/ R.H. PPC valve: bucket CURL port
R.H. PPC valve: boom RAISE port T : To tank
P2 : L.H. PPC valve: arm OUT port/
R.H. PPC valve: boom LOWER port
P3 : L.H. PPC valve: swing RIGHT port/
R.H. PPC valve: bucket DUMP port
PC45MR-3, PC55MR-3 10-430 35

SEN04609-00 PPC valve
10-430 36 PC45MR-3, PC55MR-3

1. Spool
2. Piston
3. Disc
4. Nut (for connecting lever)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm

Free length
Centering spring × Outside
10 length load length load
(for P3, P4 port) diameter
Replace spring
9.81 N 7.85 N
38.71 × 15.5 34 — if damaged or
{1 kg} {0.8 kg}
deformed
Centering spring 17.7 N 14.1 N
11 42.48 × 15.5 34 —
(for P1, P2 port) {1.8 kg} {1.44 kg}
16.7 N 13.3 N
12 Metering spring 26.53 × 8.15 24.9 —
{1.7 kg} {1.36 kg}
PC45MR-3, PC55MR-3 10-430 37

Operation q The relationship in the position of spool (1) and

At neutral body (10) (fine control hole (f) is at a point mid-
q Ports (A) and (B) of the control valve and ports way between drain hole (D) and pump pres-
(P1) and (P2) of the PPC valve are connected sure chamber (PP)) does not change until
to drain chamber (D) through fine control hole retainer (9) contacts spool (1).
(f) in spool (1). q Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever.
q So the pressure at port (P1) also rises in pro-
portion to the travel of the control lever.
q In this way, the control valve spool moves to a
position where the pressure in chamber (A)
[the same as the pressure at port (P1)] and the
force of the control valve spool return spring
are balanced.
During fine control (neutral o fine control)

q When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
q When this happens, fine control hole (f) is shut
off from drain chamber (D), and at almost the
same time, it is connected to pump pressure
chamber (PP).
q So pilot pressure oil from the control pump
passes through fine control hole (f) and goes
from port (P1) to port (A).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP).
q At almost the same time, it is connected to
drain chamber (D) to release the pressure at
port (P1).
q When this happens, spool (1) moves up or
down so that the force of metering spring (2) is
balanced with the pressure at port (P1).
10-430 38 PC45MR-3, PC55MR-3

During fine control At full stroke

(when control lever is returned) q When disc (5) pushes down piston (4), and
q When disc (5) starts to be returned, spool (1) is retainer (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is connected with pump
q When this happens, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D) and the pressure q Therefore, the pilot pressure from the solenoid
oil at port (P1) is released. valve passes through fine control hole (f) and
q If the pressure at port (P1) drops too far, spool flows to chamber (A) from port (P1), and
(1) is pushed down by metering spring (2). pushes the control valve spool.
q Fine control hole (f) is shut off from drain q The oil returning from chamber (B) passes
chamber (D). At almost the same time, it is from port (P2) through fine control hole (f') and
connected to pump pressure chamber (PP). flows to drain chamber (D).
q The pump pressure is supplied until the pres-
sure at port (P1) recovers to a pressure that
corresponds to the lever position.
q When the spool of the control valve returns, oil
in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not
working. The oil passes through port (P2) and
enters chamber (B) to fill the chamber with oil.
PC45MR-3, PC55MR-3 10-430 39

Travel PPC valve
a For operation, see the sections of the “Work

equipment and swing PPC valve”.
P : From pilot pump through solenoid valve

P1 : R.H. travel FORWARD port
P2 : R.H. travel REVERSE port
P3 : L.H. travel FORWARD port
P4 : L.H. travel REVERSE port
T : To tank
10-430 40 PC45MR-3, PC55MR-3

1. Valve 4. Plate
2. Body 5. Piston
3. Collar 6. Bolt
Unit: mm

Free length
7 Centering spring × Outside
length load length load Replace spring
diameter
if damaged or
135 N 108 N deformed
52.06 × 15.5 31.9 —
{13.8 kg} {11.0 kg}
16.7 N 13.3 N
8 Metering spring 24.04 × 8.16 23.05 —
{1.7 kg} {1.36 kg}
PC45MR-3, PC55MR-3 10-430 41

Blade, boom swing and attachment PPC valve
a For operation, see the sections of the “Work

equipment and swing PPC valve”.
10-430 42 PC45MR-3, PC55MR-3

P : From pilot pump through solenoid valve

P1 : To blade, boom swing and attachment valve
P2 : To blade, boom swing and attachment valve
T : To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm

Free length
8 Centering spring × Outside
length load length load Replace spring
diameter
if damaged or
125 N 100 N deformed
33.88 × 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
9 Metering spring 22.73 × 8.1 22 —
{1.7 kg} {1.36 kg}
PC45MR-3, PC55MR-3 10-430 43

SEN04609-00

©2008 KOMATSU
All Rights Reserved
10-430 44
SEN04610-00
PC45MR-3,
PC55MR-3


500 Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of each part of work equipment ................................................................................................... 6
PC45MR-3, PC55MR-3 10-500 1

500 Work equipment
SEN04610-00 Work equipment
Work equipment 1
10-500 2 PC45MR-3, PC55MR-3

500 Work equipment
Work equipment SEN04610-00
PC45MR-3, PC55MR-3 10-500 3

500 Work equipment
SEN04610-00 Work equipment
Unit: mm

size Shaft Hole clearance limit
1a Clearance between mount-
ing pin of revolving frame – 0.036 + 0.095 0.07 –
and swing bracket and 120 1.0
– 0.090 + 0.034 0.185
bushing
– 0.036 + 0.054 0.036 –
1b 120 1.0
– 0.090 0 0.144
– 0.025 + 0.086 0.060 –
2a Clearance between mount- 50 1.0
– 0.064 + 0.035 0.150
ing pin of swing bracket and
boom and bushing – 0.025 + 0.039 0.025 –
2b 50 1.0
– 0.064 0 0.103
Clearance between mount- – 0.025 + 0.039 0.025 –
3 ing pin of swing bracket and 50 1.0
boom cylinder and bushing – 0.087 0 0.126
Clearance between mount- Replace pin and

– 0.025 + 0.089 0.06 – bushing
4 ing pin of boom and arm 50 1.0
– 0.064 + 0.035 0.153
and bushing
Clearance between mount-
– 0.170 – 0.012 0.105 –
5 ing pin of arm and bucket 45 1.0
– 0.230 – 0.065 0.218
and bushing
– 0.170 – 0.012 0.105 –
6 ing pin of link and bucket 45 1.0
– 0.230 – 0.065 0.218
and bushing
Clearance between mount- – 0.170 – 0.012 0.105 –
7 45 1.0
ing pin of links and bushing – 0.230 – 0.065 0.218
– 0.170 – 0.012 0.105 –
8 ing pin of arm and link and 45 1.0
– 0.230 – 0.065 0.218
bushing
Clearance between mount- – 0.025 + 0.142 0.105 –
9 ing pin of track frame and 35 1.0
blade and bushing – 0.087 + 0.080 0.229
10-500 4 PC45MR-3, PC55MR-3

500 Work equipment
Work equipment SEN04610-00
PC45MR-3, PC55MR-3 10-500 5

500 Work equipment
SEN04610-00 Dimensions of each part of work equipment
Dimensions of each part of work equipment 1

Arm section (STD)
10-500 6 PC45MR-3, PC55MR-3

500 Work equipment
Dimensions of each part of work equipment SEN04610-00
Unit: mm
PC45MR-3
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.1
1 — 45
– 0.064 0
+1
Arm side 55.5
0
2
0
Cylinder head side 55
– 0.5
– 0.025 + 0.039
3 — 50
– 0.064 0
+ 0.5
Boom side 163
0
4
– 0.3
Arm side 163
– 1.0
5 — 168.1 ±1
+1
6 — 182
0
+1
7 — 333.6
0
8 — 1,685.2 —
9 — 1,395 ±1
10 — 193.5 ±1
11 — 8.2 ±1
12 — 330 ± 0.5
13 — 303 ± 0.5
14 — 230.3 ± 0.5
15 — 871 —
– 0.170 – 0.050
16 — 45
– 0.230 – 0.089
+ 0.7
Link side 168
+ 0.2
17
Bucket side 170 ±1
– 0.170 – 0.050
18 — 45
– 0.230 – 0.089
+ 0.7
Arm side 168
+ 0.2
19
Bucket side 170 ±1
Min. 900 ± 1.5

20
Max. 1,480 —
PC45MR-3, PC55MR-3 10-500 7

500 Work equipment
SEN04610-00 Dimensions of each part of work equipment
Unit: mm
PC55MR-3
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.1
1 — 45
– 0.064 0
+1
Arm side 55.5
0
2
0
Cylinder head side 55
– 0.5
– 0.025 + 0.039
3 — 50
– 0.064 0
+ 0.5
Boom side 163
0
4
– 0.3
Arm side 163
– 1.0
5 — 117 ±1
6 — 199.4 ± 0.5
7 — 375.3 ± 0.5
8 — 1,640 ±3
9 — 1,364.5 ±1
10 — 193.3 ±1
11 — 12.8 ±1
12 — 330 ± 0.5
13 — 303 ± 0.5
14 — 230.3 ± 0.5
15 — 871 —
– 0.170 – 0.050
16 — 45
– 0.230 – 0.089
+ 0.7
Link side 168
+ 0.2
17
Bucket side 170 ±1
– 0.170 – 0.050
18 — 45
– 0.230 – 0.089
+ 0.7
Arm side 168
+ 0.2
19
Bucket side 170 ±1
Min. 900 ± 1.5

20
Max. 1,480 —
10-500 8 PC45MR-3, PC55MR-3

500 Work equipment
Dimensions of each part of work equipment SEN04610-00
Bucket section
Unit: mm
PC45MR, PC55MR-3
No.
Measuring point Standard size Tolerance
1 — 230.3 ± 0.5
2 — 0 —
3 — 719.6 —
4 — 55 —
5 — 55 —
6 — 45° —
7 — 45° —
8 — 13.5 —
9 — 170 ±1
10 — 60 —
11 — 42 —
12 — 258 ±1
13 — 85 —
14 — 85 —
– 0.050
15 — 45
– 0.089
PC45MR-3, PC55MR-3 10-500 9

SEN04610-00

©2008 KOMATSU
All Rights Reserved
10-500 10
SEN04611-00
PC45MR-3,
PC55MR-3


600 Cab and its attachments
Floor................................................................................................................................................................ 2
PC45MR-3, PC55MR-3 10-600 1

SEN04611-00 Floor
Floor 1
Tilt floor
a This diagram shows for canopy specification.
1. Gas spring Outline

2. Wire q The tilt floor can be tilted open for the ease of
3. Hinge pin adjusting of the fan belt, inspection and main-
4. Lock pin tenance such as replacement of the hydraulic
5. Tilt lock bracket hoses, etc.
6. Reset lever Tilt open angle (a): Approx. 35°
7. Floor assembly
10-600 2 PC45MR-3, PC55MR-3

Floor SEN04611-00
PC45MR-3, PC55MR-3 10-600 3

SEN04611-00

©2008 KOMATSU
All Rights Reserved
10-600 4
SEN04612-01
PC45MR-3,PC55MR-3
SEN04612-01
HYDRAULIC EXCAVATOR
Shop Manual
PC45MR-3
PC55MR-3

10 Structure,function and
maintenance standard
700 Electrical system
Engine control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Electrical control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Auto-deceleration function- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Attachment proportional switch, breaker operation switch, work mode selection, flow control function - - - - - - - - - - 14
KOMTRAX system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
Component parts of system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Monitor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Sensors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
PC45MR-3,PC55MR-3 10-700 1
SEN04612-01 Engine control system
Engine control system
1. Battery
2. Starting switch
3. Fuse box
4. Engine stop solenoid
5. Lock lever
6. PPC lock switch
7. Neutral engine start relay
8. Safety relay
9. Starting motor
10. Fuel control lever
11. KOMTRAX terminal
12. KOMTRAX engine cut-out relay
10-700 2 PC45MR-3,PC55MR-3
Engine control system SEN04612-01
Starting engine
q If starting switch (2) is set to the "ON" position,
engine stop solenoid (4) sets the governor stop
lever to the "RUN" position. Accordingly, if the
electric system has a failure, the engine stops,
that is, a fail-safe mechanism is formed.
q If starting switch (2) is set to the "START" posi-
tion while lock lever (5) is in the "LOCK" position,
the start signal flows in starting motor (9) and the
engine starts. If lock lever (5) is in the "FREE"
position, neutral engine start relay (7) operates
to shut off the start signal to starting motor (9),
thus the engine does not start.
q If the machine is equipped with the KOMTRAX
terminal system and receives an engine cut-out
command generated by an external operation,
KOMTRAX terminal (11) turns KOMTRAX en-
gine cut-out relay (12) ON to shut off the current
to starting motor (9), thus the engine cannot
start.
Engine speed control

q If fuel control lever (10) is operated, the cable is
extended or retracted to control the engine
speed.
Engine stopped
q If starting switch (2) is set to the "OFF" position,
lever to the "STOP" position to stop the engine.
PC45MR-3,PC55MR-3 10-700 3
SEN04612-01 Engine control system
(Auto-deceleration specification)
1. Battery 10. KOMTRAX terminal

2. Starting switch 11. KOMTRAX engine cut-out relay
3. Fuse box 12. Controller
4. Engine stop solenoid 13. Fuel control dial
5. Lock lever 14. Fuel control motor
6. PPC lock switch 15. Fuel control motor relay (For driving)
7. Neutral engine start relay 16. Fuel control motor relay (For acceleration)
8. Safety relay 17. Fuel control motor relay (For deceleration)
9. Starting motor 18. Machine monitor
10-700 4 PC45MR-3,PC55MR-3
Engine control system SEN04612-01
Starting engine
q If starting switch (2) is set to the "ON" position,
lever to the "RUN" position. Accordingly, if the
electric system has a failure, the engine stops,
that is, a fail-safe mechanism is formed.
q If starting switch (2) is set to the "START" posi-
tion while lock lever (5) is in the "LOCK" position,
the start signal flows in starting motor (9) and the
engine starts.
If lock lever (5) is in the "FREE" position, neutral
engine start relay (7) operates to shut off the
start signal to starting motor (9), thus the engine
does not start.
q If the machine is equipped with the KOMTRAX
terminal system and receives an engine cut-out
command generated by an external operation,
KOMTRAX terminal (10) turns KOMTRAX en-
gine cut-out relay (11) ON to shut off the current
to starting motor (9), thus the engine cannot
start.
Controlling engine speed

q Fuel control motor (14) outputs the acceleration
(engine speed raising) signal and deceleration
(engine speed lowering) signal to controller (12)
according to the position of fuel control dial (13).
q Upon receiving the signal, controller (12) outputs
the drive signal through fuel control motor relays
(15), (16), and (17) to fuel control motor (14).
q Fuel control motor (14) lengthens or shortens
the cable to control the engine speed
Stopping engine
q If starting switch (2) is set to the "OFF" position,
lever to the "STOP" position to stop the engine.
PC45MR-3,PC55MR-3 10-700 5
SEN04612-01 Electrical control system
Electrical control system

General system drawing
10-700 6 PC45MR-3,PC55MR-3
Electrical control system SEN04612-01
1. Battery
2. Starting switch
3. Fuse box
4. Machine monitor
5. 2nd travel speed selection solenoid relay
6. Lock lever
7. PPC lock switch
8. PPC lock solenoid relay
11. Right work equipment PPC valve
12. Travel PPC valve
13. Left work equipment PPC valve
14. Boom swing PPC valve
15. Blade PPC valve
16. Travel motor
17. Travel pressure switch
18. Travel alarm
19. Engine
20. Hydraulic pump
20a. Servo valve
20b. LS valve
20c. PC valve
21. Control valve
21a. Self-pressure reducing valve
PC45MR-3,PC55MR-3 10-700 7
(Attachment switch, auto-deceleration specification)
10-700 8 PC45MR-3,PC55MR-3
Travel control function
1. Battery Input and output signals

2. Starting switch a. Machine monitor power supply
3. Fuse box b. Solenoid power supply
4. Machine monitor c. 2nd travel speed selection signal
5. 2nd travel speed selection solenoid relay d. Solenoid valve drive signal
7. Left travel motor
8. Right travel motor
9. Control valve
10. Engine
11. Hydraulic pump
12. Travel pressure switch
13. Travel alarm
PC45MR-3,PC55MR-3 10-700 9
Function
Changing travel speed
q If the travel speed selector switch of the blade le-
ver is operated, the motor capacity changes,
thus the travel speed changes.
a Even while the machine is traveling at the high

speed (High), if the load changes largely on a
soft ground or on a slope, the travel speed is set
to the low speed (Low) automatically.
At this time, the 2nd travel speed selector
monitor keeps lighting up.
A: 21.6 MPa {221 kg/cm2}

B: 23.1 MPa {236 kg/cm2}
2nd travel speed selector

Low speed High speed
switch
OFF ON
monitor
OFF ON
solenoid valve
Motor capacity (cm3/rev) 33.08 19.11
Travel speed (km/h) 2.8 4.6
Travel motor swash plate
Max. Min.
angle
10-700 10 PC45MR-3,PC55MR-3
PPC lock function
1. Battery Input and output signals

2. Starting switch a. PPC lock signal
3. Fuse box b. Solenoid power supply
4. Lock lever c. Solenoid valve drive signal
5. PPC lock switch
6. PPC lock solenoid relay Function
7. PPC lock solenoid valve q The PPC lock switch is interlocked with the lock
8. Left PPC valve lever. If the lock lever is set in the LOCK posi-
9. Right PPC valve tion, the PPC lock switch is turned OFF.
10. Travel PPC valve q When the PPC lock switch is turned "OFF" , the
11. Boom swing PPC valve current to the PPC lock solenoid valve is cut-off,
12. Blade PPC valve causing neither the work equipment nor machine
13. Engine moves even if levers or pedal is operated.
14. Hydraulic pump
15. Control valve
PC45MR-3,PC55MR-3 10-700 11
SEN04612-01 Auto-deceleration function
Auto-deceleration function
General system drawing
1. Controller (Auto-deceleration) a. Swing holding brake release sensor signal

2. Oil pressure sensor (Input as operation signal of Swing [Left-Right]
3. Oil pressure switch and Arm [in] to controller)
4. Auto-deceleration switch b. Travel control lever, operation oil pressure switch
5. Fuel control dial signal
6. Fuel control motor c. Work equipment control lever, operation oil pres-
7. Starting switch sure switch signal
8. Fuse box d. Fuel control dial, potentiometer signal
9. Fuel control motor relay (For driving) e. Fuel control motor, potentiometer signal
10. Fuel control motor relay (For acceleration) f. Auto-deceleration switch, ON/OFF signal
11. Fuel control motor relay (For deceleration) g. Fuel control motor, drive signal
12. Travel alarm h. Fuel control motor, acceleration signal
13. Engine i. Fuel control motor, deceleration signal
14. Hydraulic pump j. Fuel control motor, secondary monitor signal of
15. Control valve drive signal
17. Swing motor
17a. Swing holding brake
10-700 12 PC45MR-3,PC55MR-3
Auto-deceleration function SEN04612-01
Function
q If all the control levers are set in neutral when
waiting for a dump truck or a next work, the en-
gine speed is decreased to the control speed au-
tomatically to reduce fuel consumption and
noise.
q If any lever is operated, the engine speed in-
creases to the speed set with the fuel control di-
al.
Operation
When all levers are set in neutral
q While the engine is running at a speed above the
engine control speed, if all the control levers are
kept in neutral for 4 seconds, the engine speed
is decreased and kept at the engine control
speed until a control lever is operated.
When control lever is operated

q While the engine speed is kept at the engine
control speed, if any control lever is operated,
the engine speed increases to the speed set with
the fuel control dial.
A: All work equipment control levers in "neutral"

B: Work equipment control lever "operated"
C: Speed set with fuel control dial
D: Engine control speed
E: 4 sec
F: Max. 2 sec
G: Max. 2 sec
Engine control speed

Model PC45MR-3 PC55MR-3
Engine control
1,450 1,450
speed (rpm)
PC45MR-3,PC55MR-3 10-700 13
SEN04612-01 Attachment proportional switch, breaker operation switch, work mode selection, flow control function
Attachment proportional switch, breaker operation switch, work mode

selection, flow control function
1. Controller a. Attachment proportional switch signal (Main)

2. Machine monitor b. Attachment proportional switch signal (Sub)
3. Attachment proportional switch c. 5V potentiometer power supply
4. Starting switch d. Attachment proportional switch ground (Main)
5. Fuse box e. Attachment proportional switch ground (Sub)
6. Breaker operation switch f. Breaker operation switch signal
7. Service switch (Auto-deceleration switch if ma- g. PPC lock switch signal
chine is equipped with auto-deceleration function) h. EPC valve drive signal (Port (A) side of control
8. Mode changeover switch valve)
9. Lock lever i. EPC valve drive signal (Port (B) side of control
10. PPC lock switch valve)
11. PPC lock solenoid relay j. Mode changeover switch signal (Attachment
12. PPC lock solenoid valve mode)
13. Engine k. Mode changeover switch signal (Breaker mode)
14. Hydraulic pump l. Service switch, ON/OFF signal
15. Control valve m. CAN signal
16. EPC valve (Port (A) side of control valve)
17. EPC valve (Port (B) side of control valve)
18. Attachment circuit selector valve
19. Attachment
10-700 14 PC45MR-3,PC55MR-3
Attachment proportional switch, breaker operation switch, work mode selection, flow control function SEN04612-01
Function Flow control function

Attachment proportional switch function The flow rates of the attachment mode and breaker
q Hydraulic oil is supplied to the attachment piping mode are set respectively with the service switch (or
according to the operation distance of the at- auto-deceleration switch if the machine is equipped
tachment proportional switch to operate a 2-way with the auto-deceleration function) and mode
attachment such as the crusher. changeover switch.
q This function operates only when the work mode In the attachment mode, the oil flow to the attach-
is set to the attachment mode. ment when the attachment proportional switch is
q Right switch: Right attachment piping of work leaned to the right or left stroke end is controlled.
equipment In the breaker mode, the oil flow to the breaker when
q Left switch: Left attachment piping of work the breaker operation switch is depressed is con-
equipment trolled.
Breaker operation switch function

q If the breaker operation switch is depressed
once, certain quantity of hydraulic oil is supplied
to the attachment piping to operate a 1-way at-
tachment such as the breaker.
q This function operates only when the work mode
is set to the breaker mode.
q Breaker operation switch: Left attachment
piping of work equipment
Work mode changeover function

q A proper work mode is selected with the work
mode changeover switch for each type of work.
(Prevention of overwork of attachment)
Symbol at work
mode changeover Work mode
switch section
Attachment mode: Attachment pro-
Lights up (a)
portional switch becomes effective
Breaker mode: Breaker operation
Lights up (b)
switch becomes effective
Normal mode: Attachment propor-
Both are off tional switch and breaker operation
switch are ineffective
a If the lighting side of the work mode changeover
switch is depressed again, both sides go off (The
machine is set in the normal mode).
PC45MR-3,PC55MR-3 10-700 15
Controller
10-700 16 PC45MR-3,PC55MR-3
Input and output signals

TYCO-1241434-81P[CN-G1]
CN1
Input/ Input/
Pin Pin
Signal name Output Signal name Output
No. No.
signal signal
1 Unswitched power supply Output Motor power supply relay secondary
41 Input
2 Unswitched power supply return Input monitor signal
3 NC (*) ― 42 Height set switch Input
4 Unswitched power supply Output 43 Work equipment PPC pressure switch Input
5 Unswitched power supply return Input 44 Pulse input ground Input
6 NC (*) Input 45 NC (*) ―
7 CAN_H ― 46 Analog signal ground Input
8 Potentiometer power supply (5 V) Output 47 Analog signal ground Input
9 Potentiometer power supply (5 V) Output 48 Arm angle sensor Input
10 NC (*) Input Right ATT switch (main), boom raise
49 Input
Swing lock reset PPC pressure sensor, PPC pressure sensor
11 Input
travel PPC pressure sensor 50 Analog input Input
12 Governor stroke sensor Input 51 Analog signal ground Input
13 Analog signal ground Input 52 Analog signal ground Input
14 Terminal resistance ― 53 NC (*) ―
15 NC (*) ― 54 NC (*) ―
16 NC (*) ― 55 NC (*) ―
17 Starting switch ACC Input 56 NC (*) ―
18 NC (*) ― 57 NC (*) ―
19 Digital signal ground Input 58 NC (*) ―
20 Digital signal ground Input 59 Boom swing neutral signal Input
21 Auto-deceleration ON/OFF switch Input 60 Auto-escape ON switch Input
22 Height limit clear switch Input 61 Breaker switch Input
23 Counterweight selection signal Input 62 Starting switch ACC Input
24 External start signal Input 63 NC (*) ―
25 NC (*) Input 64 NC (*) ―
26 CAN_H ― 65 Analog signal ground Input
27 NC (*) ― 66 Analog signal ground Input
28 NC (*) ― Right ATT switch (sub), offset angle sen-
29 Boom angle sensor Input 67 Input
sor
30 Boom bottom pressure sensor Input 68 Fuel control dial Input
31 NC (*) Input 69 NC (*) Input
32 Analog signal ground Input 70 Analog signal ground Input
33 Terminal resistance ― 71 Pulse input ground Input
34 NC (*) ― 72 NC (*) ―
35 NC (*) ― 73 NC (*) ―
36 NC (*) ― 74 NC (*) ―
37 NC (*) ― 75 NC (*) ―
38 Digital signal ground Input 76 Digital signal ground Input
39 Breaker mode switch Input 77 NC (*) Input
40 ATT mode switch Input 78 Travel PPC pressure switch Input
79 NC (*) Input
*: Never connect to NC or malfunctions or failures
80 Emergency reset switch Input
will occur. 81 NC (*) ―
*: Never connect to NC or malfunctions or failures
will occur.
PC45MR-3,PC55MR-3 10-700 17
CN2
Input/
Pin
Signal name Output
No.
signal
82 NC (*) ―
83 ATT mode LED Output
Boom swing neutral sensor power sup-
84 Output
ply, Offset left stop solenoid
85 Motor power supply relay Output
86 Travel alarm Output
87 NC (*) ―
88 NC (*) ―
89 NC (*) ―
90 NC (*) ―
91 Breaker mode LED Output
92 Arm crane rotary lamp drive relay Output
93 2nd travel speed selector relay, solenoid Output
94 Bucket dump stop solenoid Output
95 NC (*) ―
96 NC (*) ―
97 NC (*) ―
98 Height limit LED Output
99 NC (*) ―
100 Height limit rotary lamp drive relay Output
101 Motor drive relay (–) Output
102 Boom raise stop EPC Output
103 ATT (Port B) EPC Output
104 NC (*) ―
105 NC (*) ―
106 Auto-deceleration LED Output
107 PPC lock solenoid Output
108 NC (*) ―
109 Motor drive relay (+) Output
110 Arm in stop EPC Output
111 ATT (Port A) EPC, Arm dump EPC Output
112 NC (*) ―
113 NC (*) ―
114 Solenoid load return Input
116 Battery relay secondary power supply Input
119 NC (*) ―
121 Battery relay secondary power supply Input
* : Never connect to NC or malfunctions or failures
will occur.
10-700 18 PC45MR-3,PC55MR-3
Fuel control dial

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
q The fuel control dial is installed to the right con-
sole box. Potentiometer (5) is installed under
knob (1). If knob (1) is rotated, the shaft of poten-
tiometer (5) is rotated.
q The resistance of the variable resistor in potenti-
ometer (5) changes and a throttle signal is sent
to the controller.
q The hatched areas in the graph is the abnormal-
ity detection areas. In those areas, the engine
speed is set to high idle.
PC45MR-3,PC55MR-3 10-700 19
Fuel control motor

1. Motor assembly Input and output signals

2. Cable
3. Connector DT04-06P [CN-E1]
Wire
Pin No. Signal name
Color Type
1 Green AVX 0.75 Potentiometer VCC
2 Yellow AVX 0.75 Potentiometer OUT
3 Black AVX 0.75 Potentiometer GND
4 ― ― Dummy plug
5 Pink AVX 0.75 Motor (+)
6 White AVX 0.75 Motor (–)
10-700 20 PC45MR-3,PC55MR-3
KOMTRAX system SEN04612-01
KOMTRAX system
q The KOMTRAX terminal transmits various kinds

of machine information wirelessly. The
KOMTRAX operator can refer to the information
at the office to provide various kinds of services
for customers.
a To provide the services, a separate arrange-

ment for setting up the KOMTRAX terminal is
required.
Information transmittable from KOMTRAX

terminal system includes the following.
1. Operation information
2. Service meter
3. Location information
4. Fuel level
PC45MR-3,PC55MR-3 10-700 21
SEN04612-01 KOMTRAX system
KOMTRAX terminal
1. GPS antenna connector

2. Connector (A)
3. Connector (B)
4. Connector (C)
5. Communication antenna connection
Outline
q The KOMTRAX terminal can obtain various
kinds of information from network signals or in-
put signals in the machine and transmit them
through the wireless communication antenna. It
has a CPU (Central Processing Unit) in it and
also has wireless communication function and
GPS (Global Positioning System) function.
q This terminal has LED lamps and 7-segment in-
dicator lamps used for inspection and trouble-
shooting on its unit.
10-700 22 PC45MR-3,PC55MR-3
KOMTRAX system SEN04612-01

174480-1 AMP (18 + 12 + 12 pins)
Input/ Input/
Pin Input/Out-
Signal name Output Pin No. Signal name Pin No. Signal name Output
No. put signal
signal signal
1 NC 1 NC 1 (GND)
2 NC 2 NC 2 (GND)
3 NC 3 NC 3 ACC Input Input
4 NC 4 NC 4 R terminal input Input
5 NC 5 NC 5 Fuel sensor input 1 Input
6 NC 6 NC 6 Constant power supply Input
B C
7 Network selection 2 Input 7 NC 7 Constant power supply Input
8 Network selection 1 Input 8 NC 8 Relay output Output
9 CAN shield 9 NC 9 Inspection mode selection signal Input
A Input/
10 CAN (H) Output
10 NC 10 NC
Input/
11 CAN (L) Output
11 NC 11 C terminal input Input
12 Fuel sensor selection 2 Input 12 NC 12 Fuel sensor input 2 Input
13 Fuel sensor selection 1 Input
14 NC
15 NC
16 NC
17 NC
18 NC
PC45MR-3,PC55MR-3 10-700 23
SEN04612-01 Component parts of system
Component parts of system
PPC lock solenoid valve
2nd travel speed selector solenoid valve

a See “Solenoid valve”.
Machine monitor
a See “Monitor system”.
10-700 24 PC45MR-3,PC55MR-3
Monitor system SEN04612-01
Monitor system
1. Machine monitor Outline

2. Battery q The machine monitor system uses the net work
3. Each sensor circuit between the controllers and sensor in-
4. Alarm buzzer stalled to all parts of the machine to observe the
condition of the machine. It processes this infor-
Input and output signals mation, and display it on a panel to inform the
a. Power supply operator of condition of the machine.
b. Sensor signal
c. Alarm buzzer signal
PC45MR-3,PC55MR-3 10-700 25
SEN04612-01 Monitor system
Machine monitor
Outline
q The machine monitor has the monitor display function, gauge display function and service meter function.
q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the infor-
mation.
q If there is a trouble in the machine monitor unit, the monitor does not display normally.

AMP070-20P [CN-F15]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 (GND) Input 11 Buzzer output Output
2 NC Input 12 Working lamp switch Input
3 NC Input 13 Fuel level sensor Input
4 Wake up switch Input 14 CAN+ Input/Output
5 CAN– Input/Output 15 Speed increase solenoid relay output Output
6 Speed increase Input 16 Engine coolant temperature sensor Input
7 Engine oil pressure switch Input 17 Charge level Input
8 Preheating switch Input 18 NC Input
9 Key input Input 19 ACC Input
10 Sensor GND Input 20 Constant power supply Input
10-700 26 PC45MR-3,PC55MR-3
Monitor system SEN04612-01
Operation
Gauge and monitor display unit

Light
Type of
No. Displayed item Display range Display method Display color source
display
element
When below red When normal: OFF
1a Pilot Red LCD
Fuel gauge range When below red range: Flashing
1b Gauge Empty - Full Indication with pointer White LCD
Display of
2 Service meter 0 - 99999.9 h Operation during run of engine
clock time
3a Gauge 55 – 135 °C Indication with pointer White
Coolant tem- When coolant
When normal: OFF
3b Pilot perature temperature is Red
When above 110 °C: Flashing
abnormal
4 Caution Preheating During preheating During operation: Flashing (18 sec) Green
Electrical sys- When system is
5 Caution When abnormal: Lighting or flashing LED
tem warning abnormal
Engine oil Below specified
6 Caution When abnormal: Flashing Red
pressure pressure
Battery charge When charge is
7 Caution When abnormal: Flashing
level defective
When travel
Travel speed
8 Pilot speed is When speed is increased: Lighting Orange
increase
increased
PC45MR-3,PC55MR-3 10-700 27
SEN04612-01 Sensors
Sensors
q The signals from the sensors are input to the panel directly.
q The sensors are classified into contact type and resistance type.
q Either side of a sensor of contact type is always connected to the chassis ground.
Display category Sensor name Type of sensor When normal When abnormal
Caution Engineoil pressure Contact OFF (Open) ON (Closed)
Coolant temperature Resistance ― ―
Gauge
Fuel level Resistance ― ―
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
q The engine oil pressure sensor is installed to the engine cylinder block and its diaphragm senses oil pres-
sure. If the oil pressure lowers below the set level, the switch is turned ON.
Coolant temperature sensor
1. Connector 3. Thermistor
2. Plug
Function
q The coolant temperature sensor is installed to the engine cylinder block. It senses changes of temperature
as changes of resistance of the thermistor in it, and then generates signals according to the measured
temperature.
10-700 28 PC45MR-3,PC55MR-3
Sensors SEN04612-01
Fuel level sensor
1. Float
2. Arm
3. Variable resistor
4. Connector
Function
q The fuel level sensor is installed to the top of the fuel tank and its float moves up and down according to
the fuel level in the tank.
The movement of the float operates the variable resistor through the arm. As a result, signals of change
in resistance are generated.
PC45MR-3,PC55MR-3 10-700 29
SEN04612-01 Sensors
PPC pressure sensor

(Travel and swing brake cancel)
1. O-ring Input and output signals

2. Sensor
3. Connector
Function
q The PPC pressure sensor is installed to the con-
trol valve joint of the pilot circuit. It detects pilot
pressure and outputs a variable voltage.
10-700 30 PC45MR-3,PC55MR-3
Sensors SEN04612-01
PC45MR-3,PC55MR-3 10-700 31
SEN04612-01
©2009 KOMATSU
All Rights Reserved
10-700 32
SEN04648-00
HYDRAULIC EXCAVATOR
PC45MR-3,
PC55MR-3

20 Standard value table 20
100 Standard service value table

Standard service value table for engine related parts ..................................................................................... 2
Standard service value table for chassis related parts.................................................................................... 4
PC45MR-3, PC55MR-3 20-100 1

SEN04648-00 Standard service value table for engine related parts
Standard service value table for engine related parts 1
Applicable model: PC45MR-3
Applicable model PC45MR-3

Engine 4D88E-6
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle 2,550 ± 50 —
Engine speed Low idle rpm 1,175 ± 50 —
Rated speed 2,400 —
At sudden acceleration Bosch Max. 25 35
Exhaust gas color
At high idle index — —
Valve clearance Intake valve 0.20 —

mm
(Normal temperature) Exhaust valve 0.20 —
Oil temperature: 40 – 60ºC MPa 3.43 ± 0.1 2.75 ± 0.1
Compression pressure
Engine speed: 250 rpm {kg/cm2} {35 ± 1} {28 ± 1}
(Coolant temperature: operating range) kPa — —
Blow-by pressure
At high idle {mmH2O} {—} {—}
(Coolant temperature: operating range) 0.32 – 0.47 Min. 0.32
At high idle {3.3 – 4.8} {Min. 3.3}
Oil pressure MPa
(SAE30W) {kg/cm2} Min. 0.06 Min. 0.06
At low idle
{Min. 0.6} {Min. 0.6}
Oil temperature Whole speed range (inside oil pan) °C Max. 120 Max. 120
Fuel injection timing
Before Top Dead Center °(degree) 14.5 —
(Reference value)
Deflection when pressed with finger force of
Alternator belt tension mm 7 – 10 14
approx. 98 N{10 kg}
20-100 2 PC45MR-3, PC55MR-3

Standard service value table for engine related parts SEN04648-00
Applicable model PC55MR-3

Engine 4D88E-6
Standard value for
new machine
High idle 2,550 ± 50 —
Engine speed Low idle rpm 1,175 ± 50 —
Rated speed 2,400 —
At sudden acceleration Bosch Max. 25 35
Exhaust gas color
At high idle index — —
Valve clearance Intake valve 0.20 —

mm
(Normal temperature) Exhaust valve 0.20 —
Oil temperature: 40 – 60ºC MPa 3.43 ± 0.1 2.75 ± 0.1
Compression pressure
Engine speed: 250 rpm {kg/cm2} {35 ± 1} {28 ± 1}
(Coolant temperature: operating range) kPa — —
Blow-by pressure
At high idle {mmH2O} {—} {—}
(Coolant temperature: operating range) 0.32 – 0.47 Min. 0.32
At high idle {3.3 – 4.8} {Min. 3.3}
Oil pressure MPa
(SAE30W) {kg/cm2} Min. 0.06 Min. 0.06
At low idle
{Min. 0.6} {Min. 0.6}
Oil temperature Whole speed range (inside oil pan) °C Max. 120 Max. 120
Fuel injection timing
Before Top Dead Center °(degree) 14.5 —
(Reference value)
Deflection when pressed with finger force of
Alternator belt tension mm 7 – 10 14
approx. 98 N{10 kg}
PC45MR-3, PC55MR-3 20-100 3

SEN04648-00 Standard service value table for chassis related parts
Standard service value table for chassis related parts 1
Machine model PC45MR-3

Category
Standard value for

new machine
• Hydraulic oil temperature: 45 – 55°C

Speed when 1 pump is relieved • Engine oil pressure: Within operating Min. 2,220 Min. 2,220
Engine speed
range
• Engine coolant temperature: Within
rpm
operating range
• Relief of 1 pump: Relieve bucket circuit.
Speed when 2 pumps are relieved Min. 2,150 Min. 2,150
• Relief of 2 pumps: Relieve bucket and
swing circuits.
Boom control valve
Stroke of control valve spool
Arm control valve

Bucket control valve
Swing control valve
a For details, see Fig. A at the end of this l = 30 l = 30
Breaker control valve mm a=6 a=6
section. b=6 b=6
Boom swing control valve
Blade control valve
Left travel control valve
Right travel control valve
Boom control lever N o RAISE, LOWER 85 ± 10 85 ± 10
Arm control lever N o IN, OUT 85 ± 10 85 ± 10
Bucket control lever N o CURL, DUMP 85 ± 10 85 ± 10
Stroke of control lever and pedal
• Stop engine. N o Swing to LEFT,

Swing control lever RIGHT 85 ± 10 85 ± 10
• Measure at
center of lever N o Swing boom to
Boom swing control pedal grip. 25 ± 5 25 ± 5
LEFT, RIGHT
Blade control lever • Measure at N o RAISE, LOWER mm 50 ± 5 50 ± 5
pedal tip.
• Read max. N o FORWARD,
Travel control lever 100 ± 10 100 ± 10
value to stroke REVERSE
end (excluding SLOW i
o FULL
Fuel control lever 160 ± 20 160 ± 20
neutral play). THROTTLE
Work equipment,
Max. 5 Max. 5
Play of control lever swing
Travel Max. 5 Max. 5
20-100 4 PC45MR-3, PC55MR-3

Standard service value table for chassis related parts SEN04648-00

Category
Standard value for

new machine
15.68 ± 4.9 15.68 ± 9.8

Boom control lever
{1.6 ± 0.5} {1.6 ± 1}
Operating effort of control levers and pedals
15.68 ± 4.9 15.68 ± 9.8

Arm control lever {1.6 ± 0.5} {1.6 ± 1}
Bucket control lever 15.68 ± 4.9 15.68 ± 9.8

• Run engine at full throttle. {1.6 ± 0.5} {1.6 ± 1}
15.68 ± 4.9 15.68 ± 9.8
Swing control lever • Install push-pull scale to center of lever {1.6 ± 0.5} {1.6 ± 1}
grip or pedal tip to measure.
N 78.4 ± 19.6 78.4 ± 29.4
Boom swing control pedal • Read max. value to stroke end. {kg} {8.0 ± 2.0} {8.0 ± 3.0}
29.4 ± 9.8 29.4 ± 19.6
Blade control lever {3.0 ± 1.0} {3.0 ± 2}
Travel control lever 22.5 ± 4.9 22.5 ± 9.8

{2.3 ± 0.5} {2.3 ± 1}
29.4 ± 14.7 29.4 ± 29.4
Idle o Full throttle
{3.0 ± 1.5} {3.0 ± 3}
Fuel control lever
29.4 ± 14.7 29.4 ± 29.4
Full throttle o Idle {3.0 ± 1.5} {3.0 ± 3}
• Set all levers in neutral. 3.23 ± 0.49 3.23 ± 0.49
Unload pressure
• Run engine at full throttle. {33 ± 5} {33 ± 5}
• Measure pump outlet pressure.
26.5 ± 0.98 26.5 ± 0.98
Boom relief pressure
{270 ± 10} {270 ± 10}
26.5 ± 0.98 26.5 ± 0.98

Arm relief pressure • Hydraulic oil temperature: 45 – 55°C {270 ± 10} {270 ± 10}
• Run engine at full throttle and measure
Bucket relief pressure 26.5 ± 0.98 26.5 ± 0.98
relief pressure (Relieve only circuit to be {270 ± 10} {270 ± 10}
measured).
Swing relief pressure • Measure pump outlet pressure. 19.6 ± 0.98 19.6 ± 0.98
{200 ± 10} {200 ± 10}
Oil pressure
Boom swing relief pressure 26.5 ± 0.98 26.5 ± 0.98

MPa {270 ± 10} {270 ± 10}
{kg/cm2}
+ 0.98 + 0.98
21.6 ± – 0.49 21.6 ± – 0.49
Raise
+ 10 + 10
{220 ± – 5 } {220 ± – 5 }
Blade relief pressure
+ 0.98 + 0.98
21.6 ± – 0.49 21.6 ± – 0.49
Lower
+ 10 + 10
{220 ± – 5 } {220 ± – 5 }
26.5 ± 0.98 26.5 ± 0.98

Travel relief pressure
{270 ± 10} {270 ± 10}

• Run engine at full throttle. + 0.59 + 0.59
4.90 + 0.1 4.90 + 0.1
Control circuit oil pressure • Measure circuit oil pressure when all +6 +6
control levers are in neutral. {50 + 1 } {50 + 1 }
• Measure pump outlet pressure
PC45MR-3, PC55MR-3 20-100 5


Category
Standard value for

new machine
• Hydraulic oil
temperature: When all levers are in 3.23 ± 0.49 3.23 ± 0.49
neutral {33 ± 5} {33 ± 5}
Oil pressure
45 – 55°C
• Run engine at full MPa
LS differential pressure
throttle. {kg/cm2}
While bucket is curled
• Pump outlet 1.57 ± 0.1 1.57 ± 0.1
with no load
pressure – {16 ± 1} {16 ± 1}
(full throttle)
LS pressure
a For measuring posture, see Fig. B at
end of this section.
• No load, max. reach
• Run engine at full throttle.
deg. Max. 40 50
Overrun of swing • Hydraulic oil temperature: 45 – 55°C
(mm) (–) (–)
• Stop after swinging 1 turn and measure
shifting distance of swing circle.
• Value in ( ) is shifting distance of outside
of swing circle.
a For measuring posture, see

Fig. B at end of this section.
90° 2.3 ± 0.3 2.9
Time required to start swinging • Hydraulic oil temperature:
45 – 55°C
• Measure time required to
180° — —
pass 90° and 180° points
after starting swinging. sec.

Swing

Time required for swinging • Run engine at full throttle. 33 ± 3 38
• Measure time required to swing 5 turns
after swinging 1 turn.
a For measuring posture, see Fig. C at
• Max. reach
• Stop engine.
• Fill bucket with rated load or dirt and
Hydraulic drift of swing deg. 0 0
sand. (Rated load: 1,422 N {145 kg}) (mm) (0) (0)
• Stop machine on slope of 15° and set its
upper structure at 45° upward.
• Make match marks on swing circle outer
race and track frame.
• Measure shifting distance of match
marks in 15 minutes.
Leakage from swing motor cc/min. — —
• Relieve swing circuit and measure
leakage in 1 minute.
20-100 6 PC45MR-3, PC55MR-3


Category
Standard value for

new machine

Fig. D at end of this section.
• Run engine at full throttle. 27.7 ± 2 27.7 ± 4
Low speed
(26.9 ± 2) (26.9 ± 4)
• Hydraulic oil temperature:
45 – 55°C
Travel speed • After approach run of at sec.
least 10 m on flat ground,
measure time required to
High 15.7 ± 2 15.7 ± 4
travel 20 m. speed (15.3 ± 2) (15.3 ± 4)
• ( ): Machine with steel shoe
specification
• Run engine at full throttle. Low speed Max. 300 330
45 – 55°C
Travel
• After approach run of at

Travel deviation mm
least 10 m on hard and flat
ground, measure travel
deviation (X) in the travel of High
20 m after approach run (For Max. 300 330
speed
details, see Fig. E at end of
this section).
a For measuring posture, see Fig. F at end
of this section.
• Stop engine.
Hydraulic drift of travel mm 0 0
• Stop machine on slope of 30° with
sprocket on upper side.
• Measure hydraulic drift of travel in 5
minutes.
Leakage from travel motor • Hydraulic oil temperature: 45 – 55°C l/min. — —
• Lock shoe to relieve travel circuit.
Whole work equipment

(Hydraulic drift of bucket a For measuring posture, see Fig. G at Max. 300 450
tooth tip) end of this section.
• Measure extension and retraction of
each cylinder and lowering of bucket
Boom cylinder (Retraction of tooth tip from above position. Max. 6 30
cylinder) • Stop machine on level and flat ground.
• Bucket: Rated load
(Rated load: 1,422 N {145 kg})
Arm cylinder (Extension of • Set lever in neutral.
Work equipment
Max. 30 30
Hydraulic drift
cylinder) • Stop engine

• Start measurement just after setting. mm
Bucket cylinder (Retraction of • Measure hydraulic drift every 5 minutes

for 15 minutes. Max. 16 30
cylinder)
• Stop engine
Boom swing cylinder
(Retraction and extension of Max. 20 30
• Set machine in above position on slope
cylinder)
of 15° with upper structure at right angle
to its body and measure retraction and
extension of cylinder for 15 minutes.
PC45MR-3, PC55MR-3 20-100 7


Category
Standard value for

new machine
Hydraulic drift
• Stop engine
Blade (Hydraulic drift of blade • Hydraulic oil temperature: 45 – 55°C
mm Max. 30 45
tip) • Measure hydraulic drift of blade tip from
maximum raising height for 15 minutes.

Fig. H at end of this section.
• Run engine at full throttle. RAISE 2.8 ± 0.3 3.4
45 – 55°C
Boom speed • Measure time required to
move cylinder between
extension stroke end and
position at which bucket LOWER 2.8 ± 0.3 3.4
tooth is in contact with
ground.

Fig. I at end of this section.
IN 3.0 ± 0.3 3.6
Arm speed 45 – 55°C
OUT 2.5 ± 0.3 3.0
extension and retraction
stroke ends.
Work equipment

Work equipment speed
Fig. J at end of this section.

CURL 2.9 ± 0.3 3.5
Bucket speed 45 – 55°C sec.
DUMP 2.0 ± 0.3 2.4
stroke ends.

Fig. K at end of this section.
45 – 55°C
Blade speed • Measure time required to
move cylinder between posi-
tion at which blade is in con-
tact with ground and LOWER 1.3 ± 0.3 1.6
maximum blade raising posi-
tion.

Swing
Fig. L at end of this section.
boom to 7.0 ± 1.5 10
LEFT
Boom swing speed 45 – 55°C
Swing
boom to 7.0 ± 1.5 10
RIGHT
stroke ends.
20-100 8 PC45MR-3, PC55MR-3


Category
Standard value for

new machine
a For measuring posture, see Fig. M at

• Run engine slow.
Boom time lag • Set arm to OUT stroke end, bucket to Max. 2 Max. 3.9
DUMP stroke end, and boom at RAISE
stroke end. Then, lower bucket and
measure time required to raise machine
after bucket touches ground.
a For measuring posture, see Fig. N at
Arm time lag • Set upper side of boom horizontally, Max. 1 Max. 2
bucket to DUMP stroke end, and arm to
IN stroke end. Then, move arm IN and
Time lag
measure time required to start it again

after it stops temporarily. sec.
Work equipment
a For measuring posture, see Fig. O at

Bucket time lag • Set upper side of boom horizontally, arm Max. 1 Max. 2
to IN stroke end, and bucket to DUMP
stroke end. Then, CURL bucket and
after it stops temporarily.
a For measuring posture, see Fig. P at end
of this section.
Blade time lag • Hydraulic oil temperature: 45 – 55°C Max. 2 Max. 3.9
• Lower blade from RAISE stroke end and
after blade touches ground.
Internal leakage
Leakage from each cylinder Max. 2 10

• Run engine at full throttle. cc/min
Leakage from center swivel • Relieve circuit to be measured. — —
joint
— Performance of hydraulic pump See section of “Performance of hydraulic pump”.
PC45MR-3, PC55MR-3 20-100 9


Category
Standard value for

new machine

Speed when 1 pump is relieved • Engine oil pressure: Within operating Min. 2,220 Min. 2,220
Engine speed
range
• Engine coolant temperature: Within
rpm
operating range
• Relief of 1 pump: Relieve bucket circuit.
Speed when 2 pumps are relieved Min. 2,150 Min. 2,150
• Relief of 2 pumps: Relieve bucket and
swing circuits.
Boom control valve
Stroke of control valve spool
Arm control valve

Bucket control valve
Swing control valve
a For details, see Fig. A at the end of this l = 30 l = 30
Breaker control valve mm a=6 a=6
section. b=6 b=6
Boom swing control valve
Blade control valve
Left travel control valve
Right travel control valve
Boom control lever N o RAISE, LOWER 85 ± 10 85 ± 10
Arm control lever N o IN, OUT 85 ± 10 85 ± 10
Bucket control lever N o CURL, DUMP 85 ± 10 85 ± 10
Stroke of control lever and pedal
• Stop engine. N o Swing to LEFT,

Swing control lever 85 ± 10 85 ± 10
• Measure at RIGHT
center of lever N o Swing boom to
Boom swing control pedal grip. 25 ± 5 25 ± 5
LEFT, RIGHT
Blade control lever • Measure at N o RAISE, LOWER mm 50 ± 5 50 ± 5
pedal tip.
• Read max. N o FORWARD,
Travel control lever 100 ± 10 100 ± 10
value to stroke REVERSE
end (excluding SLOW i
o FULL
Fuel control lever 160 ± 20 160 ± 20
neutral play). THROTTLE
Work equipment,
Max. 5 Max. 5
Play of control lever swing
Travel Max. 5 Max. 5
20-100 10 PC45MR-3, PC55MR-3


Category
Standard value for

new machine
15.68 ± 4.9 15.68 ± 9.8

Boom control lever
{1.6 ± 0.5} {1.6 ± 1}
Operating effort of control levers and pedals
15.68 ± 4.9 15.68 ± 9.8

Arm control lever {1.6 ± 0.5} {1.6 ± 1}
Bucket control lever 15.68 ± 4.9 15.68 ± 9.8

• Run engine at full throttle. {1.6 ± 0.5} {1.6 ± 1}
15.68 ± 4.9 15.68 ± 9.8
Swing control lever • Install push-pull scale to center of lever {1.6 ± 0.5} {1.6 ± 1}
grip or pedal tip to measure.
N 78.4 ± 19.6 78.4 ± 29.4
Boom swing control pedal • Read max. value to stroke end. {kg} {8.0 ± 2.0} {8.0 ± 3.0}
29.4 ± 9.8 29.4 ± 19.6
Blade control lever {3.0 ± 1.0} {3.0 ± 2}
Travel control lever 22.5 ± 4.9 22.5 ± 9.8

{2.3 ± 0.5} {2.3 ± 1}
29.4 ± 14.7 29.4 ± 29.4
Idle o Full throttle
{3.0 ± 1.5} {3.0 ± 3}
Fuel control lever
29.4 ± 14.7 29.4 ± 29.4
Full throttle o Idle {3.0 ± 1.5} {3.0 ± 3}
• Set all levers in neutral. 3.23 ± 0.49 3.23 ± 0.49
Unload pressure
• Run engine at full throttle. {33 ± 5} {33 ± 5}
• Measure pump outlet pressure.
26.5 ± 0.98 26.5 ± 0.98
Boom relief pressure
{270 ± 10} {270 ± 10}
26.5 ± 0.98 26.5 ± 0.98

Arm relief pressure • Hydraulic oil temperature: 45 – 55°C {270 ± 10} {270 ± 10}
• Run engine at full throttle and measure
Bucket relief pressure 26.5 ± 0.98 26.5 ± 0.98
relief pressure (Relieve only circuit to be {270 ± 10} {270 ± 10}
measured).
Swing relief pressure • Measure pump outlet pressure. 19.6 ± 0.98 19.6 ± 0.98
{200 ± 10} {200 ± 10}
Oil pressure
Boom swing relief pressure 26.5 ± 0.98 26.5 ± 0.98

MPa {270 ± 10} {270 ± 10}
{kg/cm2}
+ 0.98 + 0.98
21.6 ± – 0.49 21.6 ± – 0.49
Raise
+ 10 + 10
{220 ± – 5 } {220 ± – 5 }
Blade relief pressure
+ 0.98 + 0.98
21.6 ± – 0.49 21.6 ± – 0.49
Lower
+ 10 + 10
{220 ± – 5 } {220 ± – 5 }
26.5 ± 0.98 26.5 ± 0.98

Travel relief pressure
{270 ± 10} {270 ± 10}

• Run engine at full throttle. + 0.59 + 0.59
4.90 + 0.1 4.90 + 0.1
Control circuit oil pressure • Measure circuit oil pressure when all +6 +6
control levers are in neutral. {50 + 1 } {50 + 1 }
• Measure pump outlet pressure
PC45MR-3, PC55MR-3 20-100 11


Category
Standard value for

new machine
• Hydraulic oil
temperature: When all levers are in 3.23 ± 0.49 3.23 ± 0.49
neutral {33 ± 5} {33 ± 5}
Oil pressure
45 – 55°C
• Run engine at full MPa
LS differential pressure
throttle. {kg/cm2}
While bucket is curled
• Pump outlet 1.57 ± 0.1 1.57 ± 0.1
with no load
pressure – {16 ± 1} {16 ± 1}
(full throttle)
LS pressure
deg. Max. 40 50
Overrun of swing • Hydraulic oil temperature: 45 – 55°C
(mm) (–) (–)
• Stop after swinging 1 turn and measure
shifting distance of swing circle.
• Value in ( ) is shifting distance of outside
of swing circle.

Fig. B at end of this section.
90° 2.3 ± 0.3 2.9
Time required to start swinging • Hydraulic oil temperature:
45 – 55°C
180° — —
pass 90° and 180° points
after starting swinging. sec.

Swing

Time required for swinging • Run engine at full throttle. 33 ± 3 38
• Measure time required to swing 5 turns
after swinging 1 turn.
a For measuring posture, see Fig. C at
• Max. reach
• Stop engine.
• Fill bucket with rated load or dirt and
Hydraulic drift of swing deg. 0 0
sand. (Rated load: 1,422 N {145 kg}) (mm) (0) (0)
• Stop machine on slope of 15° and set its
upper structure at 45° upward.
• Make match marks on swing circle outer
race and track frame.
• Measure shifting distance of match
marks in 15 minutes.
Leakage from swing motor cc/min. — —
• Relieve swing circuit and measure
leakage in 1 minute.
20-100 12 PC45MR-3, PC55MR-3


Category
Standard value for

new machine

• Run engine at full throttle. 27.7 ± 2 27.7 ± 4
Low speed
(26.9 ± 2) (26.9 ± 4)
45 – 55°C
Travel speed • After approach run of at sec.
least 10 m on flat ground,
measure time required to
High 15.7 ± 2 15.7 ± 4
travel 20 m. speed (15.3 ± 2) (15.3 ± 4)
• ( ): Machine with steel shoe
specification
• Run engine at full throttle. Low speed Max. 300 330
45 – 55°C
Travel
• After approach run of at

Travel deviation mm
least 10 m on hard and flat
ground, measure travel
deviation (X) in the travel of High
20 m after approach run (For Max. 300 330
speed
details, see Fig. E at end of
this section).
a For measuring posture, see Fig. F at end
of this section.
• Stop engine.
Hydraulic drift of travel mm 0 0
• Stop machine on slope of 30° with
sprocket on upper side.
• Measure hydraulic drift of travel in 5
minutes.
Leakage from travel motor • Hydraulic oil temperature: 45 – 55°C l/min — —
• Lock shoe to relieve travel circuit.
Whole work equipment

(Hydraulic drift of bucket a For measuring posture, see Fig. G at Max. 300 450
tooth tip) end of this section.
• Measure extension and retraction of
each cylinder and lowering of bucket
Boom cylinder (Retraction of tooth tip from above position. Max. 6 30
cylinder) • Stop machine on level and flat ground.
Arm cylinder (Extension of • Set lever in neutral.
Work equipment
Max. 30 30
Hydraulic drift
cylinder) • Stop engine

• Start measurement just after setting. mm
Bucket cylinder (Retraction of • Measure hydraulic drift every 5 minutes

for 15 minutes. Max. 16 30
cylinder)
• Stop engine
Boom swing cylinder
(Retraction and extension of Max. 20 30
• Set machine in above position on slope
cylinder)
of 15° with upper structure at right angle
to its body and measure retraction and
extension of cylinder for 15 minutes.
PC45MR-3, PC55MR-3 20-100 13


Category
Standard value for

new machine
Hydraulic drift
• Stop engine
Blade (Hydraulic drift of blade • Hydraulic oil temperature: 45 – 55°C
mm Max. 30 45
tip) • Measure hydraulic drift of blade tip from
maximum raising height for 15 minutes.

Fig. H at end of this section.
45 – 55°C
Boom speed • Measure time required to
extension stroke end and
position at which bucket LOWER 2.9 ± 0.3 3.5
tooth is in contact with
ground.

Fig. I at end of this section.
IN 3.1 ± 0.3 3.7
Arm speed 45 – 55°C
OUT 2.5 ± 0.3 3.0
stroke ends.
Work equipment

Work equipment speed
Fig. J at end of this section.

CURL 2.8 ± 0.3 3.4
Bucket speed 45 – 55°C sec.
DUMP 2.0 ± 0.3 2.4
stroke ends.

Fig. K at end of this section.
45 – 55°C
Blade speed • Measure time required to
move cylinder between posi-
tion at which blade is in con-
tact with ground and LOWER 1.3 ± 0.3 1.6
maximum blade raising posi-
tion.

Swing
Fig. L at end of this section.
boom to 7.0 ± 1.5 10
LEFT
Boom swing speed 45 – 55°C
Swing
boom to 7.0 ± 1.5 10
RIGHT
stroke ends.
20-100 14 PC45MR-3, PC55MR-3


Category
Standard value for

new machine
a For measuring posture, see Fig. M at

Boom time lag • Set arm to OUT stroke end, bucket to Max. 2 Max. 3.9
DUMP stroke end, and boom at RAISE
stroke end. Then, lower bucket and
after bucket touches ground.
a For measuring posture, see Fig. N at
Arm time lag • Set upper side of boom horizontally, Max. 1 Max. 2
bucket to DUMP stroke end, and arm to
IN stroke end. Then, move arm IN and
Time lag

after it stops temporarily. sec.
Work equipment
a For measuring posture, see Fig. O at

Bucket time lag • Set upper side of boom horizontally, arm Max. 1 Max. 2
to IN stroke end, and bucket to DUMP
stroke end. Then, CURL bucket and
after it stops temporarily.
a For measuring posture, see Fig. P at end
of this section.
Blade time lag • Hydraulic oil temperature: 45 – 55°C Max. 2 Max. 3.9
• Lower blade from RAISE stroke end and
after blade touches ground.
Internal leakage
Leakage from each cylinder Max. 2 10

• Run engine at full throttle. cc/min
Leakage from center swivel • Relieve circuit to be measured. — —
joint
— Performance of hydraulic pump See section of “Performance of hydraulic pump”.
PC45MR-3, PC55MR-3 20-100 15

Posture of machine for measuring performance and measurement procedure
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
20-100 16 PC45MR-3, PC55MR-3

a Fig. G a Fig. J
a Fig. H a Fig. K
a Fig. I a Fig. L
PC45MR-3, PC55MR-3 20-100 17

a Fig. M a Fig. P
a Fig. N
a Fig. O
20-100 18 PC45MR-3, PC55MR-3

Performance of hydraulic pump
Machine Standard value for

model new machine

Discharge of PC45MR-3
• Run engine at rated speed. l/min. 33.1 26.5
gear pump PC55MR-3
• Measure at set pressure of relief valve.
Discharge Discharge Average

Standard
Measurement Machine pressure of pressure of the discharge Criterion
Item Checkpoint discharge
conditions model test pump other pump pressure Q(l/min)
Q(l/min)
(MPa{kg/cm2}) (MPa{kg/cm2}) (MPa{kg/cm2})
• Hydraulic oil temper-
ature: 45 – 55°C
• Engine speed:
at rated speed
Discharge
• Apply no load to
of piston PC45MR-3 aSee aSee
gear pump. Any point P1 P2 (P1+P2)/2
pump PC55MR-3 Fig. Q. Fig. Q.
a Avoid measuring
near broken part of
graph since error
become large at that
part.
a Fig. Q
PC45MR-3, PC55MR-3 20-100 19

SEN04648-00

©2008 KOMATSU
All Rights Reserved
20-100 20
SEN04649-00
PC45MR-3,
PC55MR-3

30 Testing and adjusting 30

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 6
Testing exhaust gas color ............................................................................................................................... 7
Testing and adjusting valve clearance ............................................................................................................ 8
Testing compression pressure ...................................................................................................................... 10
Testing engine oil pressure ............................................................................................................................11
Testing and adjusting fuel injection timing..................................................................................................... 12
Testing and adjusting alternator belt tension................................................................................................. 16
Testing and adjusting air conditioner compressor belt tension ..................................................................... 17
Adjusting fuel control lever............................................................................................................................ 18
Testing clearance in swing circle bearings.................................................................................................... 19
Testing and adjusting track shoe tension ...................................................................................................... 20
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits........ 21
Testing and adjusting LS differential pressure .............................................................................................. 26
Adjusting PC valve........................................................................................................................................ 29
Testing and adjusting control pump circuit oil pressure ................................................................................ 30
Testing solenoid valve output pressure......................................................................................................... 32
Testing PPC valve output pressure............................................................................................................... 33
Adjusting PPC valve ..................................................................................................................................... 35
Testing swing holding brake release pressure .............................................................................................. 36
Testing and adjusting travel deviation ........................................................................................................... 37
Testing oil leakage from work equipment cylinder ........................................................................................ 39
Bleeding air from each part........................................................................................................................... 41
PC45MR-3, PC55MR-3 30-100 1

SEN04649-00
Releasing residual pressure from hydraulic circuit........................................................................................ 43

Releasing residual pressure from hydraulic tank .......................................................................................... 44
Pressurizing hydraulic tank ........................................................................................................................... 44
How to open and close (tilt) floor................................................................................................................... 45
Inspection procedures for diode.................................................................................................................... 50
How to start operation of KOMTRAX terminal .............................................................................................. 51
Lamp display of KOMTRAX terminal ............................................................................................................ 55
Preparation work for troubleshooting of electrical system............................................................................. 59
30-100 2 PC45MR-3, PC55MR-3

Tools for testing, adjusting, and troubleshooting SEN04649-00
Tools for testing, adjusting, and troubleshooting 1
Sym-
Testing/Adjusting item bol Part No. Part Name Q’ty Remarks
Testing engine speed A 799-205-1100 Tachometer kit 1 Digital display: 6.0 – 99,999.9 rpm
1 799-201-9001 Handy smoke checker 1 Bosch index 0 – 9 (With standard

Testing exhaust gas color)
C
color
2 Commercially Smoke meter 1 —
available
Adjusting valve clear- D Commercially Clearance gauge 1 —
ance available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}

KIT No.: 795-502-1205
Testing compression E
pressure 2 795-111-1130 Adapter 1 —
3 795-101-1571 Joint 1 —
799-101-5002 Oil pressure gauge kit 1 Pressure gauge: 2.5, 6, 40, 60 MPa
(Analog) {25, 60, 400, 600 kg/cm2}
Testing engine oil pres- 1
sure F 790-261-1204 Oil pressure gauge kit 1 Pressure gauge: 60 MPa {600 kg/cm2}
(Digital)
2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 795-111-1140 Adapter 1
2 795-111-1150 Clamp 1
Testing and adjusting
Q
fuel injection timing 3 Commercially Dial gauge 1
available
4 795-111-1160 Extension rod 1
Testing and adjusting oil (Analog) {25, 60, 400, 600 kg/cm2}
1
pressures in work Oil pressure gauge kit
equipment, travel, G 790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm2}
(Digital)
boom swing, swing, and
blade circuits 799-101-5220 Nipple 1 10 × 1.25 mm
2
07002-11023 O-ring 1 —
(Analog) {25, 60, 400, 600 kg/cm2}
1
790-261-1204 Oil pressure gauge kit 1 Pressure gauge: 60 MPa {600 kg/cm2}
(Digital)
799-101-5220 Nipple 2 10 × 1.25 mm
Testing LS differential 2
pressure H 07002-11023 O-ring 2 —
3 799-401-2701 Differential pressure 1 —

gauge
799-401-2930 Adapter 1 Face seal type (#03)
4 Both male and female: 11/16-16UNF
02896-11009 O-ring 1 (Female: R1/8)
PC45MR-3, PC55MR-3 30-100 3

SEN04649-00 Tools for testing, adjusting, and troubleshooting
Sym-
Oil pressure gauge kit Pressure gauge: 2.5, 6, 40, 60 MPa

799-101-5002 (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge kit
790-261-1204 (Digital) 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing control circuit oil
pressure J
Face seal type (#02)
799-401-3100 Adapter 1 Both male and female: 9/16-18UNF
2 (Female: R1/8)
02896-11008 O-ring 1
799-101-5002 (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Testing and adjusting Oil pressure gauge kit
control pump circuit oil K 790-261-1204 (Digital) 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure
799-101-5220 Nipple 1 10 × 1.25 mm
2
07002-11023 O-ring 1 —
799-101-5002 (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Testing solenoid valve L 790-261-1204 (Digital) 1 Pressure gauge: 60 MPa {600 kg/cm2}
output pressure
799-401-3100 Adapter 1 Face seal type (#02)
02896-11008 O-ring 1 (Female: R1/8)
799-101-5002 (Analog) 1 {25, 60, 400, 600 kg/cm2}
Testing PPC valve out- 1
put pressure and swing M 790-261-1204 (Digital) 1 Pressure gauge: 60 MPa {600 kg/cm2}
holding brake release
pressure 799-401-3100 Adapter 1 Face seal type (#02)
02896-11008 O-ring 1 (Female: R1/8)
Testing leakage from
work equipment cylin- N Commercially Measuring cylinder 1 —
der available
Testing swing circle Commercially

bearing clearance P available Dial gauge 1 —
Testing temperature — 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C

Testing operating effort 79A-264-0021 1 0 – 300 N {0 – 30 kg}
and pressing force — Push-pull scale
79A-264-0091 1 0 – 500 N {0 – 50 kg}
Testing stroke and Commercially
hydraulic drift — available Scale 1 —
Testing work equip- Commercially

ment speed — available Stopwatch 1 —
Testing voltage and Commercially

resistance — available Multimeter 1 —
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
Diagnosis for chassis
side sensor, actuator — For ECONO *3 (Max. 21P)
and harness 799-601-2600 • T-adapter 1
(Excl. 799-601-7000)
799-601-7090 • T-adapter 1 For M2P
799-601-7110 • T-adapter For M3P
799-601-7050 • T-adapter For SWP6P (Excl. 799-601-8000)
30-100 4 PC45MR-3, PC55MR-3

Tools for testing, adjusting, and troubleshooting SEN04649-00
Sym-

799-601-7010 • T-adapter For X1P
799-601-7500 T-adapter assembly
799-601-7520 • T-adapter For AMP070-12P
799-601-9000
or T-adapter assembly
799-601-9200
For DT2P (Incl. in 799-601-4101
799-601-9040 • T-adapter
and 799-601-4201)
799-601-9020 • T-adapter For DT2P
Diagnosis for chassis 799-601-9030 • T-adapter For DT3P
side sensor, actuator —
and harness 799-601-9050 • T-adapter For DT6P
799-601-9060 • T-adapter For DT8P (Gray)
799-601-9070 • T-adapter For DT8P (Black)
799-601-9080 • T-adapter For DT8P (Green)
799-601-9090 • T-adapter For DT8P (Brown)
799-601-9110 • T-adapter For DT12P (Gray)
799-601-9120 • T-adapter For DT12P (Black)
799-601-9130 • T-adapter For DT12P (Green)
799-601-9140 • T-adapter For DT12P (Brown)
For 5P-relay
(Kit No. is not registerd)
For 6P-relay
(Kit No. is not registerd)
For AMP3P (Incl. in 799-601-4101
and 799-601-4201)
PC45MR-3, PC55MR-3 30-100 5

SEN04649-00 Testing engine speed
Testing engine speed 1 4. Run the engine and measure the engine speed
under the following condition.
1) Measuring low idle and high idle speeds:
a Measuring instruments for engine speed Set the fuel control lever to the low idle
Symbol Part No. Part Name and high idle positions and measure the
engine speed.
A 799-205-1100 Tachometer kit
2) Measuring pump relief engine speed:
a Measure the engine speed under the following Lock the work equipment or travel system
condition. to relieve the main pump, run the engine
q Engine coolant temperature: at full throttle, and measure the engine
Within operating range speed.
q Hydraulic oil temperature : 45 – 55°C
k When installing and removing the measur-

ing instruments, take care not to touch a
hot part of the engine.
1. Open the engine rear cover.
2. Stick reflection tape [1] of tachometer kit A to

the crankshaft pulley.
3. Set probe [3] with stand [2], matching it to

reflection tape [1], and connect it to tachometer
[4].
30-100 6 PC45MR-3, PC55MR-3

Testing exhaust gas color SEN04649-00
Testing exhaust gas color 1 3) Connect the power cable to AC socket.

a Confirm that the smoke meter power
switch is in the OFF position, before
a Measuring instruments for exhaust gas color connecting the power cable to an out-
Symbol Part No. Part Name let.
4) Fit a filtering paper by loosening the suc-
1 799-201-9001 Handy smoke checker
tion pump cap nut [5].
C Commercially
2 Smoke meter a Fit the filtering paper securely so that
available
air may not leak.
k Be careful not to touch the highly heated 5) Move the smoke meter C2 power switch
parts, while fitting and detaching a mea- to the ON position.
surement tool. 6) Accelerate the engine sharply and
a If no compressed air or power is not available depress accelerator pedal [3] of smoke
in the field, use Handy Smoke Checker C1. For m e te r C 2 s i m u l ta n e o u s l y to l e t t h e
recording official data, use Smoke Meter C2. exhaust gas stay on the filtering paper.
a Measure the exhaust gas color under the fol- 7) Put the polluted filtering paper on non-pol-
lowing condition. luted filtering paper (more than 10 sheets)
q Engine coolant temperature: in the filtering paper holder, and read the
Within operating range indicated value.
1. Measurement with handy smoke checker

C1
1) Fit a filtering paper to handy smoke checker
C1.
2) Insert the exhaust gas intake pipe into the
exhaust pipe.
3) Accelerate the engine sharply and operate
the handle of smoke checker C1 simulta-
neously to let the exhaust gas stay on the
filtering paper.
4) Take out the filtering paper and compare it
with the attached scale for judgement.
2. Measurement with smoke meter C2

1) Insert probe [1] of the smoke meter C2
into the exhaust gas pipe outlet, and fas-
ten it to the outlet with a clip.
2) Connect the probe hose [2], accelerator
switch [3] outlet and air hose [4] to the
smoke meter C2.
a Keep the pressure of the supplied
compressed air below 1.47 MPa
{15 kg/cm2}.
PC45MR-3, PC55MR-3 30-100 7

SEN04649-00 Testing and adjusting valve clearance
Testing and adjusting valve 4. Watching the movement of the valve of the No.
clearance 1
1 cylinder (on the flywheel side), rotate the
crankshaft forward to match stamp line (a) of
the flywheel housing to stamp line (b) of fly-
a Measuring and adjusting tools for valve clear- wheel No. 4.
ance a The cylinder on the flywheel side is the
Symbol Part No. Part Name No. 1 cylinder.
a When the cylinder piston is at the com-
Commercially
D
available
Clearance gauge pression top dead center, the rocker arms
of both intake valve and exhaust valve can
1. Tilt up the floor frame. be moved by the valve clearance. If the
For details, see “How to open and close (tilt) rocker arms do not move, rotate the crank-
floor”. shaft 1 more turn.
a It is easy to confirm it when using a mirror
2. Remove cylinder head cover (1). [1].
3. Remove the inspection window cap (2) of the 5. Insert clearance gauge D between rocker arm
flywheel housing. (3) and valve cap (4) to check the valve clear-
ance.
a Rotate the crankshaft by 180° and adjust

the valve clearance of each cylinder in the
firing order.
q Firing order: 1 – 3 – 2 – 4
q When the cylinder is at the compression
top dead center, the rocker arm of the cyl-
inder can be moved by the valve clear-
ance with the hand.
30-100 8 PC45MR-3, PC55MR-3

Testing and adjusting valve clearance SEN04649-00
6. If the valve clearance is out of the standard

value, loosen locknut (6) and insert clearance
gauge D between rocker arm (3) and valve cap
(4) and adjust the clearance with adjustment
screw (5) so that the clearance gauge will
move lightly and then tighten locknut (6).
3 Locknut:
25.48 ± 2.94 Nm {2.6 ± 0.3 kgm}
7. After finishing adjustment, tilt down the floor

frame.
For details, see “How to open and close (tilt)
floor”.
PC45MR-3, PC55MR-3 30-100 9

SEN04649-00 Testing compression pressure
Testing compression pressure 1 4. Install adapter E2 and joint E3 to the nozzle

holder mounting part and connect compres-
sion gauge E1.
3 Adapter mounting nut:
a Measuring instruments for compression pres-
sure 4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}
Symbol Part No. Part Name
1 795-502-1590 Compression gauge
E 2 795-111-1130 Adapter
3 795-101-1571 Joint
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in the fan, fan belt, or another rotat-
ing part.
1. Adjust the valve clearance.

For details, see “Testing and adjusting valve
clearance”. 5. Disconnect connector (4) of the engine stop
motor.
2. Warm up the engine until the engine oil tem-
perature rises to 40 – 60°C.
3. Remove fuel tube (1), spill hose (2) and nozzle

holder assembly (3) of the cylinder to be mea-
sured.
6. Crank the engine with the starting motor and

measure the compression pressure.
a Read the compression gauge when its
pointer is stabilized.
a After measuring the compression pres-
sure, install the nozzle holder assembly.
3 Nozzle holder assembly mounting nut:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}
3 Fuel tube mounting nut:
29 – 34 Nm {3.0 – 3.5 kgm}
30-100 10 PC45MR-3, PC55MR-3

Testing engine oil pressure SEN04649-00
Testing engine oil pressure 1
a Measuring instruments for engine oil pressure

799-101-5002
(Analog)
1
F Oil pressure gauge kit
790-261-1204
(Digital)
2 799-401-2320 Oil pressure gauge
a Measure the engine oil pressure under the fol-

lowing condition.
q Coolant temperature: Within operating range
1. Open the engine side cover and remove

engine oil pressure switch (1).
2. Install nipple [1] of oil pressure gauge kit F1

and connect oil pressure gauge F2 (1 MPa {10
kg/cm2}) by hose [2].
3. Start the engine and measure the oil pressure

at low idle and high idle.
PC45MR-3, PC55MR-3 30-100 11

SEN04649-00 Testing and adjusting fuel injection timing
Testing and adjusting fuel 3) Calculate the fuel injection timing angle.
injection timing 1
q The FIR No. depends on the engine
model No.
q The engine model is stamped on the
a Testing and adjusting tools for fuel injection engine nameplate.
timing q Substitute the injection timing No. on
Symbol Part No. Part Name the side of the fuel injection and the
FIR No. in the following calculation
1 795-111-1140 Adapter
formula.
2 795-111-1150 Clamp (Fuel injection pump injection timing
Q Commercially No. x 2) + FIR No. = Fuel injection
3 Dial gauge
available timing angle
4 795-111-1160 Extension rod a Example of engine model No.
4D88E-6 having injection timing
1. Setting standard value of fuel injection tim- No. “68”
ing (6.8 × 2) + 4.5 = 13.6 + 4.5
1) Check and record the fuel injection timing = 18.1°
No. of the fuel injection pump indicated on (Fuel injection timing angle)
boss (2) on the engine side of fuel injec-
tion pump housing (1). Consider that 2. Testing fuel injection timing
there is a decimal point in the injection tim- a Some fuel may leak from the fuel injection
ing value. For example, handle 68 as 6.8. pump during the following work. Prepare
a container to receive the leaking fuel
before starting the work.
1) Close the fuel tank valve.
2) Close the water separator handle.
3) Clean the top of the fuel injection pump so
that dirt will not enter when the plunger
plug of the fuel injection pump is removed.
4) Remove fuel injection pump plunger plug
(3) on the top front side of the fuel injec-
tion pump.
2) Check the FIR (Fuel Injection Reference)

No . o f t h e e n g i n e t o b e t e s t e d a n d
adjusted.
FIR No.:
4.5 (PC45/55MR-3 [4D88E-6 engine])
30-100 12 PC45MR-3, PC55MR-3

Testing and adjusting fuel injection timing SEN04649-00
5) Install dial indicator adapter Q1 to the 7) Put a wrench on the crankshaft pulley
opening of the fuel injection pump plunger mounting bolt and rotate the crankshaft
and set clamp Q2 to Q1. clockwise, seeing from the gear case side,
until the injection timing mark on the fly-
wheel side is seen through inspection win-
dow (4) of the flywheel.
6) Set extension rod Q4 to dial gauge Q3

and install dial gauge Q3 to adapter Q1.
a Secure dial gauge Q3 to about the
center of the moving range with 8) The marks on the flywheel are usually
plunger adapter clamp Q2. arranged as shown in the following figure.
a : TDC (Top Dead Center)
b : 10° BTDC
(Before Top Dead Center)
c : 15° BTDC
d : 20° BTDC
e : 25° BTDC
f : Rotating direction
a The TDC (Top Dead Center) mark
can be identified by the cylinder No.
stamped near the TDC mark of the
flywheel.
PC45MR-3, PC55MR-3 30-100 13

SEN04649-00 Testing and adjusting fuel injection timing
a If the timing scale angle on the flywheel is 10) Check timing mark (j) to be adjusted on
clear, the timing angle can be obtained by the flywheel side according to the calcula-
measuring the timing scale. tion result of “Setting standard value of
q First, measure the distance between the 2 long fuel injection timing”.
divisions (5° apart from each other). Next,
measure the distance between the TDC mark
and the long division nearest to the TDC mark.
Divide this value with the distance between the
2 long divisions. From the division result, you
can obtain the angle between the TDC mark
and the division nearest to it.
q Example:
If the distance between the 2 long divisions is
about 2.0 cm and the distance between the
TDC mark and the long division near to it is
about 4.0 cm, the division result is about 2.
From this, the angle between the TDC mark
and the long division near to it is 10° (2 × 5°).
As a result, it is seen that the 1st long division 11) Rotate the crankshaft counterclockwise
shows 10° BTDC, the 2nd long division 15° until the dial indicator indicates that the
BTDC, and 3rd long division 20° BTDC. If the fuel injection pump plunger is at the lowest
division result is 3, the angle between the TDC position of the moving stroke. Rotate the
mark and the first long division is 15° (3 × 5°), crankshaft a little to the right and left and
and the 1st long division shows 15° BTDC, the find a point where the dial indicator does
2nd long division 20° BTDC, and 3rd long divi- not move at all and then set the dial indi-
sion 25° BTDC. cator to zero.
12) Rotate the crankshaft counterclockwise
9) Check the timing datum mark (g) of the fly- slowly until the dial indicator indicates that
wheel housing and the TDC (Top Dead the fuel injection pump plunger is raised
Center) mark stamped on flywheel (5). by 2.5 mm.
13) See where timing mark (j) to be set on the
flywheel side (determined by the above
procedure) is for timing datum mark (g) of
the flywheel housing. If timing mark (j) is
at the target timing division mark, the fuel
injection timing is proper. If not, adjust
according to “Adjusting fuel injection tim-
ing”.
14) If the injection timing is proper, remove the
dial indicator and adapter and return the
removed parts.
3 Plunger plug:
30 – 35 Nm {3.1 – 3.6 kgm}
30-100 14 PC45MR-3, PC55MR-3

Testing and adjusting fuel injection timing SEN04649-00
3. Adjusting fuel injection timing 4) Loosen the 3 nuts securing the fuel injec-
As a result of “Testing fuel injection timing”, if tion pump to the gear case or front plate
the timing mark is not set properly, adjust it and the rear bracket of the fuel injection
according to the following procedure to correct pump.
the fuel injection timing. a If the fuel high-pressure pipe nuts of
1) Keep the dial indicator installed to the fuel the fuel injection pump are loosened,
injection pump and take care that the the pump can be rotated easily.
pointer of the dial gauge will not move. 5) Rotate the fuel injection pump until the dial
2) Rotate the flywheel until timing mark (j) to gauge indicates 2.5 mm.
be set is matched to timing datum mark q To “advance” the fuel injection timing,
(g) of the flywheel. rotate the fuel injection pump and
a Do not rotate the crankshaft during bring its top away from the engine.
the following procedure. q To “delay” the fuel injection timing,
rotate the fuel injection pump and
bring its top near the engine.
6) If the timing mark to be set on the flywheel
is matched to the datum mark on the fly-
wheel housing or engine back plate while
the dial gauge is indicating that the lift of
the fuel injection pump plunger is 2.5 mm,
the fuel injection timing is proper.
7) Tighten the fuel injection pump mounting
nuts and rear bracket.
3 Fuel injection pump mounting nut:
23 – 28 Nm {2.3 – 2.9 kgm}
3 Fuel high-pressure pipe nut:
29 – 34 Nm {3.0 – 3.5 kgm}
3) Check the value indicated by dial gauge 8) Remove the dial gauge and adapter and
Q3. return the removed parts.
q If the indicated value is less than 2.5 3 Plunger plug:
m m , th e fu e l i n j ec ti o n ti m i n g i s 30 – 35 Nm {3.1 – 3.6 kgm}

delayed.
q If the indicated value is 2.5 mm or
larger, the fuel injection timing is
advanced.
PC45MR-3, PC55MR-3 30-100 15

SEN04649-00 Testing and adjusting alternator belt tension
Testing and adjusting alternator Adjusting

belt tension 1 a If the belt deflection is not normal, adjust it
according to the following procedure.
Testing 1. Loosen belt tension adjustment bolt (4) and

1. Tilt up the floor frame. alternator mounting nut (5).
For details, see “How to open and close (tilt) a The hexagonal part of belt tension adjust-
floor”. ment bolt (4) is on the fan side.
2. Press the intermediate point between the 2. Using a bar, move alternator (6) toward the
crankshaft pulley (1) and fan pulley (2) with a front of the machine and tighten belt tension
force of about 98 N {10 kg}. If the belt (3) adjustment bolt (4).
deflection at this time is 7 – 10 mm, the belt
tension is normal. 3. Tighten alternator mounting nut (5).
4. Check the belt tension again.
5. After finishing adjustment, tilt down the floor

frame.
floor”.
30-100 16 PC45MR-3, PC55MR-3

Testing and adjusting air conditioner compressor belt tension SEN04649-00
Testing and adjusting air Adjusting

conditioner compressor belt a If the deflection of the belt is abnormal, adjust it
tension 1
1. Loosen nut (5) of idler pulley (4).
Testing 2. Adjust the belt tension with adjustment nut (6).

1. Tilt up the floor frame. For details, see "How to
open and close (tilt) floor". 3. Tighten nut (5).
2. Open the engine side cover.
3. Remove mounting bolts (1) and fan guard (2).
4. Press the intermediate point of the belt

between compressor pulley (3) and idler pulley
(4) with a finger and measure deflection (a) of
the belt.
q Force to press belt: Approx. 58.8 N {6 kg}
q Deflection: 5 – 6 mm
4. Check the belt tension again.
5. After adjusting, install fan guard (2).
6. Tilt down the floor frame. For details, see "How

to open and close (tilt) floor".
PC45MR-3, PC55MR-3 30-100 17

SEN04649-00 Adjusting fuel control lever
Adjusting fuel control lever 1
1. Adjusting low idle

1) Lean fuel control lever (1) forward until it
touches stopper (2) on the low idle side.
2) Turn low idle adjustment screw (3) on the
injection pump side so that low idle is set
to the specified speed.
2. Adjusting high idle

1) Lean fuel control lever (1) backward until
injection pump lever (4) touches stopper
bolt (5) on the high idle side.
2) Under the above condition, bring stopper
bolt (6) in contact with fuel control lever
(1), then return it by 1/2 turn and secure it
with the locknut.
a The screw on the high idle side of the
injection pump cannot be adjusted. .
Accordingly, if the high idle speed is
still low when stopper bolt (5) on the
high idle side touches the governor
lever of the injection pump, test the
injection nozzle, etc.
30-100 18 PC45MR-3, PC55MR-3

Testing clearance in swing circle bearings SEN04649-00
Testing clearance in swing circle 4. Hold the arm nearly perpendicular to the
bearings 1
ground, and lower the boom until the track
shoes will be lifted at the machine front.
a The upper structure is raised at the front
a Measuring instruments for swing circle bearing and lowered at the rear at that time.
clearance
Symbol Part No. Part Name 5. Read off the value in dial gauge P in this condi-
tion.
Commercially
P Dial gauge a The value indicated in dial gauge P
available
expresses clearance in the bearings.
a Follow the steps explained below, when mea-
suring clearance in the swing circle bearing in
the actual machine.
k Be careful not to put a hand or foot under
the track shoe, while taking measurement.
1. Fasten dial gauge P to swing circle outer race

(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race
(1) on the opposite side.
a Set dial gauge P at the machine front or
rear.
6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge P is
zero.
a If zero value is not indicated, repeat the
steps in Items 3 through 5.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
frame.
3. Set dial gauge P at zero point.
PC45MR-3, PC55MR-3 30-100 19

SEN04649-00 Testing and adjusting track shoe tension
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
Testing 1. When tension is too high

1. Run the engine at low idle and move the 1) Loosen valve (1) and discharge grease.
machine by the length of track on ground, then k Do not loosen the valve more than 1
stop slowly. turn. If it is loosened more, it may
jump out because of the high-pres-
2. Place wood block (3) on the track shoe sure grease in it.
between idler (1) and carrier roller (2). a If the grease does not flow out, move
the machine slowly forward and in
3. Measure maximum slack (a) between the top reverse.
of the track shoe and wood block (3). 2) To check that the tension is normal, run the
q Standard slack (a): engine at low idle and move the machine
Rubber shoe: 1 – 3 mm forward by the length of track on ground,
Road liner, steel shoe: 10 – 30 mm then stop slowly.
3) Test the track shoe tension again. If it is
abnormal, adjust it again.
2. When tension is low

1) Supply grease through grease fitting (2).
a If the shoe is not tensed properly,
move the machine slowly forward and
in reverse.
3 Grease fitting: Grease (G2-LI)
2) To check that the tension is normal, run
the engine at low idle and move the
machine forward by the length of track on
ground, then stop slowly.
3) Test the track shoe tension again. If it is
abnormal, adjust it again.
30-100 20 PC45MR-3, PC55MR-3

Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits SEN04649-00
Testing and adjusting oil 2) Install nipple G2 and connect oil pressure
pressures in work equipment, gauge G1 (40 MPa {400 kg/cm2}) by hose
[1].
travel, boom swing, swing, and
blade circuits 1
a Measuring instruments for oil pressures in

work equipment, travel, boom swing, swing,
and blade circuits
799-101-5002
(Analog)
1
G 790-261-1204
(Digital)
799-101-5220 Nipple
2
07002-11023 O-ring
Measuring
a Hydraulic oil temperature for measurement:
45 – 55°C
k Lower the work equipment to the ground

and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank and
set the work equipment lock lever in the
LOCK position.
a Remove the triangular cover from the left rear
of the machine.
1. Measuring oil pressures in work equip-

ment, travel, and boom swing circuits
1) Remove main pump circuit oil pressure
pickup plugs (1).
a Either of plugs (1) may be removed.
PC45MR-3, PC55MR-3 30-100 21

SEN04649-00 Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits
3) Measuring relief pressure 2) Install nipple G2 and connect oil pressure

Start the engine, operate the actuator of gauge G1 (40 MPa {400 kg/cm2}) by hose
the circuit to be measured, and measure [1].
the relief pressure.
q Set the actuator to be measured as
explained below.
1] Work equipment and boom swing:
Set each cylinder to the stroke end.
2] Travel:
Put block [2] between the sprocket
and track frame to lock the travel
motor.
4) Measuring unload oil pressure
Set all the control levers in neutral, run
engine at full throttle, and measure the oil
pressure.
2. Measuring oil pressures in swing and blade

circuits
1) Remove the swing and blade circuit oil
pressure pickup plug (1).
30-100 22 PC45MR-3, PC55MR-3

3) Start the engine, operate the actuator of Adjusting

the circuit to be measured, and measure a If any of the oil pressures in the work equip-
the relief pressure. ment, travel, boom swing, swing, and blade cir-
q Set the actuator to be measured as cuits is abnormal, adjust the corresponding
explained below. valve according to the following procedure.
1] Blade: a The unload valve cannot be adjusted.
Set the cylinder to the stroke end. a Tilt up the floor frame.
2] Swing: For details, see “How to open and close (tilt)
Lock the swing motor. floor”.
k Since a swing holding brake is
not installed, lock the machine 1. Adjusting main relief valves of work equip-
securely with the work equipment, travel, and boom swing circuits
ment. 1) Loosen locknut (2) of main relief valve (1)
a The set pressure of the safety and turn adjustment screw (3).
valve of the swing motor is lower Reference: Only the 9-spool valve specifi-
than that of the main relief valve. cation has part "a" in the figure.
Accordingly, if the swing circuit is a If the adjustment screw is
relieved, the set pressure of the q Turned to the right, the pressure
safety valve is obtained. is increased.
q Turned to the left, the pressure is
decreased.
a Amount of adjustment per turn of
adjustment screw:
12.6 MPa {128 kg/cm2}
2) After adjusting, tighten locknut (2).
3 Locknut: 59 – 79 Nm {6 – 8 kgm}
3) Referring to the section of measuring,
check the relief pressure again.
PC45MR-3, PC55MR-3 30-100 23

SEN04649-00 Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits
2. Adjusting main relief valves of swing and 4) Referring to the section of measuring,
blade circuits check the relief pressure again.
a The set pressure of the safety valve of the
swing motor is lower than that of the main
relief valve. Accordingly, the relief pres-
sure of only the blade circuit is obtained.
1) Swing the upper structure to direct the
work equipment valve side toward the rear
of the machine.
a Access from a hole (1).
a Under the work equipment valve at
underside of the machine.
2) Loosen locknut (3) of relief valve (2) and

turn adjustment nut (4).
Reference: Only the 9-spool valve specifi-
cation has part "a" in the figure.
a If the adjustment screw is
q Turned to the right, the pressure
is increased.
decreased.
adjustment screw:
19.6 MPa {200 kg/cm2}
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
30-100 24 PC45MR-3, PC55MR-3

3. Adjusting safety valve of swing motor

a If the swing relief pressure is abnormal,
adjust the swing motor safety valve
1) Loosen locknut (2) of swing motor safety
valve (1) and turn adjustment screw (3).
q Turned to the right, the pressure
is increased.
decreased.
adjustment screw:
17.4 MPa {178 kg/cm2}
3 Locknut:
78.4 – 102.9 Nm {8 – 10.5 kgm}
3) Referring to the section of measuring,
check the relief pressure again.
PC45MR-3, PC55MR-3 30-100 25

SEN04649-00 Testing and adjusting LS differential pressure
Testing and adjusting LS 3. Install nipple H2 and connect differential pres-

differential pressure 1
sure gauge H3 by hose [1].
a Connect pump discharge pressure side
(1) to the high pressure side of the differ-
a Measuring instruments for LS differential pres- ential pressure gauge and connect LS
sure pressure side (2) to the low pressure side.
799-101-5002
(Analog)
1
790-261-1204
(Digital)
H 799-101-5220 Nipple
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
799-401-2930 Adapter
4
02896-11009 O-ring
Measuring
of the machine.
Measuring with differential pressure gauge

1. Remove either of oil pressure pickup plugs (1).
a Either of plugs (1) may be removed.
2. Disconnect hose (2), install adapter H4, and

connect hose (2) again.
4. Run the engine at full throttle and measure the

LS differential pressure under the following
condition.
a If the LS differential pressure is as follows,
it is normal.
Operation of lever LS differential pressure
Set all levers Unload pressure (See stan-
in neutral dard service values table)
Curl bucket Specified LS differential
(Move bucket lever pressure (See standard
to stroke end) service values table)
30-100 26 PC45MR-3, PC55MR-3

Testing and adjusting LS differential pressure SEN04649-00
Measuring with oil pressure gauge 3. Run the engine at full throttle and measure the
a Since the differential pressure is 1.96 MPa {20 pump discharge pressure under the condition
kg/cm2} at maximum, measure it with the same for measuring with the differential pressure
oil pressure gauges. gauge.
a Read the gauge pointer accurately from
1. Referring to "Measuring with differential pres- the front side of the gauge.
sure gauge", steps 1 and 2, prepare for con-
nection of the oil pressure gauge. 4. Run the engine at full throttle and measure the
LS pressure under the condition for measuring
2. Install nipple H2 and connect oil pressure with the differential pressure gauge.
gauge [2] (40 MPa {400 kg/cm2}) of H1 by hose a Read the gauge pointer accurately from
[1]. the front side of the gauge.
a Use oil pressure gauges having minimum
divisions of 1 MPa {10 kg/cm2}. 5. Calculate the LS differential pressure from the
pump discharge pressure and LS pressure.
a LS differential pressure = Pump discharge
pressure – LS pressure
PC45MR-3, PC55MR-3 30-100 27

SEN04649-00 Testing and adjusting LS differential pressure
Adjusting
a If the LS differential pressure is abnormal,
adjust the LS valve according to the above pro-
cedure.
1. Loosen locknut (2) of LS valve (1) and turn
adjustment screw (3).
q Turned to the right, the pressure is
increased.
decreased.
3 Locknut:
2. After adjusting, tighten locknut (2).
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
3. Referring to the section of measuring, check

the LS differential pressure again.
30-100 28 PC45MR-3, PC55MR-3

Adjusting PC valve SEN04649-00
Adjusting PC valve 1
a While the pump discharge pressure and LS dif-

ferential pressure are normal, if the following
faults occur, adjust the PC valve.
q When the load is increased, the engine
speed lowers.
q The engine speed is normal but the work
equipment speed is low.
1. Loosen locknut (2) of PC valve (1) and turn

a Before loosening locknut (2), be sure to
make match mark “a”.
a The PC valve is eccentric and it is uncer-
tain in which direction the absorption
torque is rotated to increase. Accordingly,
adjust while monitoring the engine speed.

3 Locknut:
27.4 – 34.4 Nm {2.8 – 3.5 kgm}
PC45MR-3, PC55MR-3 30-100 29

SEN04649-00 Testing and adjusting control pump circuit oil pressure
Testing and adjusting control 2. Install nipple K2 and connect hose [1] to oil
pump circuit oil pressure 1
pressure gauge K1 (6 MPa {60 kg/cm2}).
3. Run the engine at full throttle, set the control

a Measuring instruments for control pump circuit lever in neutral, and measure the circuit oil
oil pressure pressure.
799-101-5002
(Analog)
1
K 790-261-1204
(Digital)
799-101-5220 Nipple
2
07002-11023 O-ring
Measuring
45 – 55°C
of the machine.
1. Remove oil pressure pickup plug (1) of the Adjusting

control pump outlet hose. a If the control circuit oil pressure is abnormal,
adjust control relief valve according to the fol-
lowing procedure.
a Tilt up the floor frame.
floor”.
1. Loosen locknut (3) of relief valve (2) and turn

q Turned to the right, the pressure is
increased.
decreased.
a Amount of adjustment per turn of adjust-
ment screw: 0.92 MPa {9.4 kg/cm2}

3 Locknut: 9.8 Nm {1.0 kgm}
30-100 30 PC45MR-3, PC55MR-3

Testing and adjusting control pump circuit oil pressure SEN04649-00
3. Tilt down the floor frame.

floor”.
4. Referring to the section of measuring, check

the pressure again.
PC45MR-3, PC55MR-3 30-100 31

SEN04649-00 Testing solenoid valve output pressure
Testing solenoid valve output 3. Connect oil pressure gauge [3] (6 MPa {60 kg/
pressure 1
cm2}) by hydraulic hose [2].
a Measuring instruments for solenoid valve out-

put pressure
799-101-5002
(Analog)
1
L 790-261-1204
(Digital)
799-401-3100 Adapter
2
02896-11008 O-ring
Measuring
45 – 55°C
a Measure the pressure at the outlet of each
solenoid valve.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 2nd travel speed selection solenoid valve
1. Tilt up the floor frame.

floor”.
2. Disconnect outlet hose (3) or (4) of the sole-

noid valve to be measured and install adapter 4. Tilt down the floor frame.
L2, then install nipple [1] of oil pressure gauge For details, see “How to open and close (tilt)
kit L1 to adapter L2. floor”.
a Hose (3) is on the PPC lock solenoid side
and (4) is on 2nd travel speed selection 5. Run the engine at full throttle and measure the
solenoid side. output pressure under the following conditions.
Solenoid Measurement Operation Oil pressure
No.
valve conditions of solenoid (MPa{kg/cm2})
Lock lever: OFF 0{0}

LOCK
1 PPC lock
+ 0.49
Lock lever: 2.94 – 0.1
ON
FREE +5
{30 – 1 }
2nd travel
speed selection OFF 0{0}
2nd travel pedal: OFF
2 speed
selection 2nd travel + 0.49
2.94 – 0.1
speed selection ON +5
pedal: ON {30 – 1 }
30-100 32 PC45MR-3, PC55MR-3

Testing PPC valve output pressure SEN04649-00
Testing PPC valve output 3. Connect oil pressure gauge [3] (6 MPa {60 kg/
pressure 1
cm2} by hydraulic hose [2].
a Measuring instruments for PPC valve output

pressure
799-101-5002
(Analog)
1
M 790-261-1204
(Digital)
799-401-3100 Adapter
2
02896-11008 O-ring
Measuring
a Measure the PPC valve output pressure when 4. Tilt down the floor frame.
the work equipment speed or swing speed is For details, see “How to open and close (tilt)
low or the work equipment does not move. floor”.
45 – 55°C 5. Run the engine at full throttle, operate the lever
(pedal) of the circuit to be measured, and mea-
1. Tilt up the floor frame. sure the PPC valve output pressure.
floor”.
2. Disconnect PPC hose (1) of the circuit to be

measured from the PPC valve or control valve,
install adapter M2, and install nipple [1] of oil
pressure gauge kit M1.
a The connection diagram of the PPC valve
and control valve is shown on the next
page.
.
PC45MR-3, PC55MR-3 30-100 33

SEN04649-00 Testing PPC valve output pressure
Connection diagram of PPC valve and control valve
30-100 34 PC45MR-3, PC55MR-3

Adjusting PPC valve SEN04649-00
Adjusting PPC valve 1
a If the work equipment/swing control lever has

excessive play, adjust it according to the fol-
lowing procedure.

and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank and
set the work equipment lock lever in the
LOCK position.
1. Remove the PPC valve.
2. Remove boot (1).
3. Loosen locknut (2) and screw in disc (3) until it

touches the heads of 4 pistons (4).
a At this time, do not move the pistons.
4. Fix disc (3) and tighten locknut (2) to the speci-

fied torque.
3 Locknut: 107.9 ± 9.8 Nm {11 ± 1 kgm}
5. Install boot (1).

a After the above adjustment, clearance
between disc (3) and piston (4) is elimi-
nated.
PC45MR-3, PC55MR-3 30-100 35

SEN04649-00 Testing swing holding brake release pressure
Testing swing holding brake 4. Tilt down the floor frame.

release pressure 1
floor”.
a Measuring instruments for swing holding brake 5. Run the engine at full throttle, swing to right or
release pressure left or move the arm IN, and measure the
Symbol Part No. Part Name swing holding brake release pressure.
799-101-5002
(Analog)
1
M 790-261-1204
(Digital)
799-401-3100 Adapter
2
02896-11008 O-ring
Measuring
45 – 55°C

floor”.
2. Disconnect swing motor inlet hose (1), install

adapter M2, and install nipple [1] of oil pres-
sure gauge kit M1.
3. Connect oil pressure gauge [3] (6 MPa {60 kg/

cm2} by hydraulic hose [2].
30-100 36 PC45MR-3, PC55MR-3

Testing and adjusting travel deviation SEN04649-00
Testing and adjusting travel deviation 1
Testing Adjusting
1. Set the machine to the travel posture. a If the machine deviates, it can be corrected by
a Extend the bucket cylinder and arm cylin- partially draining the oil discharged more from
der to the stroke end and set the boom the pump through the adjustment plug. (If the
angle to 45°. travel deviation is corrected by this method,
however, the pump discharge is reduced. As a
result, the travel speed, work equipment speed
in compound operation, and relief pressure
may lower.)
a If the machine deviates in the same direction

regardless of the travel direction, correct it
a Only when the travel deviation is 200 mm or
less, it can be corrected by the following
method.
k If the adjustment plug is loosened more
than the adjustment limit, high-pressure oil
will spout out. Take care extremely.
2. After approach run of 10 m, measure travel k Lower the work equipment to the ground
deviation (a) in the tr avel of 20 m after and stop the engine. Loosen the oil filler
approach run. cap of the hydraulic tank slowly to release
a Keep running the engine at full throttle. the residual pressure from the tank.
a Install an oil pressure gauge and measure
the hydraulic pump discharge pressure, 1. Remove the triangle cover from the left rear of
too. the machine.
PC45MR-3, PC55MR-3 30-100 37

SEN04649-00 Testing and adjusting travel deviation
2. Check the locations of adjustment plugs (1) 7. Check the travel deviation again according to
and (2) of the main pump. the above described testing procedure. If it is
q (1): Right deviation adjustment plug not corrected completely, adjust it again.
q (2): Left deviation adjustment plug a Do not adjust more than the adjustment
limit of the adjustment plug (2 turns/720°).
3. Insert hexagonal wrench (width across flats: 4

mm) in adjustment plug (1) or (2).
a Insert the hexagonal wrench securely.
4. Fix the hexagonal wrench and loosen locknut

(3).
a Before loosening the locknut, make match
marks on it and pump case to check its
turning angle.
q Loosening angle of locknut: 90 – 180°
5. Loosen adjustment plug (1) or (2) to adjust the

travel deviation.
q Amount of adjustment per turn of adjust-
ment plug: 150 mm (Reference)
a The plug is fully tightened when shipped.
Adjust the deviation by the loosening
angle of the plug from the fully tightened
position.
a When the locknut is loosened, if the
adjustment plug is dragged, tighten the
adjustment plug fully, and then adjust it
again.
3 Adjustment plug:
2.94 – 4.9 Nm {0.3 – 0.5 kgm}
a The adjustment plug can be loosened by 2
turns (720°) from the fully tightened posi-
tion.
6. Fix the adjustment plug with the hexagonal

wrench and tighten locknut (3).
3 Locknut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
30-100 38 PC45MR-3, PC55MR-3

Testing oil leakage from work equipment cylinder SEN04649-00
Testing oil leakage from work 2. Disconnect the hose on the head side and plug
equipment cylinder 1
the hose on the chassis side.
q Hose (1): Boom cylinder
q Hose (2): Arm cylinder
a Measuring instruments for oil leakage from q Hose (3): Bucket cylinder
work equipment cylinder k Take care not to disconnect the hose
Symbol Part No. Part Name on the cylinder bottom side.
N Commercially Measuring cylinder

available

45 – 55°C
a If the hydraulic drift of the work equipment is
out of the standard range, measure the leak-
age in the cylinder according to the following
procedure to see if the cause of the hydraulic
drift is on the control valve side.
q If the leakage is within the standard range, the
cause is on the cylinder side.
1. Fully extend the rod of the cylinder to be mea-

sured and stop the engine.
q Posture for measuring boom cylinder
q Posture for measuring arm cylinder

and bucket cylinder
PC45MR-3, PC55MR-3 30-100 39

SEN04649-00 Testing oil leakage from work equipment cylinder
3. Run the engine at full throttle and apply the

relief pressure to the bottom side of the cylin-
der.
a Boom cylinder: Operate to RAISE the
boom.
Arm cylinder: Operate to move the arm IN.
Bucket cylinder:
Operate to CURL the bucket.
4. Relieve the oil for 30 seconds, and then mea-

sure the oil leakage for 1 minute.
30-100 40 PC45MR-3, PC55MR-3

Bleeding air from each part SEN04649-00
Bleeding air from each part 1
Air bleeding item Air bleeding procedure
1 2 3 4 5 6 7
Bleeding Bleeding Pressur-

Bleeding Bleeding
Starting air from air from izing Starting
air from air from
engine swing travel hydrau- operation
pump cylinder
Contents of work motor motor lic tank
• Replacement of hydraulic oil

• Cleaning strainer
Q Q Q Q Q Q Q
(Note) (Note)
• Replacement of return filter element Q Q Q

• Replacement or repair of pump
• Removal of suction piping
Q Q Q Q Q
• Replacement or repair of control valve Q Q Q Q

• Replacement or repair of cylinder
• Removal of cylinder piping
Q Q Q Q
• Replacement or repair of swing motor
• Removal of swing motor piping
Q Q Q Q
• Replacement or repair of travel motor
and swivel
• Removal of travel motor and swivel
Q Q Q Q
piping
Note: Bleed air from the swing motor and travel motor only after the oil in the motor cases is drained.
PC45MR-3, PC55MR-3 30-100 41

SEN04649-00 Bleeding air from each part
1. Bleeding air from pump 2. Bleeding air from cylinder

a Remove the triangular cover from the left 1) Run the engine at low idle for about 5 min-
rear of the machine. utes.
a When masking cap is attached to bleeder, 2) Run the engine at slow speed and raise
it detaches it. and lower the boom 4 – 5 times.
1) Loosen air bleeder (1) to bleed air. a Stop the piston rod about 100 mm
a Bleed air until oil without air flows out. before each stroke end. Never relieve
2) Tighten air bleeder (1). the oil.
3 Air bleeder:
8.8 ± 1 Nm {0.9 ± 0.1 kgm}
a After the above work, run the engine
at low idle for about 10 minutes.
3) Run the engine at full throttle and perform

step 2), then run the engine at low speed
and move the piston rod to the stroke end
and relieve the oil.
a Bleed air from the arm cylinder,
bucket cylinder, boom swing cylinder,
and blade cylinder according to steps
2) and 3).
3. Bleeding air from swing motor

1) Run the engine at low idle and swing the
upper structure to the left by 3 turns.
2) Swing the upper structure to the right by 3
turns.
30-100 42 PC45MR-3, PC55MR-3

Releasing residual pressure from hydraulic circuit SEN04649-00
4. Bleeding air from travel motor Releasing residual pressure from

1) Run the engine at low idle and float the left hydraulic circuit 1
track shoe by using the work equipment.
2) Running the engine at low idle, rotate the
left track shoe idle for about 30 seconds. k When disconnecting the piping between
3) Performance procedures 1) and 2) for the hydraulic cylinder, hydraulic motor and
right track shoe. control valve, release the residual pressure
in the circuit according to the following
procedure.
a There is not residual pressure in the swing
motor circuit and travel motor circuit but
the residual pressure in the hydraulic tank
is applied to those circuits. Accordingly,
perform the following procedure at least
up to opening of the hydraulic tank cap.
1. Lower the work equipment to the ground and

release the residual pressure in the hydraulic
tank. For details, see “Releasing residual
pressure in hydraulic tank”.
5. Pressurizing hydraulic tank 2. Turn the starting switch ON and set the PPC
1) Before pressurizing the hydraulic tank, lock lever in the reset position.
check the hydraulic oil level. a If the power is not supplied to the PPC
2) Referring to “Pressurizing hydraulic tank”, lock valve, the PPC lock valve does not
pressurize the hydraulic tank. operate. Accordingly, be sure to turn the
starting switch ON.
3. Operate the lever to release the residual pres-

sure in the piping.
a If the lever is operated 2 – 3 times, the
pressure in the accumulator is lost.
4. Start the engine and run it for about 10 sec-

onds at low idle to increase the pressure in the
accumulator and then stop the engine.
5. Repeat steps 3 – 4 several times.
6. Loosen the sleeve nut of the piping gradually

to release the residual pressure from the pip-
ing until oil does not come out any more, then
remove the piping.
PC45MR-3, PC55MR-3 30-100 43

SEN04649-00 Releasing residual pressure from hydraulic tank
Releasing residual pressure from Pressurizing hydraulic tank 1
hydraulic tank 1
a If the oil filler cap is removed from the hydraulic

k The hydraulic tank is enclosed and pres- tank, pressurize the hydraulic tank according
surized. When removing a hose or a plug to the following procedure.
connected to the hydraulic tank, release the
residual pressure from the hydraulic tank 1. Run the engine at low idle and set the work
according to the following procedure. equipment in the position for pressurizing the
hydraulic tank (Extend the rods of the boom,
1. Lower the work equipment to the ground and arm, and bucket cylinders to the respective
stop the engine. stroke ends).
2. Loosen the oil filler cap of the hydraulic tank 2. Stop the engine and open the oil filler cap of
gradually to release the pressure from the the hydraulic tank and tighten it again.
tank.
3. Start the engine and lower the work equipment
to the ground.
a The hydraulic tank is pressurized by the
above operation.
30-100 44 PC45MR-3, PC55MR-3

How to open and close (tilt) floor SEN04649-00
How to open and close (tilt) floor 1 5. Remove cover (2).

a Canopy specification
a When testing or servicing the underside of the
floor or inside of the revolving frame, open and
close (tilt) the floor according to the following
procedure.
Opening (Tilting open)

1. Move the arm in and lower the boom until the
work equipment and blade touch the ground.
a If the machine is not set in this state, the
cab (canopy) tilted up will interfere with
the work equipment etc. and will be dam-
aged. Accordingly, perform this work
securely.
6. Open engine rear cover (3) and lock it.
2. Stop the engine and set the work equipment

lock lever in the lock position.
3. Put blocks to the front and rear of the track

shoes to secure the machine.
4. Remove triangular cover (1).
PC45MR-3, PC55MR-3 30-100 45

SEN04649-00 How to open and close (tilt) floor
7. Loosen floor tilt lock bolts (5). a Cab specification

a Canopy specification
30-100 46 PC45MR-3, PC55MR-3

8. Close the engine rear cover (3). 10. After the floor rises, push up handle (8) until
lock pin (9) is fitted to lock groove (11) of lock
9. Open inspection window (6). While pulling plate (10).
floor lock release lever (7) in the direction of a When lock pin (9) moves to lock groove
the arrow with the left hand, push up handle (8) (11), the 1st locking is completed.
with the right hand in the direction of the arrow
(about 45°). 11. Insert 2nd lock pin (12) in lock hole (13)
q Machine with canopy: The floor and can- securely.
opy rise together.
q Machine with cab: The floor and cab rise 12. Ensure that the lock hook at the top of lock pin
together. (12) is hitched on pin (14) at the insertion sec-
a If the floor does not rise, release lever (7) tion and does not come off.
is not in the release position. In this case, a Check that lock pin (12) is hitched on pin
pull back handle (8) with the right hand (14) and does not come off.
and perform the above procedure again.
k Do not put any part of your body under
the floor while opening or closing the
floor.
a Since the gas cylinder assists you in
opening the floor, the operating effort is
increased when the ambient temperature
is low. Take care.
PC45MR-3, PC55MR-3 30-100 47

SEN04649-00 How to open and close (tilt) floor
Closing (Tilting close)

a Before closing the floor, check that the wiring,
piping, and seats on the underside of the floor
and inside of the revolving frame are free from
damage and abnormality.
1. Remove lock pin (12) and insert it in storage

hole (15).
a If you cannot remove the lock pin, perform
the following work.
q Canopy specification: While holding
the handle and pushing up the floor,
pull out the lock pin.
q Cab specification: While holding the
handle and pushing down the floor,
pull out the lock pin.
3. Open and lock engine rear cover (3).
2. While pulling floor lock release lever (7) in the

direction of the arrow (backward) with the left
hand, pull down handle (8) slowly with the right
hand in the direction of the arrow (about 45°).
a While checking that the wiring and piping
are not caught or damaged, pull down the
floor slowly.
k Do not put any part of your body under
the floor while opening or closing the
floor.
4. Tighten floor tilt lock bolts (5).

3 Lock bolt: 156 – 196 Nm {16 – 20 kgm}
30-100 48 PC45MR-3, PC55MR-3

a Canopy specification 5. Close the engine rear cover (3).
6. Install cover (2).

a Cab specification
7. Install rectangular cover (1).
a Cab specification
a The floor closing (tiling close) work is finished.
PC45MR-3, PC55MR-3 30-100 49

SEN04649-00 Inspection procedures for diode
Inspection procedures for diode 1
a Check an assembled-type diode (8 pins) and

single diode (2 pins) in the following manner.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Check the needle swing in case of the fol-
lowing connections.
a The conductive direction of each diode is i) Put the red probe (+) of the test lead
marked on its surface as shown below. to the anode (P) and the black probe
(–) to the cathode (N) of diode.
ii) Put the red probe (+) of the test lead
to the cathode (N) and the black
probe (–) to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
q If the needle does not swing in Case
i), but swings in Case ii): Normal (but
the breadth of swing (i.e. resistance
value) will differ depending on a cir-
cuit tester type or a selected mea-
surement range)
q If the needle swings in either case of
i) and ii): Defective (short-circuited
1. When using digital type circuit tester internally)
1) Switch the testing mode to diode range q If the needle does not swing in any
and confirm the indicated value. case of i) and ii): Defective (short-cir-
a Voltage of the battery inside is dis- cuited internally)
played with conventional ci rcuit
testers.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe (–) to the
cathode (N) of diode, and confirm the dis-
played value.
3) Determine if a specific diode is good or no
good with the indicated value.
q No change in the indicated value: No
continuity (defective).
q Change in the indicated value: Conti-
nuity established (normal) (Note)
Note: A silicon diode shows a value
between 460 and 600.
30-100 50 PC45MR-3, PC55MR-3

How to start operation of KOMTRAX terminal SEN04649-00
How to start operation of

KOMTRAX terminal 1
In the case where the KOMTRAX terminal has

already been installed at the plant before ship-
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, model number and

serial number
Notify the model, model number and serial 4) Turn the starting switch ON and keep that
number of the machine to the KOMTRAX oper- condition for 5 seconds.
ations administrator. q Check that the 7-segment indicator
lamp indicates a bar.
2. Registration of machine
The KOMTRAX operations administrator regis-
ters the machine using a KOMTRAX client per-
sonal computer.
a For the procedure, see “Manual for
KOMTRAX operations administrator”.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted on the machine after shipment:
a Implement the following procedure in the
case where the KOMTRAX terminal is ret-
rofitted after shipment of the machine (ret-
rofitted machine).
5) Disconnect test connectors F33 and F34
1. Sign-up test on machine side and keep that condition for 5 seconds.
a Complete procedures 4) – 6) in 60 sec- 6) Reconnect test connectors F33 and F34
onds. and keep that condition for 5 seconds.
1) Park the machine in a place sufficiently a If the KOMTRAX terminal detects dis-
apart from buildings etc. where its top is connection or reconnection of the
seen from every direction so that it can connectors, the dot of the 7-segment
receive the radio waves from the satellite. indicator lamp blinks 2 – 3 times.
a The inspection cannot be completed a If procedures 4) – 6) are not com-
normally indoors. Be sure to perform pleted in 60 seconds, repeat from 2).
the inspection outdoors.
2) Turn the starting switch OFF and wait for
at least 5 seconds and then go to the next
step.
3) Check visually that the test connectors
under KOMTRAX terminal (1) are con-
nected.
a Test connectors: F33, F34 (male,
female)
PC45MR-3, PC55MR-3 30-100 51

SEN04649-00 How to start operation of KOMTRAX terminal
7) Check that the 7-segment indicator lamp a Go to the next step if you can check
of the KOMTRAX terminal is displaying that the display is “normal”.
normally. a If the display is “abnormal”, repeat
a If the indication is normal, the 7-seg- from procedure 2) again. (“–” is dis-
ment indicator lamp (a) is displayed played continuously.)
for 30 seconds after 6) is completed. 8) Turn the starting switch to the START
(“d”, “0” and “–” are displayed repeat- position, keep it more than 5 seconds, and
edly.) check that the engine does not start.
q Display of the 2nd letter “0” may a If the engine starts, repeat from pro-
be different from the first. cedure 2).
q Display of the 3rd letter “–” a If the engine starts again, the engine
changes 30 seconds after the start lock function does not work nor-
operation of 6). mally. Stop the inspection and check
of the relays and wiring harnesses for
trouble.
9) Return the starting switch to the ON posi-
tion and keep it there for 5 seconds.
a Do not return the starting switch to
the OFF position.
10) Turn the starting switch to the START
position again and ensure that the engine
starts.
11) Check that the 7-segment indicator lamp
of the KOMTRAX terminal is indicating
normally without stopping the engine.
a Go to the next step if you ensured
that the display is [normal]. (It takes
from 90 seconds to 15 minutes before
the display turns normal.)
a If [GPS position data detection trou-
ble ([B] in next page) is indicated,
check if there is any external abnor-
mality on the GPS antenna or cable.
If there is any abnormality, repair it
and repeat from procedure 1) again.
a If [Reception trouble ([C] in next
page)] is indicated, check if there is
any external abnormality on the
appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trou-
ble and reception trouble ([B] and [C]
in next page)] is indicated, check if
there is any external abnormality on
the GPS antenna or cable and com-
munication antenna or cable. If there
is any abnormality, repair it and
repeat from procedure 1) again.
a If [Network trouble] is indicated,
check the display of [LED-4] referring
to “Lamp display of KOMTRAX termi-
nal”. (If CAN is not recognized, check
the CAN harness of the KOMTRAX
terminal, and then if there is any
abnormality, repair it and repeat from
procedure 1) again.)
30-100 52 PC45MR-3, PC55MR-3

How to start operation of KOMTRAX terminal SEN04649-00
[A]: Normal finish (It takes at least 90 seconds 12) Turn the starting switch OFF.
for the system to display this) 13) Check that the 7-segment indicator lamp
[B]: GPS position data detection trouble is indicating normally in 10 seconds.
“Check the GPS antenna and cable for a If you checked that the display is
external abnormality.” [Normal], that is the end of the sign-
(It takes 90 seconds – 5 minutes) up test.
[C]: Incomplete receiving a If the display shows [Abnormal],
“Check the communication antenna and r ep eat fr om pr oc ed ur e 1) a gai n
cable for external abnormality.” because the sign-up test has not
(It takes 30 seconds – 1 minute) been completed successfully.
[D]: Network trouble or wiring harness trouble
“The network type selection input does not
agree with the obtained network data.”
“Check the machine wiring for an error.”
a If the display is not any of the above, call

Customer Support Division.
a It takes 90 seconds – 5 minutes for the
system to display “Normal finish” after the
operation of 6).
PC45MR-3, PC55MR-3 30-100 53

SEN04649-00 How to start operation of KOMTRAX terminal
2. Application for the start of use

a Application for the start of use must be
made only after the sign-up test is fin-
ished.
1) Notify to the KOMTRAX operations
administrator of the following information
concerning the machine whose sign-up
test on the machine side is completed.
1] Information on the machine whose
sign-up test on the machine side is
completed (Model, model number
and serial number)
2] Part number and serial number of the
KOMTRAX terminal
3] Reading of the service meter when
the KOMTRAX terminal was installed
(0.1h unit)
2) The KOMTRAX operations administrator

registers the machine using KOMTRAX
client personal computer.
a For the procedure, see “Manual for
KOMTRAX operations administrator”.
a Now the terminal is ready for use.
30-100 54 PC45MR-3, PC55MR-3

Lamp display of KOMTRAX terminal SEN04649-00
Lamp display of KOMTRAX terminal 1
CPU LED 7-segment and dot for CPU

1. LED-1 [Green] (R signal and ACC signal) 6. 7-segment [Red] (Sign-up test status and oper-
2. LED-2 [Red] (Starting output status) ation status)
3. LED-3 [Yellow] (S-NET status and C signal sta- 7. Dot [Red] (GPS positioning status and test
tus) connector disconnection/connection status))
4. LED-4 [Green] (Fuel sensor and CAN connec-
tion status)
5. LED-5 [Red] (Downloading and writing status)
PC45MR-3, PC55MR-3 30-100 55

SEN04649-00 Lamp display of KOMTRAX terminal
In the KOMTRAX system, various information and processing details are displayed on the LED of the upper
surface of the KOMTRAX terminal. Therefore, if a defect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side must be completed in advance in order
to use KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna must not be off or damaged.
q The communication antenna cable must not be broken and must be connected to the KOMTRAX termi-
nal normally.
q The GPS antenna must not be off or damaged.
q The GPS antenna cable must not be broken and must be connected to the KOMTRAX terminal nor-
mally.
30-100 56 PC45MR-3, PC55MR-3

Lamp display of KOMTRAX terminal SEN04649-00
1. Contents of CPU LED, 7-segment and dot displays

a The LED displays must be checked with the starting switch in the ON or START position or with the
engine started.
No. LED (Color) Name/Function Display (*1) Contents of display

ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
LED-1
1 signal and alternator
(Green) Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
R signal
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
LED-2 Starting output ON Engine control signal: ON
2
(Red) status OFF Engine control signal: OFF
S-NET connection Fast blinking Starting switch C signal: ON
LED-3 status and starting
3 ON Starting switch C signal: OFF, S-NET: Connected
(Yellow) switch C signal
status OFF Starting switch C signal: OFF, S-NET: Disconnected
ON CAN: Connected, (Fuel sensor: Disconnected)
Fuel sensor and Fast blinking CAN: Connected, (Fuel sensor: Connected)
LED-4
4 CAN connection
(Green) Slow blinking CAN: Disconnected, (Fuel sensor: Connected)
status
OFF CAN: Disconnected, (Fuel sensor: Disconnected)
LED-5 Downloading and ON Downloading and writing mode: ON
5
(Red) writing status OFF Downloading and writing mode: OFF (Normal mode)
Before execution of sign-up test
When sign-up test is not completed, “–” (bar) is always
Sign-up status [–]
displayed.
During sign-up test
Sign-up progress * For display during sign-up test, see “How to start operation
*
status of KOMTRAX terminal”.
After completion of sign-up test
[C] If server initialization communication is not completed, [C] is
7-segment Initialization displayed.
6
(Red) communication ON “ON” indicates that machine is within communication range.
incompletion status Fast blinking “Fast blinking” indicates that machine is out of communication
range.
Operation status
[0 – 9] Figure indicates number of mails waiting for to be sent (9 is
Number of unsent displayed when number is 9 or larger).
mails or within/out ON “ON” indicates that terminal is capturing satellite.
of communication [0 – 9] Figure indicates number of mails waiting for to be sent (9 is
range status displayed when number is 9 or larger).
Fast blinking Fast blinking indicates that terminal has not captured satellite.
GPS connector ON GPS positioning has been executed. See *2.
positioning/
Dot OFF GPS positioning has not been executed. See *2.
7 Test connector
(Red)
disconnection and If sign-up test connector is disconnected or connected, dot
connection status Fast blinking
blinks 2 – 3 times.
*1 Types and periods of blinking

Fast blinking: Blinking at cycles of about 1 second (ON for 0.5 seconds o OFF for 0.5 seconds)
Slow blinking: Blinking at cycles of about 4 seconds (ON for 2 seconds o OFF for 2 seconds)
*2 It may take more than 1 minute from turning on the starting switch to the completion of positioning even
in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio
waves.
PC45MR-3, PC55MR-3 30-100 57

SEN04649-00 Removal and installation of KOMTRAX terminal
Removal and installation of Installation

KOMTRAX terminal 1 q Carry out installation in the reverse order to
removal.
Removal
1. Turn the starting switch to the OFF position.
2. Remove the cover, garnish, etc. to expose

KOMTRAX terminal (1).
3. Remove the cab wiring harness from

KOMTRAX terminal (1).
a Be sure to remove the cab wiring harness
before the antenna cable (described in
step 4).
4. Remove the communication antenna cable

and GPS antenna cable from KOMTRAX ter-
minal (1).
5. Remove all mounting bolts (2) and washers (3)

of the KOMTRAX terminal.
Reference: The mounting bolt size is M8.
6. Remove KOMTRAX terminal (1) from bracket

(4).
a When handling the KOMTRAX terminal,
take care not to give an impact on it.
(Never hit it against another part or drop
it.)
30-100 58 PC45MR-3, PC55MR-3

Preparation work for troubleshooting of electrical system SEN04649-00
Preparation work for

troubleshooting of electrical
system 1
a When carrying out troubleshooting of an elec-

tric circuit related to the KOMTRAX terminal,
expose the related connectors according to the
following procedure.
a The KOMTRAX terminal is installed at the rear
of the operator seat.
1. Remove the top cover of the KOMTRAX termi-

nal.
2. Remove KOMTRAX terminal (1).
3. Insert or connect a troubleshooting T-adapter

to connector F32 of KOMTRAX terminal (1).
a Cable (2) is for the communication
antenna (system 1).
a Cable (3) is for the GPS antenna.
PC45MR-3, PC55MR-3 30-100 59

SEN04649-00

©2008 KOMATSU
All Rights Reserved
30-100 60
SEN04650-00
PC45MR-3,
PC55MR-3

40 Troubleshooting 40
100 General information on troubleshooting

Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures of troubleshooting ........................................................................................... 5
Information contained in troubleshooting table ............................................................................................... 6
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
PC45MR-3, PC55MR-3 40-100 1

SEN04650-00 Points to remember when troubleshooting
Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
40-100 2 PC45MR-3, PC55MR-3

Sequence of events in troubleshooting SEN04650-00
Sequence of events in troubleshooting 1
PC45MR-3, PC55MR-3 40-100 3

SEN04650-00 Checks before troubleshooting
Checks before troubleshooting 1
Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check for clogging of fuel filter cartridge — Replace
4. Check engine oil level in oil pan, type of oil — Add oil
Lubricating oil,
5. Check for clogging of engine oil filter — Replace

coolant
6. Check coolant level — Add coolant

7. Check for clogging of air cleaner — Clean or replace
8. Check hydraulic oil level, type of oil — Add oil
9. Check for clogging of hydraulic oil strainer — Clean, drain
10. Check for clogging of hydraulic oil filter — Replace
11. Check swing machinery oil level, type of oil — Add oil
12. Check final drive oil level, type of oil — Add oil
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
mechanical equipment
Hydraulic, Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
1. Check for abnormal noise, smell — Repair
equipment
2. Check for oil leakage — Repair

3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 10 – 15V Charge or replace
2. Check battery electrolyte level — Add or replace
3. Check for discolored, burnt, exposed wiring — Replace
Electrics, electrical equipment
4. Check for missing wiring clamps, hanging wiring — Repair

5. Check for water leaking on wiring (be particularly careful attention Disconnect
—
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
After
running for
7. Check alternator voltage (engine running at 1/2 throttle or above) several Replace
minutes :
13.5 – 14.5V
8. Check operating sound of battery relay
— Replace
(when switch is turned ON/OFF)
40-100 4 PC45MR-3, PC55MR-3

Classification and procedures of troubleshooting SEN04650-00
Classification and procedures of troubleshooting 1
Classification of troubleshooting
Mode Contents
E-mode Troubleshooting for electrical system
H-mode Troubleshooting for hydraulic and mechanical system
S-mode Troubleshooting for engine unit
Procedure for troubleshooting

If a possible fault is detected in the machine, find a corresponding fault in the table of “Possible faults and
troubleshooting Nos.”, then go to the indicated troubleshooting section.
PC45MR-3, PC55MR-3 40-100 5

SEN04650-00 Information contained in troubleshooting table
Information contained in troubleshooting table 1
Failure
Problem that appears on machine
information
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (12 V) circuit comes
into contact with the power (12 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3 as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
4 • Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
40-100 6 PC45MR-3, PC55MR-3

Information contained in troubleshooting table SEN04650-00
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• “Connector No. and pin No.” from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
PC45MR-3, PC55MR-3 40-100 7

SEN04650-00 Information contained in troubleshooting table
Possible faults and troubleshooting Nos.
Troubleshooting
No. Possible fault
E-mode H-mode S-mode
Possible faults related to engine

1 Engine does not start easily (It always takes time to start) S-1
2 Engine does not crank E-1 S-2
Engine does not
3 Engine cranks but exhaust smoke does not come out S-2
start
4 Exhaust smoke comes out but engine does not start S-2
5 Engine speed does not rise sharply (Follow-up performance is low) S-3
6 Engine stops during operation S-4
7 Engine rotation is abnormal (Engine hunts) S-5
8 Output is insufficient or power is low S-6
9 Exhaust gas color is bad (Incomplete combustion) S-7
10 Oil is consumed much or exhaust gas color is bad S-8
11 Oil becomes dirty quickly S-9
12 Fuel is consumed much S-10
13 Coolant contains oil, blows back, or reduces S-11
14 Engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
15 Oil level rises (Water or fuel is mixed in oil) S-13
16 Coolant temperature rises too high (Overheating) S-14
17 Abnormal sound comes out S-15
18 Vibration is excessive S-16
19 Engine does not stop E-2
20 Engine is not preheated normally E-8
Possible faults related to work equipment, travel, swing, and blade
21 Speed or power of whole work equipment, travel, swing, and blade is low H-1
22 Engine speed lowers extremely or engine stalls H-2
23 Work equipment, travel, swing, and blade systems do not work H-3
24 Abnormal sound comes out from around hydraulic pump H-4
25 Fine control performance or response is low H-5
Possible faults related to work equipment
26 When work equipment lock lever is set in LOCK position, work equipment still E-14
moves
27 Speed or power of boom is low H-6
28 Speed or power of arm is low H-7
29 Speed or power of bucket is low H-8
30 Speed or power of boom swing is low H-9
31 Work equipment does not move singly H-10
32 Hydraulic drift of work equipment is large H-11
33 Time lag of work equipment is large H-12
40-100 8 PC45MR-3, PC55MR-3

Troubleshooting
No. Possible fault
E-mode H-mode S-mode
34 In compound operation of work equipment, speed of part loaded more is low H-13
Possible faults related to travel
35 Machine deviates during travel H-14
36 Speed or power of travel is low (While work equipment operates normally) H-15
37 Machine is not steered well or steering power is low H-16
38 Travel speed does not change H-17
39 Travel motor does not work H-18
Possible faults related to swing
40 Speed or power of swing is low H-19
41 Machine does not swing H-20
42 Swing acceleration is low H-21
43 Machine overruns when it stops swinging H-22
44 Large shock is made when machine stops swinging H-23
45 Large sound is made when machine stops swinging H-24
46 Hydraulic drift of swing is large H-25
Possible fault related to blade
47 Speed or power of blade is low H-26
48 Blade does not move H-27
49 Hydraulic drift of blade is large H-28
Possible fault related to monitor panel
50 When starting switch is turned ON, any item does not operate E-3
51 When starting switch is turned ON, some items do not operate E-4
52 Alarm buzzer is abnormal E-5
53 Engine oil pressure caution is turned ON E-6
54 Charge level caution is turned ON E-7
55 Preheating system does not operate or preheater does not become hot E-8
56 Coolant temperature gauge is abnormal E-9
57 Fuel level gauge is abnormal E-10
58 Service meter does not operate while engine is running E-11
59 2nd travel speed is not selected E-12
60 Working lamp does not light up E-13
Other possible faults
61 Windshield wiper does not operate E-15
62 Windshield washer does not operate E-16
63 Defective air conditioner E-17
64 KOMTRAX system does not operate normally E-18
PC45MR-3, PC55MR-3 40-100 9

SEN04650-00 Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2007.12)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
40-100 10 PC45MR-3, PC55MR-3

Connection table for connector pin numbers SEN04650-00
PC45MR-3, PC55MR-3 40-100 11

40-100 12 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 13

40-100 14 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 15

40-100 16 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 17

40-100 18 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 19

40-100 20 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 21

40-100 22 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 23

40-100 24 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 25

40-100 26 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 27

40-100 28 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 29

40-100 30 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 31

40-100 32 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 33

40-100 34 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 35

40-100 36 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 37

40-100 38 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 39

40-100 40 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 41

40-100 42 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 43

40-100 44 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-100 45

SEN04650-00 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table (Rev. 2008.02)1
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
40-100 46 PC45MR-3, PC55MR-3

T- branch box and T- branch adapter table SEN04650-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
PC45MR-3, PC55MR-3 40-100 47

SEN04650-00 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
40-100 48 PC45MR-3, PC55MR-3

T- branch box and T- branch adapter table SEN04650-00
PC45MR-3, PC55MR-3 40-100 49

SEN04650-00

©2008 KOMATSU
All Rights Reserved
40-100 50
SEN04651-00
PC45MR-3,
PC55MR-3

200 Troubleshooting of electrical system

(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 2
E-1 Engine does not start ............................................................................................................................... 4
E-2 Engine does not stop.............................................................................................................................. 12
E-3 When starting switch is turned ON, any item does not operate ............................................................. 14
E-4 When starting switch is turned ON, some items do not operate ............................................................ 16
E-5 Alarm buzzer is abnormal....................................................................................................................... 17
E-6 Engine oil pressure caution is turned ON............................................................................................... 19
E-7 Charge level caution is turned ON ......................................................................................................... 20
E-8 Preheating system does not operate or preheater does not become hot .............................................. 22
E-9 Coolant temperature gauge is abnormal ................................................................................................ 24
E-10 Fuel level gauge is abnormal ............................................................................................................... 28
E-11 Service meter does not operate while engine is running ...................................................................... 32
E-12 2nd travel speed is not selected........................................................................................................... 35
E-13 Working lamp does not light up ............................................................................................................ 38
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK,
work equipment still moves .................................................................................................................. 40
E-15 Windshield wiper does not operate ...................................................................................................... 42
E-16 Windshield washer does not operate ................................................................................................... 44
E-17 Defective air conditioner....................................................................................................................... 46
E-18 KOMTRAX system does not operate normally..................................................................................... 54
PC45MR-3, PC55MR-3 40-200 1

200 Troubleshooting of electrical system (E-mode)
SEN04651-00 Before carrying out troubleshooting of electrical system
Before carrying out troubleshooting of electrical system 1
Connection table of fuse box and slow blow fuse

a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies powers while the starting switch is in the ON
position and unswitched power supply is a device which supplies power while the starting switch is in
the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and slow
blow fuse to see if the power is supplied normally.
Type of power supply Fuse

Fuse No. Destination of power supply
(Power source) capacity
30 A (CAB)
1 Working lamp
10 A (CAN)
Fuel pump
2 10 A PPC lock solenoid relay
Horn switch
Machine monitor
3 10 A Alarm buzzer
Speedup solenoid relay, PPC lock switch
Accessory power supply
(Starting switch ACC 4 10 A Arm crane
terminal) Air conditioner
20 A (CAB)
5 Heater
10 A (CAN)
Travel alarm
Room lamp (CAB)
Radio (CAB)
6 20 A (CAB)
Wiper motor (CAB)
Washer motor (CAB)
7 30 A Engine stop solenoid
Machine monitor
Unswitched power supply
8 10 A Arm crane controller
(Fusible link of 45 A: M4)
Radio
Accessory power supply
(Starting switch ACC 9 10 A For optional equipment
terminal)
— 10 — (Spare)
q CAB: Cab specification, CAN: Canopy specification
40-200 2 PC45MR-3, PC55MR-3

Before carrying out troubleshooting of electrical system SEN04651-00
PC45MR-3, PC55MR-3 40-200 3

SEN04651-00 E-1 Engine does not start
E-1 Engine does not start 1
1) Engine does not start (Starting motor does not rotat)
Failure
• Engine does not start (Starting motor does not rotat).
information
• Since the engine starting circuit has a locking function, the engine cannot start if the PPC lock lever
Relative (lock lever) is not in the LOCK position.
information • The lock lever is installed to the right and left side of the canopy specification and to the left side of
the cab specification.
Cause Standard value in normalcy and references for troubleshooting

Insufficient battery Battery voltage Electrolyte specific gravity
1
capacity Min. 12 V Min. 1.26
Defective 45-A fusible link
If the fusible link or fuse is broken, the circuit probably has a grounding
2 or fuse (2) – (12) or (3) –
fault.
(13)
1) Turn starting switch OFF.
2) Disconnect negative (–) terminal of battery.
Starting switch Position Resistance
Defective starting switch Between (T-F1) terminal OFF Min. 1 Mz
3
(Internal defective contact) B and (T-F4) terminal C START Max. 1 z
Between (T-F1) terminal OFF Min. 1 Mz
B and (T-F3) terminal
ACC ON Max. 1z

2) Disconnect connector F5.
Defective PPC lock switch 3) Connect T-adapter to F5 (male).
4 (left) F5 (male) Lock lever position Resistance
(Internal defective contact)
Presumed FREE Max. 1 z
cause and Between (1) and (2)
LOCK Min. 1 Mz
standard value
in normalcy 1) Turn starting switch OFF.
Defective PPC lock switch 2) Disconnect connector F14.
(right) 3) Connect T-adapter to F14 (male).
5 (Internal defective contact) F14 (male) Lock lever position Resistance
a Only canopy specifica-
FREE Max. 1 z
tion Between (1) and (2)
LOCK Min. 1 Mz
2) Disconnect relay R1.
3) Connect T-adapter to R1 (male).
R1 (male) Resistance
Between (1) and (2) 86 – 106 z
Defective starting motor
Between (3) and (4) Max. 1 z
relay
6 (Internal disconnection, Between (3) and (5) Min. 1 Mz
defective contact, or 1) Turn starting switch OFF.
fixing) 2) Insert T-adapter in relay R1.
3) Turn starting switch ON.
R1 Voltage
Between (4) and ground
(Set PPC lock lever in LOCK and 10 – 15 V
starting switch in START)
40-200 4 PC45MR-3, PC55MR-3

E-1 Engine does not start SEN04651-00
Causes Standard value in normalcy and references for troubleshooting

Between (1) and (2) 86 – 106 z
Defective starting motor
cutout relay
7 (Internal disconnection, Between (3) and (5) Min. 1 Mz
defective contact, or 1) Turn starting switch OFF.
fixing) 2) Insert T-adapter in relay R1.
R6 Voltage
Between (4) and ground
(Set PPC lock lever in LOCK and 10 – 15 V
starting switch in START)
1) Turn starting switch from OFF to START for troubleshooting.
(If power supply and starting input/output are normal and starting motor
does not rotate, starting motor is defective.)
8 Defective starting motor Starting
Starting motor Voltage
switch
Power supply: Between terminal B and ground ON 10 – 15 V
Starting input: Between terminal S and ground START 10 – 15 V
1) Turn starting switch from OFF to START for troubleshooting.
Defective safety relay
9 (Internal defective contact M16 Voltage
or disconnection)
Possible Between (2) and ground 10 – 15 V
causes and 1) Turn starting switch from OFF to ON or START for troubleshooting.
standard value Defective alternator
in normal state 10 (including regulator) Alternator Voltage
(Internal short circuit)
Between terminal P and ground Max. 1 V
2) Disconnect related connector or terminal.
3) Set PPC lock switch in LOCK.
Wiring harness between battery (+) and T-F1 or
Resistance Max. 1 z
M16 (female) (1)
Wiring harness between T-F3 and fuse (2) or
Resistance Max. 1 z
between (12) and F3 (1) and M15 (3)
Wiring harness between fuse (13) and F5 (2) or
between (1) and F14 (2) or between (1) and R1
Resistance Max. 1 z
(female) (1)
a Check F14 for only canopy specification.
Disconnection in wiring
Wiring harness between T-F4 and R6 (female)
harness Resistance Max. 1 z
(3)
11 (Disconnection in wiring
harness or defective Wiring harness between R1 (female) (3), F1 (3),
Resistance Max. 1 z
contact in connector) and M15 (female) (1)
Wiring harness between M15 (female) (4) and
Resistance Max. 1 z
M10 (female) (3)
Resistance Max. 1 z
starting motor terminal S
Wiring harness between R1 (female) (2), F2 (2),
Resistance Max. 1 z
and ground
Resistance Max. 1 z
ground
Wiring harness between R6 (female) (4) and R1
Resistance Max. 1 z
(female) (4)
PC45MR-3, PC55MR-3 40-200 5


Wiring harness between R6 (female) (1) and
Disconnection in wiring Resistance Max. 1 z
F32 (female) (3)
harness
Wiring harness between R6 (female) (2) and
11 (Disconnection in wiring Resistance Max. 1 z
F32 (female) (8)
harness or defective con-
Wiring harness between T-F4 and F32 (female)
tact in connector) Resistance Max. 1 z
(11)
2) Disconnect related connector or terminal.
Between wiring harness between M5 (female)
Resistance Min. 1 Mz
(2), F2 (1), T-F1, or M16 (female) (1) and ground
Between wiring harness between fuse (12), F3
(1), M15 (3), or M14 (female) (2) and ground
Between wiring harness between fuse (13) and
Possible F5 (2) or between (1) and F14 (2) or between (1)
causes and and R1 (female) (1) and ground
standard value a Test F14 for only canopy specification.
in normal state Between wiring harness between T-F4 and R6
Short circuit with chassis (female) (3) and ground
ground in wiring harness Between wiring harness between R1 (female)
12 Resistance Min. 1 Mz
(Contact with ground (3), F1 (3) and M15 (female) (1) and ground
circuit)
(4) and M10 (female) (3) and ground
(2) and starting motor terminal S and ground
Between wiring harness between R6 (female)
(4) and R1 (female) (4) and ground
(1) and F32 (female) (3) and ground
(2) and F32 (female) (8) and ground
Between wiring harness between T-F4 and F32
(female) (11) and ground
40-200 6 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-200 7

2) Engine does not start (Fault in engine stop solenoid)
Failure
• Engine does not start (Fault in engine stop solenoid).
information
Relative
• The starting motor rotates but the engine does not start.
information

1 Defective fuse (7) – (17) If the fuse is broken, the circuit probably has a grounding fault.
Defective starting switch Starting switch Position Resistance
2
B and (T-F2) terminal BR ON Max. 1 z
2) Disconnect connector M13.
Defective engine stop 3) Connect T-adapter to M13 (male).
solenoid M13 (male) Resistance
3
(Internal disconnection or
Between (1) and (3) 22 – 28 z
short circuit)
Between (2) and (3) 0.63 – 0.77 z
Between (1), (2), and body Min. 1 Mz
1) Turn starting switch from OFF to ON for troubleshooting.
Measurement
M22 Voltage
Defective timer condition
4 (Internal disconnection or For 1 second after
short circuit) starting switch is 10 – 15 V
Between (1) and (2) turned ON
Presumed After 1 second Max. 1 V
cause and 1) Turn starting switch OFF.
standard value 2) Disconnect connector M19.
in normalcy M19 (male) Resistance
Between (1) and (2) 33 – 41 z
Defective engine stop
solenoid relay
5 Measurement
(Internal disconnection or M21 Voltage
short circuit) condition
For 1 second after
starting switch is 10 – 15 V
Between (1) and ground turned ON
After 1 second Max. 1 V
2) Disconnect related connector.
Wiring harness between T-F2 and fuse (7),
between fuse (17), F1 (1) and M13 (female) (1) Resistance Max. 1 z
Disconnection in wiring or M22 (female) (4) or M20 (female) (1)
harness Wiring harness between M13 (female) (2) and
6 (Disconnection in wiring Resistance Max. 1 z
M21 (female) (1)
harness or defective
contact in connector) Resistance Max. 1 z
M19 (female) (1)
Resistance Max. 1 z
M19 (female) (2)
Wiring harness between M13 (female) (3) or
Resistance Max. 1 z
M22 (female) (3) and ground
40-200 8 PC45MR-3, PC55MR-3


Between wiring harness between fuse (17), F1
Possible (1) and M13 (female) (1) or M22 (female) (4) or Resistance Min. 1 Mz
causes and Short circuit with chassis
standard value ground in wiring harness
7
in normal state (Contact with ground Between wiring harness between M13 (female)
circuit) (2) and M21 (female) (1) and ground
a For the related circuit diagram, see 1).
PC45MR-3, PC55MR-3 40-200 9

3) Engine does not start (Fuel pump system)
Failure
• Engine does not start (Fuel pump system).
information
Relative
• Carry out following troubleshooting when engine stop solenoid system is normal.
information

1 Defective fuse (2) – (12) If fuse is broken, circuit probably has ground fault.
2) Disconnect cable from negative (–) terminal of battery.
2
B – (T-F3) terminal ACC ON Max. 1 z
2) Connect T-adapter to connector M14.
3) Turn starting switch from OFF to ON and carry out troubleshooting.
Between M14 (2) – ground Voltage 10 – 12 V
3 Defective fuel pump
Presumed 3) Connect T-adapter to connector M14 (female).
cause and
standard value Between M14 (female) (1) – ground Resistance Max. 1 z
2) Disconnect connectors M14 and M10.
Disconnection in wiring 3) Connect T-adapter to connector M14 (female).
harness Wiring harness between fuse (12) – M14
4 (Disconnection in wiring or Resistance Max. 1 z
(female) (2)
defective contact in
Wiring harness between M14 (female) (2) – M10
connector) Resistance Max. 1 z
(female) (2)
Between M14 (female) (1) – ground Resistance Max. 1 z
2) Disconnect connectors M14 and M10.
Ground fault in wiring 3) Connect T-adapter to connector M14 (female).
5 harness (Contact with Between wiring harness fuse (12) – M14
GND or GND circuit) (female) (2) and ground
Between wiring harness M14 (female) (2) – M10
40-200 10 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 40-200 11

SEN04651-00 E-2 Engine does not stop
E-2 Engine does not stop 1
Failure
• Engine does not stop.
information
Relative
information

3) Connect T-adapter to M13 (male).
Defective engine stop
1 M13 (male) Resistance
solenoid (Internal defect)
Between (1) and (3) 22 – 28 z
Presumed Between (2) and (3) 0.63 – 0.77 z
cause and
standard value 1) Turn starting switch from START to OFF for troubleshooting.
in normalcy Defective starting switch Starting switch Position Voltage
2
(Internal short circuit) Between (T-F2) termi-
OFF Max. 1 V
nal BR and ground
1) Prepare with starting switch OFF, then carry out troubleshooting
Short circuit with power without turning starting switch ON.
3 source in wiring harness
(Contact with 12 V circuit) Between wiring harness between T-F2 and
Voltage Max. 1 V
40-200 12 PC45MR-3, PC55MR-3

E-2 Engine does not stop SEN04651-00
PC45MR-3, PC55MR-3 40-200 13

SEN04651-00 E-3 When starting switch is turned ON, any item does not operate
E-3 When starting switch is turned ON, any item does not operate 1
• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the
monitor panel.
Failure 1) The warning lamps and indicators do not light up (for 3 seconds).
information 2) The buzzer does not sound (for 1 second).
• The fuel level gauge and coolant temperature gauge do not operate even a while after the starting
switch is turned ON.
Relative • Before starting troubleshooting, check that fuses No. (3) – (13) and No. (8) – (18) and fusible link are
information not broken.

Between F15 (female) (20) and ground Voltage 10 – 15 V
2) Remove fuses No. (3) – (13) and No. (8) – (18).
Presumed Disconnection in wiring Between FB1 (8) and ground Voltage 10 – 15 V
cause and harness (Disconnection in Between FB1 (3) and ground Voltage 10 – 15 V
1
standard value wiring harness or defective 1) Turn starting switch OFF.
in normalcy contact in connector) 2) Remove starting switch.
Between T-F1 and ground Voltage 10 – 15 V
3) Connect T-adapter to female side of F15.
Wiring harness between F15 (female) (1)
Resistance Max. 1 z
and ground
2 Defective monitor panel If the floor wiring harness is normal, the monitor panel is defective.
40-200 14 PC45MR-3, PC55MR-3

E-3 When starting switch is turned ON, any item does not operate SEN04651-00
PC45MR-3, PC55MR-3 40-200 15

SEN04651-00 E-4 When starting switch is turned ON, some items do not operate
E-4 When starting switch is turned ON, some items do not operate 1
• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the
monitor panel.
Failure 1) Some warning lamps and indicators do not light up (for 3 seconds).
information 2) The buzzer does not sound (for 1 second).
• The fuel level gauge and coolant temperature gauge do not operate even a while after the starting
switch is turned ON.
Relative
• Distinguish this fault from “E-3 When starting switch is turned ON, any item does not operate”.
information
Presumed Causes Standard value in normalcy and references for troubleshooting

cause and
standard value See Structure, function and maintenance standard, “Monitor
1 Defective monitor panel
in normalcy system”.
40-200 16 PC45MR-3, PC55MR-3

E-5 Alarm buzzer is abnormal SEN04651-00
E-5 Alarm buzzer is abnormal 1
1) Alarm buzzer does not sound

• When the starting switch is turned from OFF to ON, the self-check buzzer does not sound (for 1 sec-
Failure ond).
information • When the starting switch is turned ON and the 2nd travel speed selection switch and light switch are
pressed, the selection sound (a short sound) is not heard.
Relative • Before starting troubleshooting, check that fuse No. (3) – (13) is not broken.
information • Refer to troubleshooting E-3, too.

1 Defective monitor panel 3) Turn starting switch ON.
Sounds
Connect F15 (female) (11) to ground. Buzzer only when
connected.
2) Insert T-adapter in connector F28.
Presumed 3) Turn starting switch ON.
cause and 2 Defective alarm buzzer Sounds
standard value Connect T-adapter box No. 1 to ground. Buzzer only when
in normalcy connected.
Between F28 (2) and ground Voltage 10 – 15 V
2) Disconnect connectors F15 and F28.
Disconnection in wiring 3) Connect T-adapter to F15 (female) and F28 (female).
harness (Disconnection in
3 Wiring harness between F15 (female) (11)
wiring harness or defective Resistance Max. 1 z
and F28 (female) (1)
contact in connector)
Wiring harness between fuse (13) and F28
Resistance Max. 1 z
(female) (2)
PC45MR-3, PC55MR-3 40-200 17

SEN04651-00 E-5 Alarm buzzer is abnormal
2) Alarm buzzer does not stop sounding

Failure
• Alarm buzzer does not stop sounding.
information
Relative • Before starting troubleshooting, check that fuse No. (3) – (13) is not broken.

1 Defective monitor panel 3) Turn starting switch ON.
Presumed Disconnect connector F15, and turn starting Stops
Buzzer
cause and switch ON. sounding.
standard value 1) Turn starting switch OFF.
in normalcy 2) Disconnect connectors F15 and F28.
Short circuit with chassis 3) Connect T-adapter to F15 (female) and F28 (female).
2 ground in wiring harness
(Contact with ground circuit) Between wiring harness between F15
(female) (11) and F28 (female) (1) and Resistance Min. 1 Mz
ground
40-200 18 PC45MR-3, PC55MR-3

E-6 Engine oil pressure caution is turned ON SEN04651-00
E-6 Engine oil pressure caution is turned ON 1
• The monitor panel performs the following operations to notify abnormal engine oil pressure while the
Failure engine is running.
information 1) The engine oil pressure caution lamp flashes.
2) The buzzer sounds.
• Check that the engine oil pressure is normal.
• When the starting switch is turned from OFF to ON, the monitor panel performs the following opera-
Relative
information tions. This does not indicate a fault.
1) The engine oil pressure caution lamp and charge level caution lamp light up.
2) The buzzer does not sound.

Short circuit with chassis 2) Disconnect T-M3 and connector F15.
1 ground in wiring harness 3) Connect T-adapter to F15 (female).
Presumed Resistance Min. 1 Mz
(female) (7) and T-M3 and ground
cause and
in normalcy 2) Disconnect T-M3.
2 Defective monitor panel 3) Start engine.
Oil pressure
While T-M3 is disconnected caution Stopped
Defective engine oil pressure If the monitor panel and wiring harnesses are normal, the engine oil
3
switch pressure switch is defective.
PC45MR-3, PC55MR-3 40-200 19

SEN04651-00 E-7 Charge level caution is turned ON
E-7 Charge level caution is turned ON 1
• The monitor panel performs the following operations to notify abnormal charge level while the engine
Failure is running.
information 1) The charge level caution lamp flashes.
2) The buzzer sounds.
• Check that the fan belt tension is normal.
• When the starting switch is turned from OFF to ON, the monitor panel performs the following opera-
Relative
information tions. This does not indicate a fault.
1) The engine oil pressure caution lamp and charge level caution lamp light up.
2) The buzzer does not sound.

1) Prepare with starting switch OFF.
Defective alternator 2) Start engine and carry out troubleshooting.
1
(Internal disconnection) Between M10 (1) and ground (just after 13.5 –
Voltage
starting engine) 14.5 V
2) Disconnect connectors M10 and F15.
Disconnection in wiring 3) Connect T-adapter to female side of F15.
2 Wiring harness between battery (+) terminal
and alternator terminal B
Presumed contact in connector)
Wiring harness between M10 (female) (1),
cause and Resistance Max. 1 z
standard value F4 (6) and F15 (female) (17)
Short circuit with chassis 3) Connect T-adapter to female side of F15.
(female) (17), F4 (6) and M10 (female) (1) Resistance Min. 1 Mz
and ground
2) Insert T-adapter in F15.
4 Defective monitor panel 3) Start engine.
Between F15 (17) and ground (just after 13.5 –
Voltage
starting engine) 14.5 V
40-200 20 PC45MR-3, PC55MR-3

E-7 Charge level caution is turned ON SEN04651-00
PC45MR-3, PC55MR-3 40-200 21

SEN04651-00 E-8 Preheating system does not operate or preheater does not become hot
E-8 Preheating system does not operate or preheater does not become hot1
• When the starting switch is set to HEAT, the following preheating system of the monitor panel does
Failure not operate.
information 1) The preheating indicator flashes (for about 18 seconds).
2) The buzzer sounds at start and end of preheating.
Relative • Check that the fusible link is not broken.

If the fusible link is burned, the circuit probably has a grounding
1 Defective fusible link
fault.
1) Prepare with starting switch OFF.
Defective air heater 2) Turn starting switch ON and carry out troubleshooting.
2
(Internal disconnection)
Between M23 (female) (1) and ground Voltage 10 – 15 V
Presumed 1) Turn starting switch OFF.
cause and Defective starting switch 2) Disconnect negative (–) terminal of battery.
3
standard value (Internal defective contact)
Between T-F1 and T-F5 or T-F6 Resistance Max. 1 z
in normalcy
2) Disconnect related connectors and terminals.
Disconnection in wiring 3) Connect T-adapter to female side of F15.
4 Wiring harness between M23 (female) (1),
F1 (2) and T-F5, T-F6 or F15 (female) (8)
Wiring harness between T-F1 and F2 (1) and
Resistance Max. 1 z
M5 (2) (1) and positive (+) terminal of battery
40-200 22 PC45MR-3, PC55MR-3

E-8 Preheating system does not operate or preheater does not become hot SEN04651-00
PC45MR-3, PC55MR-3 40-200 23

SEN04651-00 E-9 Coolant temperature gauge is abnormal
E-9 Coolant temperature gauge is abnormal 1
1) The pointer of the gauge does not move from C on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from C on the panel.
information
• Check that the coolant temperature is normal.
Relative
• While the starting switch is in OFF, the pointer does not move from C. This is not abnormal.
information
• Refer to troubleshooting E-3, too.

Disconnection in wiring 3) Connect T-adapter to M9 (female) and F15 (female).
1 Wiring harness between F15 (female) (10),
F4 (7) and M9 (female) (1)
Wiring harness between F15 (female) (16),
Resistance Max. 1 z
F4 (1) and M9 (female) (2)
Presumed 3) Connect T-adapter to M9 (male).
cause and M9 (male) Temperature Resistance
standard value
in normalcy 25°C 38.18 – 47.77 kz
30°C 31.59 – 39.07 kz
Defective coolant temperature
2 80°C 6.199 – 6.935 kz
sensor
85°C 5.386 – 5.975 kz
Between (1) and (2)
90°C 4.695 – 5.166 kz
95°C 4.107 – 4.483 kz
100°C 3.604 – 3.903 kz
105°C 3.157 – 3.426 kz
If the wiring harness and coolant temperature sensor are normal,
the monitor panel is defective.
40-200 24 PC45MR-3, PC55MR-3

E-9 Coolant temperature gauge is abnormal SEN04651-00
PC45MR-3, PC55MR-3 40-200 25

SEN04651-00 E-9 Coolant temperature gauge is abnormal
2) The pointer of the gauge does not move from H on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from H on the panel.
information
Relative • Check that the coolant temperature is normal.

Disconnection in wiring 3) Connect T-adapter to M9 (female) and F15 (female).
1 Wiring harness between F15 (female) (10) or
wiring harness or defective Resistance Min. 1 Mz
Wiring harness between F15 (female) (16) or
Presumed 3) Connect T-adapter to M9 (male).
cause and M9 (male) Temperature Resistance
standard value
in normalcy 25°C 38.18 – 47.77 kz
30°C 31.59 – 39.07 kz
2 80°C 6.199 – 6.935 kz
sensor
85°C 5.386 – 5.975 kz
Between (1) and (2)
90°C 4.695 – 5.166 kz
95°C 4.107 – 4.483 kz
100°C 3.604 – 3.903 kz
105°C 3.157 – 3.426 kz
40-200 26 PC45MR-3, PC55MR-3

E-9 Coolant temperature gauge is abnormal SEN04651-00
3) Temperature indicated by gauge is very different from actual temperature
Failure • When the starting switch is turned ON, the temperature indicated by the gauge is very different from
information the actual temperature.
Relative • Check that the coolant temperature is normal.

M9 (male) Temperature Resistance
25°C 38.18 – 47.77 kz
Presumed 30°C 31.59 – 39.07 kz
cause and 1 80°C 6.199 – 6.935 kz
sensor
standard value
in normalcy 85°C 5.386 – 5.975 kz
Between (1) and (2)
90°C 4.695 – 5.166 kz
95°C 4.107 – 4.483 kz
100°C 3.604 – 3.903 kz
105°C 3.157 – 3.426 kz
PC45MR-3, PC55MR-3 40-200 27

SEN04651-00 E-10 Fuel level gauge is abnormal
E-10 Fuel level gauge is abnormal 1
1) The pointer of the gauge does not move from E on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from E on the panel.
information
• Check that the fuel level is normal.
Relative
• While the starting switch is in OFF, the pointer does not move from E. This is not abnormal.
information

3) Connect T-adapter to M6 (female) and F15 (female).
Disconnection in wiring Wiring harness between F15 (female) (13)
Resistance Max. 1 z
harness (Disconnection in and M6 (female) (1)
1
wiring harness or defective 1) Turn starting switch OFF.
contact in connector) 2) Disconnect connectors M6.
3) Connect T-adapter to M6 (female).
Presumed Wiring harness between M6 (female) (2) and
cause and Resistance Max. 1 z
ground
standard value
in normalcy
Resistance
2 Defective fuel level sensor M6 (male) Position of float
( ) is reference value.
FULL –0 z
0 +2
Between (1) and (2) 1/2 (50) z
EMPTY 150 ± 10 z
If the wiring harness and fuel level sensor are normal, the monitor
panel is defective.
40-200 28 PC45MR-3, PC55MR-3

E-10 Fuel level gauge is abnormal SEN04651-00
PC45MR-3, PC55MR-3 40-200 29

SEN04651-00 E-10 Fuel level gauge is abnormal
2) The pointer of the gauge does not move from F on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from F on the panel.
information
Relative • Check that the fuel level is normal.

Short circuit with chassis 2) Disconnect connectors M6 and F15.
1 ground in wiring harness 3) Connect T-adapter to M6 (female) and F15 (female).
(Contact with ground circuit) Wiring harness between F15 (female) (13)
and M6 (female) (1)
cause and 2) Disconnect connector M6.
standard value 3) Connect T-adapter to M6 (male).
in normalcy Resistance
2 Defective fuel level sensor M6 (male) Position of float
FULL –0 z
0 +2
Between (1) and (2) 1/2 (50) z
EMPTY 150 ± 10 z
panel is defective.
40-200 30 PC45MR-3, PC55MR-3

E-10 Fuel level gauge is abnormal SEN04651-00
3) Fuel level indicated by gauge is very different from actual oil level
Failure • When the starting switch is turned ON, the fuel level indicated by the gauge is very different from the
information actual temperature.
Relative • Check that the fuel level is normal.

Presumed Resistance
cause and 1 Defective fuel level sensor M6 (male) Position of float
standard value
in normalcy
FULL –0 z
0 +2
Between (1) and (2) 1/2 (50) z
EMPTY 150 ± 10 z
panel is defective.
PC45MR-3, PC55MR-3 40-200 31

SEN04651-00 E-11 Service meter does not operate while engine is running
E-11 Service meter does not operate while engine is running 1
1) Engine oil pressure caution is turned ON

Failure 1) Service meter (Operating hour integrator) does not
Engine oil pressure caution is turned ON.
information operate while engine is running.
• While the engine is running, the service meter operates even if the machine does not move at all.
• While the engine is stopped, the service meter does not operate.
Relative
information
a Carry out troubleshooting “E-6 Engine oil pressure caution is turned ON” first, then carry out the fol-
lowing troubleshooting.

Presumed Disconnection in wiring 3) Connect T-adapter to F15 (female).
cause and harness (Disconnection in 4) Turn starting switch to START (Do not hold for long time,
1
standard value wiring harness or defective however).
in normalcy contact in connector)
2 Defective monitor panel If the wiring harness is normal, the monitor panel is defective.
40-200 32 PC45MR-3, PC55MR-3

E-11 Service meter does not operate while engine is running SEN04651-00
2) Charge warning is displayed, too

Failure 2) Service meter (Operating hour integrator) does not
Charge warning is displayed, too.
information operate while engine is running.
Relative
information
a Carry out the troubleshooting for “E-7 Charge level caution is turned ON” first, then carry out the fol-
lowing troubleshooting.

Presumed Disconnection in wiring 3) Connect T-adapter to F15 (female).
cause and harness (Disconnection in 4) Turn starting switch to START (Do not hold for long time,
1
standard value wiring harness or defective however).
in normalcy contact in connector)
2 Defective monitor panel If the wiring harness is normal, the monitor panel is defective.
3) Engine oil pressure and charge does not indicate warning

Failure 3) Service meter (Operating hour integrator) does not Engine oil pressure and charge does not
information operate while engine is running. indicate warning.
Relative
information
a If the service meter still does not work after the troubleshooting for E-6 and E-7, the possible cause is
as follows.

cause and
standard value If any abnormality is not detected by 1) and 2), the monitor panel is
in normalcy defective.
PC45MR-3, PC55MR-3 40-200 33

SEN04651-00 E-11 Service meter does not operate while engine is running
40-200 34 PC45MR-3, PC55MR-3

E-12 2nd travel speed is not selected SEN04651-00
E-12 2nd travel speed is not selected 1
1) Monitor panel does not respond and 2nd travel speed is not selected
• When the 2nd travel speed selection switch is pressed while the engine is running, the monitor panel
Failure does not make the following responses.
information 1) Turning ON/OFF of 2nd travel speed indicator
2) Changing sound by buzzer (Short sound)
Relative
information
a Carry out troubleshooting E-3.
PC45MR-3, PC55MR-3 40-200 35

SEN04651-00 E-12 2nd travel speed is not selected
2) Monitor panel responds but 2nd travel speed is not selected

Failure
• Monitor panel responds but 2nd travel speed is not selected.
information
Relative
information

1 Defective fuse (3) – (13) If the fuse is burned, the circuit probably has a grounding fault.
2
Between terminals B OFF Min. 1 Mz
and ACC ON Max. 1 z
2) Disconnect connector R4.
Between (1) and (2) 86 – 106 z
Defective 2nd travel speed Between (3) and (5) Min. 1 Mz
3
selection relay
2) Insert T-adapter in R4.
2nd travel speed
R4 Voltage
selection switch
Between (5) and
ON 10 – 15 V
ground
cause and 2) Disconnect connector M17.
Defective 2nd travel speed 3) Connect T-adapter to M17 (male).
standard value 4
selection solenoid
in normalcy M17 Between (1) and (2) Resistance 10.5 – 12 z
(male) Between (1) and body Resistance Min. 1 Mz
2) Disconnect T-F3 and connectors F15, R4 and M17.
3) Connect T-adapter to F15, R4 and M17 (female).
Wiring harness between T-F3 and fuse (3) or
Disconnection in wiring Resistance Max. 1 z
between (13) and R4 (female) (3)
5 Wiring harness between R4 (female) (5), F4
(2) and M17 (female) (1)
Wiring harness between F15 (female) (15),
Resistance Max. 1 z
F20 (8) (12) and R4 (female) (1)
Wiring harness between R4 (female) (2), F2
Resistance Max. 1 z
(2) and ground
2) Disconnect T-F3 and connectors F15, R4 and M17.
3) Connect T-adapter to F15, R4 and M17 (female).
Between wiring harness between fuse (13)
Short circuit with chassis and R4 (female) (3) and ground
6 ground in wiring harness Between wiring harness between R4
(Contact with ground circuit) (female) (5), F4 (2) and M17 (female) (1) and Resistance Min. 1 Mz
ground
Between wiring harness between F15
(female) (15), F20 (8) (12) and R4 (female) Resistance Min. 1 Mz
(1) and ground
40-200 36 PC45MR-3, PC55MR-3

E-12 2nd travel speed is not selected SEN04651-00
PC45MR-3, PC55MR-3 40-200 37

SEN04651-00 E-13 Working lamp does not light up
E-13 Working lamp does not light up 1
Failure
• Working lamp does not light up.
information
Relative
information

1 Defective fuse (1) – (11) If the fuse is burned, the circuit probably has a grounding fault.
2) Disconnect connector W2.
3) Connect T-adapter to W2 (female).
2 Defective lamp 4) Turn starting switch ON.
5) Turn lamp switch ON.
Between W2 (female) (A) and ground Voltage 10 – 15 V
2) Disconnect relay F29.
3 Defective lamp switch F29 (female) Light switch operation Resistance
(1) and (2) ON Max. 1 z
Between (1) and (2)
Presumed (3) and (4) OFF Min. 1 Mz
cause and
in normalcy 2) Disconnect connectors F29 and W2.
Disconnection in wiring 3) Connect T-adapter to W2 (female).
4 Wiring harness between fuse (11) and F29
(female) (2)
Wiring harness between F29 (female) (1), F3
Resistance Max. 1 z
(2), W1 (2) and W2 (female) (A)
2) Disconnect connectors F29 and W2.
3) Connect T-adapters to W2 (female).
Short circuit with chassis
Between wiring harness between fuse (11)
5 ground in wiring harness Resistance Min. 1 Mz
and ground
(Contact with ground circuit)
Between wiring harness between F29
(female) (1), F3 (2), W1 (2) and W2 (female) Resistance Min. 1 Mz
(A) and ground
40-200 38 PC45MR-3, PC55MR-3

E-13 Working lamp does not light up SEN04651-00
PC45MR-3, PC55MR-3 40-200 39

E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still
SEN04651-00 moves
E-14 When work equipment lock (PPC basic pressure lock)

lever is set in LOCK, work equipment still moves 1
Failure • When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still
information moves.
Relative
information

Defective fuse (2) – (12), (3) –
1 If fuse is broken, circuit probably has ground fault.
(13)
2) Disconnect cable from negative (–) terminal of battery.
2
(Internal defective contact) Between (T-F1) termi- OFF Min. 1 Mz
nal B – (T-F3) termi-
nal ACC ON Max. 1 z
3 (left) (Internal defective F5 (male) Lock lever position Resistance
contact)
Reset Max. 1 z
Between (1) – (2)
Lock Min. 1 Mz
Presumed (right) (Internal defective
4 F14 (male) Lock lever position Resistance
cause and contact)
standard value a Canopy specification only Reset Max. 1 z
Between (1) – (2)
in normalcy Lock Min. 1 Mz
Between (1) – (2) 86 – 106 z
Defective PPC lock relay Between (3) – (4) Max. 1 z
5 (Internal disconnection,
defective contact or sticking) Between (3) – (5) Min. 1 Mz
2) Insert T-adapter in relay R2.
R2 Lock lever position Voltage
Between (5) – ground Lock 10 – 15 V
Defective PPC lock solenoid 2) Disconnect connector M18.
6 (Internal disconnection or 3) Connect T-adapter to M18 (male).
short circuit) M18 Between (1) – (2) Resistance 10.5 – 12 z
(male) Between (1) – body Resistance Min. 1 Mz
40-200 40 PC45MR-3, PC55MR-3

E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still
moves SEN04651-00

Wiring harness between (T-F3) terminal
Resistance Max. 1 z
ACC – fuse (12) – R2 (female) (3)
Disconnection in wiring Wiring harness between R2 (female) (5) –
Resistance Max. 1 z
harness (Disconnection in F4 (4) – M18 (female) (1)
7
wiring or defective contact in Wiring harness between (T-F3) terminal
connector) ACC – fuse (13) – F5 (2) or between (1) –
F14 (2) or between (1) – R2 (female) (1) Resistance Max. 1 z
a F14 is installed to only canopy specifica-
Presumed tion.
cause and
Wiring harness between R2 (female) (2) –
standard value Resistance Max. 1 z
in normalcy F2 (2) – ground
Between wiring harness fuse (12) – R2
Ground fault in wiring harness
8 (Contact with GND or GND Between wiring harness R2 (female) (5) – F4
circuit) (4) – M18 (female) (1) and ground
Between wiring harness fuse (13) – F5 (2) or
(1) – F14 (2) or (1) – R2 (female) (1) and
ground Resistance Min. 1 Mz
a F14 is installed to only canopy specifica-
tion.
PC45MR-3, PC55MR-3 40-200 41

SEN04651-00 E-15 Windshield wiper does not operate
E-15 Windshield wiper does not operate 1
Failure
• Windshield wiper does not operate.
information
Relative
• The engine can start. (If the engine cannot start, carry out troubleshooting E-1 first.)
information

1 Defective fuse (6) – (16) If the fuse is broken, the circuit probably has a grounding fault.
2) Disconnect connector wiper switch terminal.
Wiper switch Position Resistance
Between terminals (1)
OFF (Do not move) Max. 1 z
and (2)
Defective wiper switch Between terminals (2)
ON (1st position) Max. 1 z
2 (Internal disconnection or and (3)
defective contact) Between terminals (2)
WASH (2nd position) Max. 1 z
and (3)
Wiper switch Position Voltage
Presumed Between terminal (2)
ON (1st position) 10 – 15 V
cause and and ground
in normalcy 2) Disconnect wiper switch terminal.
Disconnection in wiring Wiring harness between fuse (16), F24 (1),
Resistance Max. 1 z
harness (Disconnection in F7 (4) and wiper switch terminal (3)
3
wiring harness or defective Wiring harness between wiper switch
terminal (2) and wiper motor (+) side
Wiring harness between wiper motor (–)
Resistance Max. 1 z
side, F7 (1), F24 (2), F2 (2) and ground
2) Disconnect wiper switch terminal.
Between wiring harness between fuse (16),
F24 (1), F7 (4) and wiper switch terminal (3) Resistance Min. 1 Mz
and ground
(Contact with ground circuit)
Between wiring harness between wiper
switch terminal (2) and wiper motor (+) side Resistance Min. 1 Mz
and ground
40-200 42 PC45MR-3, PC55MR-3

E-15 Windshield wiper does not operate SEN04651-00
PC45MR-3, PC55MR-3 40-200 43

SEN04651-00 E-16 Windshield washer does not operate
E-16 Windshield washer does not operate 1
Failure
• Windshield washer does not operate.
information
• Before starting troubleshooting, check the liquid level in the tank.
Relative
• The windshield wiper operates. (If the windshield wiper does not operate, carry out troubleshooting
information
E-15 first.)

Between M2 (female) (1) and ground Resistance Min. 1 Mz
Defective washer motor
1 1) Turn starting switch OFF.
2) Connect T-adapter to M2 (female).
Between M2 (female) (2) and ground Voltage 10 – 15 V
2) Disconnect wiper switch terminal.
Wiper switch Position Resistance
Between terminals (3)
Defective wiper switch WASH (2nd position) Max. 1 z
2 and (4)
Presumed 1) Turn starting switch from OFF to ON for troubleshooting.
cause and Wiper switch Position Voltage
standard value Between terminal (4)
in normalcy WASH (2nd position) 10 – 15 V
and ground
2) Disconnect connector M2 and switch terminal.
Disconnection in wiring 3) Connect T-adapter to M2 (female).
harness (Disconnection in Wiring harness between M2 (female) (2), F3
3
wiring harness or defective (4), F24 (3), F7 (3) and wiper switch terminal Resistance Max. 1 z
contact in connector) (4)
Resistance Max. 1 z
ground
2) Disconnect connector M2 and switch terminal
Short circuit with chassis 3) Connect T-adapter to M2 (female).
(Contact with ground circuit) Between wiring harness between M2
(female) (2), F3 (4), F24 (3), F7 (3) and wiper Resistance Min. 1 Mz
switch terminal (4) and ground
40-200 44 PC45MR-3, PC55MR-3

E-16 Windshield washer does not operate SEN04651-00
PC45MR-3, PC55MR-3 40-200 45

SEN04651-00 E-17 Defective air conditioner
E-17 Defective air conditioner 1
1) Air conditioner does not operate

Failure
• Air conditioner does not operate.
information
• Check in advance that the fuse is normal and the continuity of the wiring harnesses between the con-
nectors is normal.
Relative • When the blower switch is turned ON (in the 1, 2, or 3 position), the air conditioner switch is turned
information ON.
• If air does not blow out, carry out troubleshooting for “2) Air does not blow out or air flow rate does not
change” first.

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch.
Defective air conditioner Air conditioner switch
1 Operation of switch Resistance
switch connector
ON Max. 1 z
C–D
OFF Min. 1 Mz
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning starting switch.
2
wiring harness or defective Referring to the circuit diagram, check the
Presumed contact in connector) Resistance Max. 1 z
cause and continuity between connectors.
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normalcy without turning starting switch.
3 ground in wiring harness Referring to the circuit diagram, check the
(Contact with ground circuit) insulation between each connector and
chassis ground. (Do not check the ground
circuit.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective control amplifier Condition becomes Control amplifier is
Replace control normal. defective.
amplifier with normal
one. Condition does not Control amplifier is
become normal. normal.
40-200 46 PC45MR-3, PC55MR-3

E-17 Defective air conditioner SEN04651-00
2) Air does not blow out or air flow rate does not change
Failure
• Air does not blow out or air flow rate does not change.
information
Relative • Check in advance that the fuse is normal and the continuity of the wiring harnesses between the con-
information nectors is normal.

Position
Blower switch terminal Resistance
of knob
0 Between all terminals Min. 1 Mz
Between B and L/R, between B and L/W,
Max. 1 z
1 and between L/R and L/W
1 Defective blower switch
Between terminals other than above Min. 1 Mz
Between B and L/R, between B and L/Y, and
Max. 1 z
2 between L/R and L/Y
Between B and L/R, between B and L/B, and
Max. 1 z
3 between L/R and L/B
Resistor terminals Resistance
2 Defective resistor
Between L and M1 Approx. 1.8 z
Presumed Between M1 and M2 Approx. 0.7 z
cause and Between M2 and M0 Approx. 0.3 z
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normalcy
3 Defective blower motor Condition becomes Blower motor is
Replace blower motor normal. defective.
with normal one. Condition does not Blower motor is
4
continuity between connectors.
circuit.)
PC45MR-3, PC55MR-3 40-200 47

3) Blowing air temperature cannot be adjusted

Failure
• Blowing air temperature cannot be adjusted.
information
• Check in advance that hot water is supplied to the inlet side of the water valve.
Relative
information
nectors is normal.

a Turn blower switch ON (Set it to the 1, 2, or 3 position) and carry
out troubleshooting.
Temperature regulator switch connector (2) Voltage
Changes between 0
G/B – G/W
and approx. 5 V.
Changes between 0
G/B – Y/B
and approx. 5 V.
G/B – Y/W Approx. 5 V
Defective temperature a Prepare with starting switch OFF, then carry out troubleshooting
1 without turning starting switch.
regulator switch
Temperature regula-
tor switch connector Operation of knob Resistance
(2) (Switch side)
COOL-MAX o Approx. 2.3 kz o
Middle position Max. 1 z
Y/W – Y/B
Middle position o
Max. 1 z
HOT-MAX
COOL-MAX o
Approx. 2.3 kz
Middle position
Y/W – G/W
Middle position o Approx. 2.3 kz o
HOT-MAX Max. 1 z
Presumed a Prepare with starting switch OFF, then turn starting switch ON
cause and and carry out troubleshooting.
standard value a Turn blower switch ON (Set it to the 1, 2, or 3 position) and carry
in normalcy out troubleshooting.
Rod operates according to operation of temperature
Operation
Defective water valve regulator switch.
2
assembly a Prepare with starting switch OFF, then turn starting switch ON
Condition becomes Water valve assembly
Replace water valve normal. is defective.
assembly with normal
one. Condition does not Water valve assembly
become normal. is normal.
3
circuit.)
40-200 48 PC45MR-3, PC55MR-3

4) Blowing air is not cooled or temperature cannot be adjusted (Electrical system)

Failure
• Blowing air is not cooled or temperature cannot be adjusted (Electrical system).
information
• When the ambient temperature is below 2°C, this phenomenon is not a trouble.
Relative
information
nectors is normal.

1 Defective compressor clutch and carry out troubleshooting.
Between (12) and chassis ground Voltage 10 – 15 V
Defective dual pressure without turning starting switch.
2
switch
Dual pressure switch connector Resistance Max. 1 z
Defective air conditioner Air conditioner switch
3 Operation of switch Resistance
switch connector
ON Max. 1 z
C–D
OFF Min. 1 Mz
Compressor relay connector Resistance
(1) – (2) Approx. 320 z
4 Defective compressor relay
Compressor relay Source voltage
Resistance
connector between (1) and (2)
Presumed When applied Max. 1 z
(3) – (4)
cause and When not applied Min. 1 Mz
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normalcy
Inspection
5 Defective thermistor Thermistor connector Resistance
temperature
0°C Approx. 7.2 z
B/W – B/R
25°C Approx. 2.2 z
6
circuit.)
PC45MR-3, PC55MR-3 40-200 49

40-200 50 PC45MR-3, PC55MR-3

5) Defective cooling (Mechanical system)

Failure
• Defective cooling (Mechanical system)
information
Relative
—
information

Gas leakage from pipe joint or
1 Check. If abnormality is detected, repair or replace.
piping part
Natural leakage from hoses,
Check quantity of refrigerant. If insufficient, add proper amount of
2 etc. (Refrigerant has not been
refrigerant.
added for long period)
Insufficient charge with
3 Charge with refrigerant to proper level.
refrigerant
Check. If abnormality is detected, repair or replace.
4 Defective expansion valve a Check that the valve is not opened too wide. Check thermometer
tube for defective contact.
Clogging of low-pressure
5 Check. If any part is clogged, repair or replace.
circuit or evaporator
Presumed 6 Clogging of evaporator fins Check. If evaporator fins are clogged, clean them.
cause and 7 Clogging of filter Check, then clean or replace.
standard value
in normalcy Defective installation of
thermistor
Air leakage from air
9 Check. If leakage is detected, repair or replace.
conditioner unit or duct joint
10 Insufficient set air flow Increase the set air flow.
Check quantity of refrigerant. If it is too much, reduce it to proper
11 Overcharging with refrigerant
level.
Evacuate the system, then charge it with proper quantity of
12 Air in system
refrigerant and replace receiver drier.
13 Clogging of condenser fins Check. If condenser fins are clogged, clean them.
Defective compression by
compressor
Evacuate the system, then charge it with proper quantity of
15 Water in refrigerant circuit
refrigerant and replace receiver drier.
PC45MR-3, PC55MR-3 40-200 51

6) Defective heating (Defective hot-water circuit)

Failure
• Defective heating (Defective hot-water circuit)
information
Relative • Check that water is not leaking from the hot-water circuit.
information • Check that air is blowing out of the air outlet.

Check. If heater core fins are clogged, clean them.
1 Clogging of heater core fins a If this item is the cause, both temperatures at the heater core hot-
water inlet and outlet are high.
Check. If leakage is detected, repair or replace.
Air leakage from air a If this item is the cause, both temperatures at the heater core hot-
2
conditioner unit
water inlet and outlet are high.
Presumed Check. If clogging or defect is detected, repair or replace.
cause and Defective water control valve a If this item is the cause, the temperatures at the heater core hot-
standard value 3
(Clogging or defect in valve) water inlet is high and that at the heater core hot-water outlet is
in normalcy low.
Check. If clogging is detected, repair or replace.
a If this item is the cause, the temperatures at the heater core hot-
4 Clogging in heater core
water inlet is high and that at the heater core hot-water outlet is
low.
Check. If clogging is detected, repair or replace.
Clogging up to heater core a If this item is the cause, the temperatures at the heater core hot-
5
hot-water inlet
water inlet is low.
7) Abnormal sound comes out

Failure
• Abnormal sound comes out.
information
Relative
—
information

Defective installation of case
1 Check. If abnormality is detected, repair.
bolts (screws)
Interference of fan case or
breakage of fan
Foreign matter in blower
Presumed Check. If abnormality is detected, remove foreign matter and repair
3 motor or defective blower
cause and or replace.
motor
standard value
in normalcy Check. If abnormal sound (blowing or leaking sound) comes out,
4 Defective expansion valve
replace valve.
Looseness or wear of
5 Check. If looseness or wear is detected, repair or replace.
compressor V-belt
Improper quantity of
6 Check quantity of refrigerant, then adjust it properly, if necessary.
refrigerant
7 Defective compressor Check. If abnormality is detected, repair or replace.
40-200 52 PC45MR-3, PC55MR-3

8) Water leaks
Failure
• Water leaks.
information
Relative
—
information

Clogging of water drain
1 Check. If abnormality is detected, repair.
opening in air conditioner unit
Clogging, bend, defective
2 installation, or hole of drain Check. If abnormality is detected, repair or replace.
hose of air conditioner unit
Presumed Breakage (Cracking) of air
cause and 3 Check. If breakage (cracking) is detected, repair or replace.
conditioner unit case
standard value
in normalcy Defective mounting bolt
4 (screw) of air conditioner unit Check. If abnormality is detected, repair or replace.
case
Defective joint of hot-water
circuit piping
6 Defective heater core Check. If abnormality is detected, repair or replace.
7 Defective water valve Check. If abnormality is detected, repair or replace.
9) External and internal air cannot be changed

Failure
• External and internal air cannot be changed.
information
Relative
—
information

Malfunction of EXTERNAL/
Presumed 1 INTERNAL air changeover Check. If abnormality is detected, clean, repair, or replace.
cause and lever
standard value
in normalcy 2 Malfunction of intake damper Check. If abnormality is detected, clean, repair, or replace.
Clogging of external air intake
3 Check. If abnormality is detected, clean.
duct of unit
PC45MR-3, PC55MR-3 40-200 53

SEN04651-00 E-18 KOMTRAX system does not operate normally
E-18 KOMTRAX system does not operate normally 1
Failure
• KOMTRAX system does not operate normally.
information
• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
carry out following troubleshooting.
• Even if KOMTRAX system has trouble, that trouble does not particularly appear on machine.
• For details of display, see Testing and adjusting, "Lamp display of KOMTRAX terminal".
Relative
• Quick and slow blinking periods are as follows.
information
Quick blinking: Blinking at periods of about 1 second (Lamp is turned ON and OFF repeatedly at peri-
ods of 0.5 seconds)
Slow blinking: Blinking at periods of about 4 seconds (Lamp is turned ON and OFF repeatedly at peri-
ods of 2 seconds)

a Carry out troubleshooting with starting switch ON.
F32 Signal Voltage
1 Defective power supply
Between (6), (7) – Unswitched power
10 – 15 V
(1), (2) supply
a Turn starting switch ON, start engine, and carry out troubleshoot-
ing.
Display section of KOMTRAX
Normal condition
terminal
Defective starting switch ACC LED-1 (Green) ON
2 signal or defective alternator R
a Prepare with starting switch OFF, then start engine and carry out
signal
troubleshooting.
F32 Signal Voltage
Between (3) – (1), (2) Starting switch ACC 10 – 15 V
Between (4) – (1), (2) Alternator R 10 – 15 V
a Carry out troubleshooting with starting switch at START position.
Normal condition
terminal
Defective starting switch C
3 LED-3 (Yellow) Quick blinking
signal
Presumed F32 Signal Voltage
cause and Between (11) –
standard value Starting switch C 10 – 15 V
(1), (2)
in normalcy
Normal condition
terminal
LED-4 (Green) ON
Defective CAN
4
communication signal a Prepare with starting switch OFF, then turn starting switch ON
F30 Signal Voltage
Between (12) – CAN communication
0–5V
(1), (2) signal
Defective communication Display section of KOMTRAX
5 Normal condition
environment terminal
7-segment (Red) [0 – 9] are displayed
Normal condition
terminal
Defective measurement with
6 Dot (Red) ON
GPS
a Even in outdoor place where radio waves are strong enough, it
may take more than 1 minute to complete measurement after
starting switch is turned ON.
40-200 54 PC45MR-3, PC55MR-3

E-18 KOMTRAX system does not operate normally SEN04651-00
Display section KOMTRAX connector section
LED display section

1. LED-1 [Green]: R signal, ACC signal condition
2. LED-2 [Red]: Starting output condition
3. LED-3 [Yellow]: S-NET, C signal condition
4. LED-4 [Green]: Fuel sensor, CAN connection
condition
5. LED-5 [Red]: Download write condition
7-segment, dot display

6. 7-segment [Red]: Sign-up test, operation con-
dition
7. Dot [Red]: GPS measuring condition, test con-
nector insertion/disconnection condition
PC45MR-3, PC55MR-3 40-200 55

SEN04651-00

©2008 KOMATSU
All Rights Reserved
40-200 56
SEN04652-00
PC45MR-3,
PC55MR-3

300 Troubleshooting of hydraulic and

mechanical system (H-mode)
Information contained in troubleshooting table ............................................................................................... 3
H-1 Speed or power of whole work equipment, travel, swing, and blade is low ............................................. 4
H-2 Engine speed lowers extremely or engine stalls ...................................................................................... 8
H-3 Whole work equipment, travel system, swing system, and blade do not work ........................................ 9
H-4 Abnormal sound comes out from around hydraulic pump...................................................................... 13
H-5 Fine control performance or response is low ......................................................................................... 13
H-6 Speed or power of boom is low .............................................................................................................. 14
H-7 Speed or power of arm is low................................................................................................................. 15
H-8 Speed or power of bucket is low ............................................................................................................ 16
H-9 Speed or power of boom swing is low.................................................................................................... 17
H-10 Work equipment does not move singly ................................................................................................ 17
H-11 Work equipment hydraulic drift is large ................................................................................................ 18
H-12 Time lag of work equipment is large..................................................................................................... 20
H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 20
H-14 Machine deviates during travel ............................................................................................................ 21
H-15 Travel speed or travel power is low (while work equipment is normal) ................................................ 23
H-16 Machine is not steered well or steering power is low ........................................................................... 24
H-17 Travel speed does not change ............................................................................................................. 25
H-18 Travel motor does not work.................................................................................................................. 26
H-19 Speed or power of swing is low............................................................................................................ 28
H-20 Machine does not swing....................................................................................................................... 30
PC45MR-3, PC55MR-3 40-300 1

300 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04652-00
H-21 Swing acceleration performance is low ................................................................................................ 32

H-22 Machine overruns when it stops swinging............................................................................................ 34
H-23 Large shock is made when machine stops swinging ........................................................................... 35
H-24 When upper structure stops swinging, it makes large sound ............................................................... 35
H-25 Hydraulic drift of swing is large............................................................................................................. 36
H-26 Speed or power of blade is low ............................................................................................................ 37
H-27 Blade does not move............................................................................................................................ 38
H-28 Hydraulic drift of blade is large ............................................................................................................. 39
40-300 2 PC45MR-3, PC55MR-3

Information contained in troubleshooting table 1
a Troubleshooting table collectively carry the following information. Carry out troubleshooting work after
fully grasping their contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
2
Presumed Cause for presumed
cause and failure <Contents>
standard value (The attached No. for filing • The standard values in normalcy by which to judge “good” or “no
3
in normalcy and reference purpose good” about presumed causes.
only. It does not stand for • References for making judgement of “good” or “no good”
any priority)
4
PC45MR-3, PC55MR-3 40-300 3

SEN04652-00 H-1 Speed or power of whole work equipment, travel, swing, and blade is low
H-1 Speed or power of whole work equipment, travel, swing, and blade
is low 1
a Check the combination of the systems which are low in speed or power according to the following table,
then go to the specified troubleshooting item.
Q: Normal
×: Low in speed or power
Whole Trouble-
work Travel Swing Blade shooting
equipment item
× × × × Go to 1)
× × Q Q Go to 2)
Q Q × × Go to 3)
× Q Q × Go to 4)
Q × Q × Go to 5)
× Q Q Q Go to 6)
1) Speed or power of whole work equipment, travel, swing, and blade is low
Failure
• Speed or power of whole work equipment, travel, swing, and blade is low
information
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
information • Before starting troubleshooting, check that the electric system (solenoid circuit) is normal.
• If a phenomenon disappears as the engine speed is increased, it is not a fault.

a Prepare with engine stopped, then run engine at full throttle and
carry out troubleshooting.
Position of work equipment lock
Malfunction of PPC basic Solenoid valve output pressure
1 lever
pressure lock solenoid valve
LOCK 0 MPa {0 kg/cm2}
FREE 2.94 +– 0.1
0.49
MPa {30 +– 15 kg/cm2}
Presumed a Prepare with engine stopped, then run engine at full throttle and
cause and carry out troubleshooting.
standard value
in normalcy Control levers Control circuit relief pressure
Defective adjustment or
2 malfunction of control circuit Set all levers in
4.90 ++ 0.59 +6 2
0.1 MPa {50 + 1 kg/cm }
relief valve neutral
If the oil pressure does not become normal after adjustment, the
control relief valve may have a malfunction or a defect in it. Check it
directly.
If the results of 1 and 2 are normal, the strainer may be clogged.
3 Clogging of suction strainer
Check it directly.
If the results of 1, 2, and 3 are normal, the control pump may be
4 Defective control pump
defective.
40-300 4 PC45MR-3, PC55MR-3

H-1 Speed or power of whole work equipment, travel, swing, and blade is low SEN04652-00
2) Speed or power of whole work equipment and travel is low

Failure
• Speed or power of whole work equipment and travel is low.
information
Relative
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
information

Control levers Main relief pressure
• Move arm IN to relieve its cir-
1 malfunction of main relief cuit. 26.5 ± 0.98 MPa
valve • Drive machine to relieve travel {270 ± 10 kg/cm2}
circuit.
main relief valve may have a malfunction or a defect in it. Check it
directly.
Malfunction of unload valve
2 a PC35MR-3 has 2 sets of Control levers Unload pressure
this valve. Set all levers in 3.2 + 0.98
0 MPa
neutral {33 + 10
0 kg/cm 2}
standard value
Differential pressure
in normalcy
Oil pressure to be Curl bucket with no
measured Set all levers in
load (Move lever to
neutral stroke end)
Defective adjustment or Difference pressure
3
malfunction of LS valve between pump dis- 3.2 + 00.98 MPa 1.57 ± 0.1 MPa
charge pressure and + 10 2
LS valve input pres- {33 0 kg/cm } {16 ± 1 kg/cm2}
sure
If the oil pressure ratio does not become normal after adjustment,
the LS valve may have a malfunction or a defect in it. Check it
directly.
Referring to Testing and adjusting, “Adjusting PC valve”, adjust the
Defective adjustment or PC valve. If the oil pressure does not become normal after
4
malfunction of PC valve adjustment, the PC valve may have a malfunction or a defect in it.
Check it directly.
5 Malfunction of servo piston The servo piston may have a malfunction. Check it direction.
If any problem is not detected by the above checks, the cause may
6 Defective piston pump be lowering of performance, malfunction, or internal defect of the
piston pump.
PC45MR-3, PC55MR-3 40-300 5

SEN04652-00 H-1 Speed or power of whole work equipment, travel, swing, and blade is low
3) Speed or power of swing and blade is low

Failure
• Speed or power of swing and blade is low.
information
Relative
information

Control lever Main relief pressure
Presumed 21.6 +– 0.49
0.98
MPa
1 malfunction of gear pump Relieve blade lower circuit
cause and + 10
{220 – 5 kg/cm2}
relief valve
standard value
in normalcy If the oil pressure does not become normal after adjustment, the
gear pump relief valve may have a malfunction or a defect in it.
Check it directly.
If the condition does not become normal after the relief valve is
2 Defective gear pump adjusted or replaced, the performance of the gear pump may be
lowered.
4) Speed or power of whole work equipment and blade is low

Failure
• Speed or power of whole work equipment and blade is low.
information
Relative
information

Main pump pressure and
Control lever
gear pump relief pressure
• Work equipment control lever

(Both directions) 26.5 ± 0.98 MPa
Presumed • Swing control lever (Right {270 ± 10 kg/cm2}
cause and swing)
standard value Defective centralized safety
1
in normalcy valves
• Blade control lever 21.6 +– 0.49
0.98
MPa
+ 10
(Lower) {220 – 5 kg/cm2}
If the oil pressure is lower through all of the above measurements,

the centralized safety valves may be defective. Check them
directly.
a The centralized safety valves act on both sides of the boom, arm,
and bucket, on the head side of the boom swing, and on the bot-
tom side of the blade.
40-300 6 PC45MR-3, PC55MR-3

H-1 Speed or power of whole work equipment, travel, swing, and blade is low SEN04652-00
5) Speed or power of travel and blade is low

Failure
• Speed or power of travel and blade is low.
information
Relative
information

1) Stop engine.
2) Plug control valve side of hydraulic hose to travel or blade
system.
3) Run engine at full throttle.
Presumed Main pump pressure and
Control lever
cause and gear pump relief pressure
standard value 1 Defective center swivel joint Travel lever (Side from which 26.5 ± 0.98 MPa
in normalcy hose is disconnected) {270 ± 10 kg/cm2}
Blade control lever
21.6 +– 0.49
0.98
MPa
(Side from which hose is
{220 +– 510 kg/cm2}
disconnected)
If the oil pressure becomes normal during the above measurement,
the center swivel joint may be defective. Check it directly.
6) Speed or power of whole work equipment is low

Failure
• Speed or power of whole work equipment is low.
information
Relative
information

Presumed Right and left control levers and
cause and Defective seal of check valve PPC valve output pressure
boom swing control lever
standard value 1 for receiving logic valve
in normalcy control circuit pressure Set in neutral 0 MPa {0 kg/cm2}
• Operate boom, arm, and
2.94 +– 0.1
0.49
MPa
bucket in both directions. + 5
{30 – 1 kg/cm2}
• Swing boom to right.
PC45MR-3, PC55MR-3 40-300 7

SEN04652-00 H-2 Engine speed lowers extremely or engine stalls
H-2 Engine speed lowers extremely or engine stalls 1
Failure
• Engine speed lowers extremely or engine stalls.
information
Relative
information

1 malfunction of main relief Relieve arm circuit by moving 26.5 ± 0.98 MPa
valve pressure arm IN {270 ± 10 kg/cm2}
directly.
load (Move lever to
neutral stroke end)
Defective adjustment or Difference pressure
2 between pump
malfunction of LS valve 3.2 + 0.98
0 MPa 1.57 ± 0.1 MPa
discharge pressure + 10 2}
and LS valve input {33 0 kg/cm {16 ± 1 kg/cm2}
pressure
Presumed If the oil pressure does not become normal after adjustment, the LS
cause and valve may have a malfunction or a defect in it. Check it directly.
standard value Referring to Testing and adjusting, “Adjusting PC valve”, adjust the
in normalcy Defective adjustment or PC valve. If the oil pressure does not become normal after
3
malfunction of PC valve adjustment, the PC valve may have a malfunction or a defect in it.
Check it directly.
Clogging of orifice or filter in The orifice or filter in the servo mechanism may be clogged. Check
4
servo mechanism them directly.
5 Malfunction of servo piston The servo piston may have a malfunction. Check it directly.
Blade control lever Gear pump relief pressure
6 malfunction of gear pump 21.6 +– 0.49
0.98
MPa
Relieve blade lower circuit + 10
relief valve {220 – 5 kg/cm2}
relief valve may have a malfunction or a defect in it. Check it
directly.
If any problem is not detected by checks 1 – 6 above, the cause
may be lowering of the engine output. Carry out troubleshooting “S-
7 Lowering of engine output
6 Engine lacks output (or lacks power)” in Troubleshooting of engine
(S-mode).
40-300 8 PC45MR-3, PC55MR-3

H-3 Whole work equipment, travel system, swing system, and blade do not work SEN04652-00
H-3 Whole work equipment, travel system, swing system, and blade do
not work 1
a Check the systems which do not work according to the following table, then go to the specified trouble-
shooting item.
Q: Normal
×: Does not work
Whole Trouble-
work Travel Swing Blade shooting
equipment item
× × × × Go to 1)
× × Q Q Go to 2)
Q Q × × Go to 3)
× Q Q × Go to 4)
Q × Q × Go to 5)
× Q Q Q Go to 6)
1) Whole work equipment, travel system, swing system, and blade do not work
Failure
• Whole work equipment, travel system, swing system, and blade do not work.
information
Relative
information
• Before starting troubleshooting, check that the electric system (solenoid circuit) is normal.

Position of work equipment lock
Malfunction of PPC basic Solenoid valve output pressure
1 lever
pressure lock solenoid valve
LOCK 0 MPa {0 kg/cm2}
FREE 2.94 +– 0.1
0.49
MPa {30 +– 15 kg/cm2}
Presumed
cause and Defective adjustment or Control levers Control circuit relief pressure
standard value malfunction of control circuit Set all levers in
2 4.90 ++ 0.59 +6 2
in normalcy relief valve neutral 0.1 MPa {50 + 1 kg/cm }
(PC35MR-3)
control relief valve may have a malfunction or a defect in it. Check it
directly.
If the results of 1 and 2 are normal, the strainer may be clogged.
3 Clogging of suction strainer
Check it directly.
If the results of 1, 2, and 3 are normal, the control pump may be
4 Defective control pump
defective.
Disconnect the discharge hose from the main pump, crank the
Defective piston pump drive
5 engine with the starting motor, and check that oil flows out of the
shaft or damper
discharge port.
PC45MR-3, PC55MR-3 40-300 9

SEN04652-00 H-3 Whole work equipment, travel system, swing system, and blade do not work
2) Whole work equipment and travel system do not work

Failure
• Whole work equipment and travel system do not work.
information
Relative • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.

• Move arm IN to relieve its cir-
Presumed Defective adjustment or
cause and 1 malfunction of main relief cuit. 26.5 ± 0.98 MPa
standard value valve • Drive machine to relieve travel {270 ± 10 kg/cm2}
in normalcy circuit.
directly.
Disconnect pump discharge hose and crank the engine with the
2 Defective piston pump
starting motor and see if oil flows out of the discharge port.
3) Swing and blade systems do not work

Failure
• Swing and blade systems do not work.
information

Control lever Main pump pressure
Presumed Defective adjustment or
cause and 1 malfunction of gear pump Relieve blade circuit by lowering 21.6 +– 0.49
0.98
MPa
standard value relief valve blade + 10
{220 – 5 kg/cm2}
in normalcy
gear pump relief valve may have a malfunction or a defect in it.
Check it directly.
Defective gear pump drive Disconnect gear pump discharge hose and crank the engine with
2
shaft or coupling the starting motor and see if oil flows out of the discharge port.
40-300 10 PC45MR-3, PC55MR-3

H-3 Whole work equipment, travel system, swing system, and blade do not work SEN04652-00
4) Whole work equipment and blade do not work

Failure
• Whole work equipment and blade do not work.
information

Main pump pressure and
Control lever
gear pump relief pressure
• Work equipment control lever
(Both directions) 26.5 ± 0.98 MPa
Presumed • Boom swing control lever {270 ± 10 kg/cm2}
cause and (Swing to right)
standard value Defective centralized safety
1
in normalcy valves 21.6 +– 0.49
0.98
MPa
• Blade control lever (Lower) + 10
{220 – 5 kg/cm2}
If the oil pressure is lower through all of the above measurements,

the centralized safety valves may be defective. Check them
directly.
a The centralized safety valves act on both sides of the boom, arm,
and bucket, on the head side of the boom swing, and on the bot-
tom side of the blade.
5) Travel system and blade system do not work

Failure
• Travel system and blade system do not work.
information

1) Stop engine.
2) Plug control valve side of hydraulic hose to travel or blade
system.
3) Run engine at full throttle.
Presumed Main pump pressure and
Control lever
cause and gear pump relief pressure
standard value 1 Defective center swivel joint Travel lever (on the side where 26.5 +– 0.49
0.98
MPa
in normalcy hose is disconnected) {270 +– 510 kg/cm2}
Blade lever (on the side where 21.6 +– 0.49

0.98
MPa
hose is disconnected) + 10
{220 – 5 kg/cm2}
If the oil pressure becomes normal during the above measurement,
the center swivel joint may be defective. Check it directly.
PC45MR-3, PC55MR-3 40-300 11

SEN04652-00 H-3 Whole work equipment, travel system, swing system, and blade do not work
6) Whole work equipment does not work

Failure
• Whole work equipment does not work.
information

Presumed Right and left control levers and
cause and Defective seal of check valve PPC valve output pressure
boom swing control pedal
standard value 1 for receiving logic valve
in normalcy control circuit pressure Set in neutral 0 MPa {0 kg/cm2}
• Operate boom, arm, and
2.94 +– 0.1
0.49
MPa
bucket in both directions. + 5
{30 – 1 kg/cm2}
• Swing boom to right.
40-300 12 PC45MR-3, PC55MR-3

H-4 Abnormal sound comes out from around hydraulic pump SEN04652-00
H-4 Abnormal sound comes out from around hydraulic pump 1
Failure
• Abnormal sound comes out from around hydraulic pump.
information
Relative
information

1 Lowering of hydraulic oil level Check directly.
2 Trouble of hydraulic oil Hydraulic oil may contain air. Check it directly.
Presumed The hydraulic tank cap may be clogged and negative pressure may
3 Clogging of hydraulic tank cap
cause and be applied to the hydraulic tank. Check the cap directly.
standard value Clogging of hydraulic tank The hydraulic tank strainer may be clogged and negative pressure
in normalcy 4
strainer may be applied to the suction circuit. Check the strainer directly.
5 Defective main pump The main pump may have a defect in it. Check it directly.
a If the results of 1 – 5 above are normal, operate the machine for a while and see if the condition
changes.
H-5 Fine control performance or response is low 1
Failure
• Fine control performance or response is low.
information
Relative
information

1 Clogging of LS circuit orifice The LS circuit orifice may be clogged. Check it directly.
load (Move lever to
neutral stroke end)
2 Difference pressure
malfunction of LS valve
between pump 3.2 + 0.98 MPa 1.57 ± 0.1 MPa
0
discharge pressure + 10 2
Presumed and LS valve input {33 0 kg/cm } {16 ± 1 kg/cm2}
cause and pressure
standard value If the oil pressure ratio does not become normal after adjustment,
in normalcy the LS valve may have a malfunction or a defect in it. Check it
directly.
3 Malfunction of servo piston The servo piston may have a malfunction. Check it directly.
Malfunction of unload valve Control levers Unload pressure
4 a PC35MR-3 has 2 sets of
this valve. 3.2 + 0.98
0 MPa
Set all levers in neutral
{33 + 10
0 kg/cm2}
Clogging of piston pump If the results of 1 – 4 above are normal, the piston pump orifice plug
5
orifice plug may be clogged. Check it directly.
PC45MR-3, PC55MR-3 40-300 13

SEN04652-00 H-6 Speed or power of boom is low
H-6 Speed or power of boom is low 1
Failure
• Speed or power of boom is low.
information

Right work equipment control
PPC valve output pressure
Malfunction of right PPC valve lever
1
(boom circuit) Set in neutral 0 MPa {0 kg/cm2}
Operate to raise boom 2.94 +– 0.1

0.49
MPa
Operate to lower boom +5
{30 – 1 kg/cm2}
Malfunction of boom control The boom control valve spool may have a malfunction. Check it
2
valve (spool) directly.
Presumed Malfunction of boom control
cause and The pressure compensation valve of the boom control valve may be
3 valve (pressure compensation
standard value malfunction. Check it directly.
valve)
in normalcy
Malfunction of boom control The lock valve of the boom control valve may be malfunction.
4
valve (lock valve) Check it directly.
Malfunction or defective seal
The suction valve (bottom side) of the boom control valve may have
5 of boom control valve (suction
a malfunction or defective seal. Check it directly.
valve)
The centralized safety-suction valves of the control valve may have
6 of centralized safety-suction
a malfunction or defective seal. Check them directly.
valves
7 Defective boom cylinder
Boom cylinder Leakage from cylinder
Relieve by raising boom 10 cc/min
40-300 14 PC45MR-3, PC55MR-3

H-7 Speed or power of arm is low SEN04652-00
H-7 Speed or power of arm is low 1
Failure
• Speed or power of arm is low.
information

Left work equipment control lever PPC valve output pressure
Malfunction of left PPC valve
1 Set in neutral 0 MPa {0 kg/cm2}
(arm circuit)
Operated to move arm IN 2.94 +– 0.1
0.49
MPa
Operated to move arm OUT + 5
{30 – 1 kg/cm2}
Malfunction of arm control The arm control valve spool may have a malfunction. Check it
2
Presumed
cause and Malfunction of arm control
The pressure compensation valve of the arm control valve may be
standard value 3 valve (pressure compensation
malfunction. Check it directly.
in normalcy valve)
Since the suction valves of the arm control valve (on the bottom side
4 of arm control valve (suction
and head side) may have a malfunction, check them directly.
valve)
valves
6 Defective arm cylinder
Arm cylinder Leakage from cylinder
Relieved in arm-IN operation 10 cc/min
PC45MR-3, PC55MR-3 40-300 15

SEN04652-00 H-8 Speed or power of bucket is low
H-8 Speed or power of bucket is low 1
Failure
• Speed or power of bucket is low.
information

Right work equipment control
PPC valve output pressure
Malfunction of right PPC valve lever
1
(bucket circuit) Set in neutral 0 MPa {0 kg/cm2}
Operated to move CURL bucket 2.94 +– 0.1

0.49
MPa
Operated to move bucket DUMP +5
{30 – 1 kg/cm2}
Malfunction of bucket control The bucket control valve spool may have a malfunction. Check it
2
Presumed
cause and Malfunction of bucket control
The pressure compensation valve of the bucket control valve may
standard value 3 valve (pressure compensation
be malfunction. Check it directly.
in normalcy valve)
Since the suction valves of the bucket control valve (on the bottom
4 of bucket control valve
side and head side) may have a malfunction, check them directly.
(suction valve)
valves
6 Defective bucket cylinder Bucket cylinder Leakage from cylinder
Relieved in bucket-CURL
10 cc/min
operation
40-300 16 PC45MR-3, PC55MR-3

H-9 Speed or power of boom swing is low SEN04652-00
H-9 Speed or power of boom swing is low 1
Failure
• Speed or power of boom swing is low.
information

Boom swing control pedal PPC valve output pressure
Malfunction of boom swing
PPC valve
2.94 +– 0.1
0.49
MPa
Swing boom to right or left + 5
{30 – 1 kg/cm2}
Malfunction of boom swing The boom swing control valve spool may have a malfunction.
2
control valve (spool) Check it directly.
Presumed Malfunction of boom swing
cause and The pressure compensation valve of the boom swing control valve
3 control valve (pressure
standard value may have a malfunction. Check it directly.
compensation valve)
in normalcy
of boom swing control valve The suction valve (head side) of the boom swing control valve may
4
(suction valve) have a malfunction. Check it directly.
a Only right swing
valves
6 Defective boom swing cylinder
Boom swing cylinder Leakage from cylinder
Relieve at left end 10 cc/min
H-10 Work equipment does not move singly 1
(1) Boom does not move singly.

Failure • Work equipment does not move singly (2) Arm does not move singly.
information (while any part moves normally). (3) Bucket does not move singly.
(4) Boom swing system does not move singly.
Relative
information

Presumed Work equipment control lever PPC valve output pressure
cause and 1 Malfunction of PPC valve Set in neutral 0 MPa {0 kg/cm2}
standard value
in normalcy 2.94 +– 0.1
0.49
MPa
Operate lever +5
{30 – 1 kg/cm2}
Malfunction of control valve
2 The control valve spool may have a malfunction. Check it directly.
(spool)
PC45MR-3, PC55MR-3 40-300 17

SEN04652-00 H-11 Work equipment hydraulic drift is large
H-11 Work equipment hydraulic drift is large 1
1) Boom hydraulic drift is large

Failure
• Boom hydraulic drift is large.
information
Relative
information

1 Defective boom cylinder
Boom cylinder Leakage from cylinder
Presumed
cause and Relieve by raising boom 10 cc/min
standard value Defective seal of boom control The lock valve of the boom control valve may be defective seal.
2
in normalcy valve (lock valve) Check it directly.
Defective seal of boom control The boom control valve spool may have a defective seal. Check it
3
Defective seal of boom control The suction valve (bottom side) of the boom control valve may have
4
valve (suction valve) a defective seal. Check it directly.
2) Arm hydraulic drift is large

Failure
• Arm hydraulic drift is large.
information
Relative
information

Presumed 1 Defective arm cylinder Arm cylinder Leakage from cylinder
cause and Relieved in arm-IN
standard value 10 cc/min
operation
in normalcy
Defective seal of arm control The arm control valve spool may have a defective seal. Check it
2
Defective seal of arm control The suction valve (bottom side) of the arm control valve may have a
3
valve (suction valve) defective seal. Check it directly.
40-300 18 PC45MR-3, PC55MR-3

H-11 Work equipment hydraulic drift is large SEN04652-00
3) Bucket hydraulic drift is large

Failure
• Bucket hydraulic drift is large.
information
Relative
information

Presumed 1 Defective bucket cylinder Bucket cylinder Leakage from cylinder
cause and Relieved in bucket-CURL
standard value 10 cc/min
operation
in normalcy
Defective seal of bucket The bucket control valve spool may have a defective seal. Check it
2
control valve (spool) directly.
Defective seal of bucket The suction valve (bottom side) of the bucket control valve may
3
control valve (suction valve) have a defective seal. Check it directly.
PC45MR-3, PC55MR-3 40-300 19

SEN04652-00 H-12 Time lag of work equipment is large
H-12 Time lag of work equipment is large 1
Failure
• Time lag of work equipment is large.
information

cause and
standard value Malfunction of control valve The suction valve (head side) of the control valve may have a
1
in normalcy (suction valve) malfunction. Check it directly.
H-13 In compound operation of work equipment, speed of part loaded

more is low 1
Failure
• In compound operation of work equipment, speed of part loaded more is low.
information
Relative
information

The pressure compensation valve of the control valve on less load
side may have a malfunction. Check it directly.
More load Less load
Presumed Combination of operations
side side
cause and Malfunction of pressure
standard value 1 compensation valve on less Boom RAISE + Arm IN Boom Arm
in normalcy load side Boom RAISE + Arm OUT Arm Boom
Boom RAISE + Bucket CURL Boom Bucket
Arm OUT + Bucket CURL Arm Bucket
Boom LOWER + Arm OUT Arm Boom
40-300 20 PC45MR-3, PC55MR-3

H-14 Machine deviates during travel SEN04652-00
H-14 Machine deviates during travel 1
1) Machine deviates during ordinary travel

Failure
• Machine deviates during ordinary travel.
information

• Check that the track shoes on both sides are tensed evenly.
1 Defective undercarriage • Check that the front idler, rollers, etc. are free of abnormal rota-
tion, deformation, and damage.
Travel lever PPC valve output pressure
Malfunction of travel PPC
2
valve Operate to drive forward or in 2.94 +– 0.1
0.49
MPa
reverse +5
{30 – 1 kg/cm2}
Output difference between above
Max. 0.4 MPa {4 kg/cm2}
both sides
Defective adjustment of travel Adjust the travel deviation adjustment orifice of the pump.
3 deviation adjustment orifice of a See Testing and adjusting, “Testing and adjusting travel devia-
pump tion”.
Malfunction of unload valve Control levers Unload pressure
4
Presumed a Unload valve: 2 sets
cause and 3.2 + 0.98
0 MPa
standard value Set all levers in neutral
{33 + 10 2
0 kg/cm }
in normalcy
5 Malfunction of logic valve The logic valve may have a malfunction. Check it directly.
Malfunction of pump The pump merge-divider valve may have a malfunction. Check it
6
merge-divider valve directly.
Malfunction of travel control The travel control valve spool may have a function. Check it
7
Malfunction of travel control
The pressure compensation valve of the travel control valve may
have a malfunction. Check it directly.
valve)
Defective travel junction The travel junction variable throttle may have a malfunction. Check
9
variable throttle it directly.
Replace the hoses between the center swivel joint and travel motor
10 Defective center swivel joint on both sides. If the deviating direction changes at this time, the
center swivel joint is defective.
11 Defective travel motor on both sides. If the deviating direction does not change at this
time, the travel motor is defective.
The final drive may have a defect in it. Check it directly. (Its
12 Defective final drive condition can be checked by abnormal sound, abnormal heat, metal
chips in drain oil, etc.)
PC45MR-3, PC55MR-3 40-300 21

SEN04652-00 H-14 Machine deviates during travel
2) Machine deviates when it starts (It does not deviate during ordinary travel)
Failure
• Machine deviates when it starts (It does not deviate during ordinary travel).
information

Malfunction of travel motor The travel motor counterbalance valve may have a malfunction.
1
counterbalance valve Check it directly.
Presumed
cause and Malfunction of travel PPC
standard value 2 Set in neutral 0 MPa {0 kg/cm2}
valve
in normalcy
Operate to drive forward or in 2.94 +– 0.1
0.49
MPa
reverse +5
{30 – 1 kg/cm2}
If the results of 1 and 2 above are normal, release of the travel
Defective travel motor holding
3 motor holding brake may be delayed. Check the parking brake
brake
directly.
40-300 22 PC45MR-3, PC55MR-3

H-15 Travel speed or travel power is low (while work equipment is normal) SEN04652-00
H-15 Travel speed or travel power is low (while work equipment is

normal) 1
Failure
• Travel speed or travel power is low (while work equipment is normal).
information
Relative
information
• Check that the machine does not deviate during travel.

• Check that the track shoes on both sides are tensed evenly.
1 Defective undercarriage • Check that the front idler, rollers, etc. are free of abnormal rota-
tion, deformation, and damage.
2
valve Operate to drive forward or in 2.94 +– 0.1
0.49
MPa
reverse +5
{30 – 1 kg/cm2}
Output difference between above
Max. 0.4 MPa {4 kg/cm2}
both sides
Presumed Malfunction of unload valve Control levers Unload pressure
cause and 3
a Unload valve: 2 sets
standard value 3.2 + 0.98
0 MPa
in normalcy Set all levers in neutral
{33 + 10
0 kg/cm2}
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it
5
divider valve directly.
6
valve)
Defective adjustment or carry out troubleshooting.
8 malfunction of main relief Lever to be operated Main relief pressure
valve 26.5 ± 0.98 MPa
Travel lever operated to relieve
{270 ± 10 kg/cm2}
PC45MR-3, PC55MR-3 40-300 23

SEN04652-00 H-16 Machine is not steered well or steering power is low
H-16 Machine is not steered well or steering power is low 1
Failure
• Machine is not steered well or steering power is low.
information
Relative
information

valve
2.94 +– 0.1
0.49
MPa
Operate one side +5
{30 – 1 kg/cm2}
Presumed Malfunction of travel junction The travel junction variable throttle valve may have a malfunction.
cause and 3
variable throttle valve Check it directly.
standard value
in normalcy Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it
4
divider valve directly.
5
valve)
Malfunction of travel control The suction valve of the travel control valve may have a
7
valve (suction valve) malfunction. Check it directly.
Defective center swivel joint
8 The center swivel joint seal may be defective. Check it directly.
seal
40-300 24 PC45MR-3, PC55MR-3

H-17 Travel speed does not change SEN04652-00
H-17 Travel speed does not change 1
Failure
• Travel speed does not change or it is low or high.
information
Relative • Before starting troubleshooting, check that the electric system is normal.

Presumed 2nd travel speed selection switch Solenoid valve output pressure
Malfunction of travel speed
cause and 1 OFF (Monitor lamp goes OFF) 0 MPa {0 kg/cm2}
shifting solenoid valve
standard value
in normalcy 2.94 +– 0.1
0.49
MPa
ON (Monitor lamp lights up) +5
{30 – 1 kg/cm2}
Malfunction of travel motor If the oil pressure in 1 above is normal, the speed shifting section of
2
(speed shifting section) the travel motor may have a malfunction.
PC45MR-3, PC55MR-3 40-300 25

SEN04652-00 H-18 Travel motor does not work
H-18 Travel motor does not work 1
1) Travel motors on both sides do not work

Failure
• Travel motors on both sides do not work.
information

Presumed
cause and If the PPC circuit pressure of only one of the left travel (forward and
Defective PPC circuit check
standard value reverse) and right travel (forward and reverse) systems is normal,
1 valve (for pump merge-divider
in normalcy the PPC circuit check valve of that system may have a malfunction.
valve drive pressure)
Check it directly.
[Remarks]
Relationship between defect of PPC circuit check valve and “Travel motor does not work”
PPC circuit check valves (A) – (D) are installed as shown in the following figure to take out the signal pres-
sure for changing the pump merge valve from the travel PPC pressure.
If the checking function of check valves (A) – (D) is lost, the travel motors may not work.
Example: When checking function of (A) is lost

q Operation in which travel motors work normally: “Left forward”, “Left forward + Right forward”, “Left for-
ward + Right reverse”
q Operation in which travel motors may not work normally: “Left reverse”, “Right forward”, “Right reverse”,
“Left reverse + Right forward”, “Left reverse + Right reverse”
40-300 26 PC45MR-3, PC55MR-3

H-18 Travel motor does not work SEN04652-00
2) Travel motor on only one side does not work

Failure
• Travel motor on only one side does not work.
information

Defective seal of travel control The seal of the suction valve of the travel control valve may have a
1
valve (suction valve) malfunction. Check it directly.
Malfunction of travel motor The counterbalance valve of the travel motor may have a
2
(counterbalance valve) malfunction. Check it directly.
3 Defective travel motor on both sides. If the deviating direction does not change at this
time, the travel motor is defective.
The final drive may have a defect in it. Check it directly. (Its
Presumed 4 Defective final drive condition can be checked by abnormal sound, abnormal heat, metal
cause and chips in drain oil, etc.)
standard value
in normalcy
Travel PPC valve output
Travel lever
Malfunction of travel PPC pressure
5
valve Set in neutral 0 MPa {0 kg/cm2}
Operate for forward or reverse 2.94 +– 0.1

0.49
MPa
travel +5
{30 – 1 kg/cm2}
Malfunction of travel control The travel control valve spool may have a malfunction. Check it
6
valve spool directly.
PC45MR-3, PC55MR-3 40-300 27

SEN04652-00 H-19 Speed or power of swing is low
H-19 Speed or power of swing is low 1
1) Speed or power of swing is low in both directions

Failure
• Speed or power of swing is low in both directions.
information
information • Check that the blade operates normally. (If the blade speed is also low, carry out troubleshooting H-
1, 3) first.)

1 malfunction of swing motor Control lever Swing relief pressure
safety valve Relieve by swinging 19.6 ± 0.98 MPa
(in both directions respectively). {200 ± 10 kg/cm2}
Swing motor holding brake
Left control lever
release pressure
Malfunction of swing motor
2
holding brake Operate to move arm IN or swing 2.94 +– 0.1
0.49
MPa
to right or left +5
{30 – 1 kg/cm2}
Presumed
cause and If the above hydraulic pressure is normal, the brake may have a
standard value malfunction. Check it directly.
in normalcy The swing machinery may have a defect in it. Check it directly. (Its
3 Defective swing machinery condition can be checked by abnormal sound, abnormal heat, metal
Left control lever Swing PPC circuit pressure
Malfunction of swing control 2.94 +– 0.1
0.49
MPa
4 Operate to swing to right or left
valve spool +5
{30 – 1 kg/cm2}
If the above hydraulic pressure is normal, the swing control valve

spool may have a malfunction. Check it directly.
If the results of 1 – 4 above are normal, the swing motor may have a
5 Internal defect of swing motor
defect in it. Check it directly.
40-300 28 PC45MR-3, PC55MR-3

H-19 Speed or power of swing is low SEN04652-00
2) Speed or power of swing is low in only one direction

Failure
• Speed or power of swing is low in only one direction.
information
1, 3) first.)

Left control lever PPC valve output pressure
Malfunction of swing PPC
valve
2.94 +– 0.1
0.49
MPa
Operate to swing to right or left +5
{30 – 1 kg/cm2}
Presumed
cause and a Prepare with engine stopped, then run engine at full throttle and
standard value carry out troubleshooting.
in normalcy Left control lever Swing PPC circuit pressure
Malfunction of swing control 2.94 +– 0.1
0.49
MPa
2 Operate to swing to right or left
valve spool +5
{30 – 1 kg/cm2}

Defective seal of swing motor The seal of the suction valve or check valve of the swing motor may
3
suction valve or check valve be defective. Check it directly.
PC45MR-3, PC55MR-3 40-300 29

SEN04652-00 H-20 Machine does not swing
H-20 Machine does not swing 1
1) Machine does not swing in either direction

Failure
• Machine does not swing in either direction.
information
3, 3) first.)

safety valve Relieve by swinging (in both 19.6 ± 0.98 MPa
directions respectively). {200 ± 10 kg/cm2}
Left control lever
release pressure
2
holding brake Operate to move arm IN or swing 2.94 +– 0.1
0.49
MPa
to right or left +5
{30 – 1 kg/cm2}
If the above hydraulic pressure is normal, the brake may have a
The swing machinery may have a defect in it. Check it directly. (Its
Presumed chips in drain oil, etc.)
cause and a Prepare with engine stopped, then run engine at full throttle and
standard value carry out troubleshooting.
in normalcy
Malfunction of swing control
4
valve spool 2.94 +– 0.1
0.49
MPa
{30 – 1 kg/cm2}
Left control lever
release pressure
Malfunction of check valve in
5 swing holding brake release Operated to move arm IN or 2.94 +– 0.1
0.49
MPa
pressure pickup circuit swing to right and left +5
{30 – 1 kg/cm2}
If oil pressure in any hydraulic circuit is defective, the check valves
of the right and left swing PPC circuits and arm IN PPC circuit may
have a malfunction. Check those valves directly.
40-300 30 PC45MR-3, PC55MR-3

H-20 Machine does not swing SEN04652-00
2) Machine does not swing in only one direction

Failure
• Machine does not swing in only one direction.
information
3, 3) first.)

valve
2.94 +– 0.1
0.49
MPa
{30 – 1 kg/cm2}

2
0.49
MPa
Operate to swing to right or left
Presumed +5
{30 – 1 kg/cm2}
cause and
standard value If the above hydraulic pressure is normal, the swing control valve
in normalcy spool may have a malfunction. Check it directly.
3
Malfunction of load check Since the load check valve in the control valve spool may have a
4
valve in control valve spool malfunction, check it directly.
Left control lever
release pressure
Malfunction of check valve in
5 swing holding brake release Operated to move arm IN or 2.94 +– 0.1
0.49
MPa
pressure pickup circuit swing to right and left +5
{30 – 1 kg/cm2}
If oil pressure in any hydraulic circuit is defective, the check valves

of the right and left swing PPC circuits and arm IN PPC circuit may
have a malfunction. Check those valves directly.
PC45MR-3, PC55MR-3 40-300 31

SEN04652-00 H-21 Swing acceleration performance is low
H-21 Swing acceleration performance is low 1
1) Swing acceleration performance is low in both directions

Failure
• Swing acceleration performance is low in both directions.
information
1, 3) first.)

safety valve Relieve by swinging (in both 19.6 ± 0.98 MPa
directions respectively). {200 ± 10 kg/cm2}
Presumed Swing motor holding brake
cause and Left control lever
release pressure
standard value Malfunction of swing motor
2
in normalcy holding brake Operate to move arm IN or swing 2.94 +– 0.1
0.49
MPa
to right or left +5
{30 – 1 kg/cm2}
If the above hydraulic pressure is normal, the brake may have a
The swing machinery may have a defect in it. Check it directly. (Its
40-300 32 PC45MR-3, PC55MR-3

H-21 Swing acceleration performance is low SEN04652-00
2) Swing acceleration performance is low in only one direction

Failure
• Swing acceleration performance is low in only one direction.
information
1, 3) first.)

valve
2.94 +– 0.1
0.49
MPa
{30 – 1 kg/cm2}
standard value
in normalcy Left control lever Swing PPC circuit pressure
2
0.49
MPa
{30 – 1 kg/cm2}
3
Malfunction of load check Since the load check valve in the control valve spool may have a
4
valve in control valve spool malfunction, check it directly.
PC45MR-3, PC55MR-3 40-300 33

SEN04652-00 H-22 Machine overruns when it stops swinging
H-22 Machine overruns when it stops swinging 1
1) Machine overruns when it stops swinging in both directions

Failure
• Machine overruns when it stops swinging in both directions.
information

Presumed carry out troubleshooting.
Defective adjustment of swing
cause and 1 Left control lever Swing relief pressure
motor safety valve
standard value Relieve by swinging 19.6 ± 0.98 MPa
in normalcy (in both directions respectively). {200 ± 10 kg/cm2}
If the result of 1 above is normal, the swing motor may have a defect
2 Defective swing motor
in it. Check it directly.
2) Machine overruns when it stops swinging in only one direction

Failure
• Machine overruns when it stops swinging in only one direction.
information

valve
2.94 +– 0.1
0.49
MPa
{30 – 1 kg/cm2}
Presumed Malfunction of swing controlThe swing control valve spool may have a malfunction. Check it
2
cause and valve (spool) directly.
standard value a Prepare with engine stopped, then run engine at full throttle and
in normalcy carry out troubleshooting.
Swing
Defective adjustment or lock Left control lever Swing relief pressure
3 malfunction of swing motor switch
(safety valve) Operate to relieve by
swinging 19.6 ± 0.98 MPa
ON
(in both directions {200 ± 10 kg/cm2}
respectively)
Defective seal of swing motor The seal of the suction valve of the swing motor may be defective.
4
(suction valve) Check it directly.
40-300 34 PC45MR-3, PC55MR-3

H-23 Large shock is made when machine stops swinging SEN04652-00
H-23 Large shock is made when machine stops swinging 1
Failure
• Large shock is made when machine stops swinging.
information
information • When starting troubleshooting, set the hydraulic oil temperature to 45 – 55°C.

Left work equipment control lever PPC valve output pressure
Presumed 1 Set in neutral 0 MPa {0 kg/cm2}
valve
cause and
standard value 2.94 +– 0.1
0.49
MPa
Operated to swing machine +5
in normalcy {30 – 1 kg/cm2}
Malfunction of swing motor Since the swing motor safety valve may have a malfunction, check it
2
safety valve directly.
Malfunction of control valve Since the control valve spool may have a malfunction, check it
3
spool directly.
H-24 When upper structure stops swinging, it makes large sound 1
Failure
• When upper structure stops swinging, it makes large sound.
information

Malfunction of back pressure The back pressure check valve may have a malfunction. Check it
1
check valve directly.
Malfunction of swing motor The swing motor (safety valves) may have a malfunction. Check
Presumed 2
(safety valve) the valves directly.
cause and
standard value The swing motor (suction valves) may have a malfunction. Check
in normalcy 3 the valves directly. (They may be checked by exchanging with each
(suction valve)
other and checking change of the phenomenon.)
The swing machinery may have a defect in it. Check it directly. (It
4 Defective swing machinery may be checked by abnormal sound, abnormal heating, metal chips
in drain oil, etc.)
PC45MR-3, PC55MR-3 40-300 35

SEN04652-00 H-25 Hydraulic drift of swing is large
H-25 Hydraulic drift of swing is large 1
1) Hydraulic drift of swing is large (while swing holding brake is applied)

Failure
• Hydraulic drift of swing is large (when swing holding brake is applied).
information
Relative • When the control levers on the swing and arm IN side are in neutral, the swing holding brake oper-
information ates and the upper structure is fixed by the disc brake.

Control lever
Presumed release pressure
cause and Malfunction or internal defect Set in neutral 0 MPa {0 kg/cm2}
standard value 1 of swing motor (holding brake
in normalcy section) 2.94 +– 0.1
0.49
MPa
Operate to swing +5
{30 – 1 kg/cm2}
If the above hydraulic pressure is normal, the holding brake section
of the swing motor may have a malfunction or a defect in it. Check it
directly.
2) Hydraulic drift of swing is large (while swing holding brake is released)

Failure
• Hydraulic drift of swing is large (while swing holding brake is released).
information
Relative • If the arm is moved IN, the swing brake is released and the upper structure is held by only hydraulic
information pressure.

Defective seal of swing control
The seal of the swing control valve spool may be defective. Check it
1
Presumed valve (spool) directly.
cause and Defective seal of swing motor The safety valve of the swing motor may have a malfunction. Check
standard value 2
(safety valve) it directly.
in normalcy
The suction valve of the swing motor may have a malfunction.
Defective seal of swing motor
3 Check it directly. (Replace the suction valves on both sides and
(suction valve)
judge the faulty part by the change of the phenomenon.)
40-300 36 PC45MR-3, PC55MR-3

H-26 Speed or power of blade is low SEN04652-00
H-26 Speed or power of blade is low 1
Failure
• Speed or power of blade is low.
information
information • Check that the swing operation is normal. (If the swing speed is also low, carry out troubleshooting
H-1, 3) first. If the travel speed is also low, carry out troubleshooting H-1, 5) first.)

Blade control lever Gear pump relief pressure
1
Defective adjustment of gear 21.6 +– 0.49
0.98
MPa
pump relief valve Operate to lower blade + 10
{220 – 5 kg/cm2}
relief valve may have a malfunction or a defect in it. Check it
directly.
Blade control lever PPC valve output pressure
Presumed 2 Malfunction of PPC valve
cause and Set in neutral 0 MPa {0 kg/cm2}
standard value 2.94 +– 0.1
0.49
MPa
in normalcy Operate to raise or lower blade +5
{30 – 1 kg/cm2}
Malfunction of blade control The blade control valve spool may have a malfunction. Check it
3
4 Defective blade cylinder
Blade cylinder Leakage from cylinder
Relieve by lowering blade 10 cc/min
Malfunction of load check The load check valve in the control valve spool may have a
5
valve in control valve spool malfunction. Check it directly.
The suction valve of the control valve may have a malfunction.
Malfunction of suction valve of
6 Check it directly.
control valve
a The suction valve is installed on both sides.
PC45MR-3, PC55MR-3 40-300 37

SEN04652-00 H-27 Blade does not move
H-27 Blade does not move 1
Failure
• Blade does not move.
information
information • Check that the swing operation is normal. (If the machine does not swing, carry out troubleshooting
H-3, 3) first. If the machine does not travel, carry out troubleshooting H-3, 5) first.)

Blade control lever PPC valve output pressure
1 Malfunction of PPC valve Set in neutral 0 MPa {0 kg/cm2}
2.94 +– 0.1
0.49
MPa
Presumed Operate to raise and lower blade +5
{30 – 1 kg/cm2}
cause and
standard value Malfunction of blade control The blade control valve spool may have a malfunction. Check it
in normalcy 2
Blade cylinder Leakage from cylinder
Relieve by lowering blade 10 cc/min
Deformation of blade cylinder
4 The blade cylinder or blade is deformed. Check them directly.
or blade
40-300 38 PC45MR-3, PC55MR-3

H-28 Hydraulic drift of blade is large SEN04652-00
H-28 Hydraulic drift of blade is large 1
Failure
• Hydraulic drift of blade is large.
information
Relative
information

Presumed Blade cylinder Leakage from cylinder
cause and Relieve by lowering 10 cc/min
standard value
in normalcy Defective seal of blade control The seal of blade control valve spool may be defective. Check it
2
The seal of the suction valve (bottom side) of the blade control valve
Defective seal of blade control
3 may be defective. Check it directly.
valve (suction valve)
a The suction valve is installed on both sides.
PC45MR-3, PC55MR-3 40-300 39

SEN04652-00

©2008 KOMATSU
All Rights Reserved
40-300 40
SEN04653-00
PC45MR-3,
PC55MR-3

400 Troubleshooting of engine (S-mode)

Method of using troubleshooting charts .......................................................................................................... 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant/fuel)..................................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
PC45MR-3, PC55MR-3 40-400 1

SEN04653-00
40-400 2 PC45MR-3, PC55MR-3

Method of using troubleshooting charts SEN04653-00
Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-

tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
Questions
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
Check items
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
Causes
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
Troubleshooting
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items]

and related to the [Causes] are marked with E, Q,
or w.
E : Causes to be referred to for questions and
check items
Q : Causes related to questions and check
items
w : Causes highly probable among ones
marked with Q
a When narrowing the “causes”, apply the items
marked with w before those marked with Q.
When narrowing the causes, do not apply the
items marked with E. (If no items have other
marks and the causes cannot be narrowed,
however, you may apply them.)
PC45MR-3, PC55MR-3 40-400 3

SEN04653-00 Method of using troubleshooting charts
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
40-400 4 PC45MR-3, PC55MR-3

Method of using troubleshooting charts SEN04653-00
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
PC45MR-3, PC55MR-3 40-400 5

SEN04653-00 S-1 Starting performance is poor
S-1 Starting performance is poor 1
General causes why starting performance is poor Causes
Defective fuel injection pump (Stuck rack or plunger)

q Defective electrical system
q Insufficient supply of fuel
q Insufficient intake of air
Improper selection of fuel
Leaking or clogged fuel piping, entry of air

q
Clogged air breather hole of fuel tank cap
Defective alternator (generator section)

Defective alternator (regulator section)
Defective contact of valve, valve seat
Defective intake air heater system
Defective, deteriorated battery

Defective fuel injection nozzle
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
Defective fuel pump

Confirm recent repair history
Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
Starting motor cranks engine slowly w
When starting switch is turned ON and air bleeding plug of fuel filter is removed, fuel
does not flow out w w
While engine is cranked When fuel injection pipe sleeve nut is loosened, fuel w
Check items
with starting motor does not flow out

When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

Carry out troubleshooting in E-mode
When compression pressure is measured, it is found to be low q q

When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Control rack is heavy to push or does not return q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
When starting switch is turned to HEAT, intake air heater mount does not become q
warm
Is voltage 10 – 15 V between alternator terminal L and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are q
low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
40-400 6 PC45MR-3, PC55MR-3

S-2 Engine does not start SEN04653-00
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
q Internal parts of engine seized
o See “S-4 Engine stops during operations”.
Defective or deteriorated battery
Defective starting circuit wiring

q Defective electrical system (Starting circuit)
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E

Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

When specific gravity of electrolyte and voltage of battery are measured, they are low q
Carry out troubleshooting

There is not voltage (10 – 15 V) between battery relay terminal B and q
Troubleshooting
terminal E
in E-mode
When terminal B and terminal C of starting switch are connected,
q
engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry q
out troubleshooting at ON engine starts
Even if terminal B and terminal C at safety relay outlet are connected, q
engine does not start
When safety switch terminal and terminal B of starting motor are con- q
nected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
PC45MR-3, PC55MR-3 40-400 7

SEN04653-00 S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out Causes
Stuck or seized fuel injection pump plunger

General causes why engine turns but no exhaust smoke comes

out
Broken fuel injection pump drive shaft

Seized, abnormally worn feed pump
q Fuel is not being supplied
q Supply of fuel is extremely small
Defective engine stop solenoid

q Improper selection of fuel (particularly in winter)
Clogged fuel filter element
Clogged water separator

Insufficient fuel in tank
Use of improper fuel
Defective fuel pump

Questions

Exhaust smoke suddenly stopped coming out (when starting again) w Q w w
Replacement of filters has not been carried out according to Operation and Maintenance w E
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
Check items
Fuel is leaking from fuel piping w

When starting switch is turned ON and air bleeding plug of fuel filter is removed, fuel does
not flow out Q w Q w
While engine is cranked When fuel injection pipe sleeve nut is loosened, fuel does not
with starting motor flow out w w w Q w

Directly checked fuel tank cap is clogged q

Troubleshooting
Inspect fuel filter directly q
Inspect feed pump directly q
Control rack is heavy to push or does not return q q
Water and dust collected in water separator q

Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
—
—
Remedy
Add
40-400 8 PC45MR-3, PC55MR-3

S-2 Engine does not start SEN04653-00
c) Exhaust smoke comes out but engine does not start Causes
Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)
Defective fuel injection pump (Stuck rack or plunger)

General causes why exhaust smoke comes out but engine
Clogged fuel injection nozzle or defective spray

does not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

Defective intake air heater system

q Improper selection of fuel
Worn piston ring, cylinder liner
Defective, deteriorated battery


Use of improper fuel
Defective fuel pump

Clogged fuel filter
Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w
Questions
Non-specified fuel is being used Q Q

nance Manual w w Q

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally w

Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w Q
When fuel filter is removed, there is not fuel in it w
When priming pump is operated, it marks no reaction or it is heavy w Q
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
When fuel control lever is set to full position, it does not contact stopper Q
Check items
When starting switch is turned ON and air bleeding plug of fuel filter is removed, fuel
does not flow out Q w w
While engine is cranked When fuel injection pipe sleeve nut is loosened, fuel
with starting motor, does not flow out w
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q

q
Troubleshooting
When air is bled from fuel system, air comes out

When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q
not change
When specific gravity of electrolyte and voltage of battery are measured, they are
q
low
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
PC45MR-3, PC55MR-3 40-400 9

SEN04653-00 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Causes

Seized turbocharger, interference of turbocharger
Clogged fuel injection nozzle or defective spray

q Defective condition of fuel spray

Defective contact of valve and valve seat
Seized fuel injection pump plunger

Improper valve clearance

Clogged fuel filter
Degree of use of machine Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w Q w w
Replacement of filters has not been carried out according to Operation and Maintenance w w Q
Manual
Oil must be added more frequently w
Rust and water are found when fuel tank is drained w Q
When starting switch is turned ON and air bleeding plug of fuel filter is loosened, fuel does
w Q
not flow out
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low w Q
Blue under light load w w

Color of exhaust gas
Check items
Black w Q w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q
There is hunting from engine (rotation is irregular) Q Q w

Inspect valve clearance directly q
q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
40-400 10 PC45MR-3, PC55MR-3

S-4 Engine stops during operations SEN04653-00
S-4 Engine stops during operations 1
General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)

q Seized parts inside engine

q There is overheating
Broken auxiliary equipment (pump, etc.)

q Defective hydraulic pump
Broken, seized piston, connecting rod
Broken fuel injection pump drive shaft

Broken, seized crankshaft bearing
Leaking, clogged fuel piping
Problem in hydraulic pump

Broken, seized feed pump
Broken, seized gear train

Defective fuel pump

Clogged fuel filter
Abnormal noise was heard and engine stopped sud-
w w w w Q w Q w w
denly
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q
w Q
nance Manual
Fuel level monitor indicates low level w
When starting switch is turned ON and air bleeding plug of fuel filter is loosened, fuel
does not flow out w Q w
Rust and water are found when fuel tank is drained w

Check items
Metal particles are found when oil is drained w w w Q

Does not turn at all w w
When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Fuel injection pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q
Inspect gear train directly q

Troubleshooting
Directly checked feed pump gauze filter is clogged q
Inspect feed pump directly
Control rack is heavy or does not return q
Engine rotates when pump auxiliary equipment (pump, etc.) is removed q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
—
—
Remedy
Add
*1: Failure code [CA559] and failure code [CA2249]
PC45MR-3, PC55MR-3 40-400 11

SEN04653-00 S-5 Engine does not rotate smoothly
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes

q Air in fuel system

Defective adjustment of governor
Low idle speed set too low

Malfunction of control rack

Malfunction of governor
Clogged fuel filter

w w w
Questions
Occurs at a certain speed range

Occurs at low idle Q w Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q Q

When starting switch is turned ON and air bleeding plug of fuel filter is loosened, fuel does not flow
out w Q
Engine speed sometimes rises too high w w

Engine sometimes does not stop soon w w
When governor lever is moved it is found to be stiff q q

Troubleshooting
When injection pump is tested, governor is found to be improperly adjusted q

When control rack is pushed, it is found to be heavy, or does not return q
When fuel tank cap is inspected directly, it is found to be clogged q
Directly checked fuel filter is clogged q
Replace
Replace
Replace
Replace
Adjust
Adjust
Clean
Clean
Remedy
Add
40-400 12 PC45MR-3, PC55MR-3

S-6 Engine lacks output (or lacks power) SEN04653-00
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Causes
Clogged fuel injection nozzle or defective spray (Dirt caught in nozzle)

q Defective spray condition of fuel
o See “S-14 Coolant temperature becomes too
high (Overheating)”.

Air leakage from air intake piping
Defective fuel injection timing

Leaking, clogged fuel piping

Defective water separator
Clogged fuel filter

Degree of use of machine Operated for long period E E E E E
Suddenly Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q w w
Replacement of filters has not been carried out according to Operation and w Q w
Maintenance Manual
Engine oil must be added more frequently Q Q
Dust indicator is red w Q
Fuel injection pump mounting bolts are loosened Q w
Black Q w
Blue under light load w
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinders is low
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too low
High idle speed under no load is normal, but speed suddenly drops when load is
Q Q w Q Q
applied
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q

Inspect air intake piping directly q
Troubleshooting

Inspect fuel piping q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Remedy
PC45MR-3, PC55MR-3 40-400 13

SEN04653-00 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion) 1
General causes why exhaust smoke is black Causes

Defective fuel injection pump (Too much fuel injection)
Defective fuel injection pump (Seized rack or plunger)

q Defective condition of fuel injection
o See “S-14 Coolant temperature becomes too high (Over-
Clogged or seized fuel injection nozzle

heating)”.
Defective fuel injection timing


Crushed, clogged muffler
Degree of use of machine Operated for long period E E E E
Suddenly became black Q Q Q
Questions
Color of exhaust gas Gradually became black w Q

Suddenly Q Q Q Q
Power was lost
Gradually Q Q Q
Muffler is crushed w
Fuel injection pump seal is removed Q
Q w
Check items
cylinders is low
Exhaust noise is abnormal w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q w Q

Troubleshooting

When muffler is removed, exhaust color improves q
Tested fuel injection pump is disordered q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
Fuel injection pump mounting bolts and nuts are loosened q
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Clean
Remedy
40-400 14 PC45MR-3, PC55MR-3

S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN04653-00
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes

q Abnormal consumption of oil
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle (Do not
run engine at idle for more than 20 minutes continuously)
Dust sucked in from intake system

q External leakage of oil
Clogged breather, breather hose

q Wear of pats in lubrication system
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil piping

Oil leakage from oil filter
Broken piston ring
E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w
There are loose piping clamps in intake system w
There is oil in coolant
Check items
Oil level in damper chamber of applicable machine is high w

Exhaust smoke is blue under light load w w
Excessive Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

Troubleshooting
When intake manifold is removed, inside is found to be dirty abnormally q

Check breather and breather hose directly q
Inspect rear oil seal directly q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC45MR-3, PC55MR-3 40-400 15

SEN04653-00 S-9 Oil becomes contaminated quickly
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Causes

q Entry of exhaust gas into oil due to internal wear
Clogged breather, breather hose

Defective oil filter safety valve

q Clogging of lubrication passage
q Use of improper fuel
Worn valve, valve guide

q Use of improper oil
Exhaust smoke is bad

q Operation under excessive load
Clogged oil filter

Questions

Non-specified fuel is being used Q Q
Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Check items

Black w
Excessive Q w
Amount of blow-by gas
None w
q q
Troubleshooting
When compression pressure is measured, it is found to be low
See S-7
Check breather and breather hose directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Replace
Replace
Replace
Replace
Clean
—
Remedy
40-400 16 PC45MR-3, PC55MR-3

S-10 Fuel consumption is excessive SEN04653-00
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes

q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Defective adjustment of fuel lever linkage

Defective spray from fuel injection nozzle
Fuel leakage from fuel filter, piping, etc.
Defective fuel injection pump plunger

Fuel leakage inside head cover
Improper fuel injection timing

Defective feed pump oil seal
E E E
Questions

More than for other machines of same model w Q Q
Condition of fuel Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders
is low Q w
Check items
Low idle speed is high w

Fuel injection pump seal is removed w
Black w Q Q
Exhaust smoke color
White Q
Remove and inspect head cover directly q

Troubleshooting
Inspect feed pump oil seal directly q

Fuel injection rate of tested fuel injection pump is large q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When engine speed is measured, low idle speed is found to be high q
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Remedy
PC45MR-3, PC55MR-3 40-400 17

SEN04653-00 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Internal cracks in cylinder block
Holes caused by pitting

E
Questions

Suddenly increased Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q
Oil level has risen, oil is milky Q Q
Check
items
There are excessive air bubbles in radiator, coolant spurts back w
q
shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Remove and inspect oil pan directly q q
Replace
Replace
Replace
Remedy
40-400 18 PC45MR-3, PC55MR-3

S-12 Oil pressure drops SEN04653-00
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes

Leakage, clogging, wear of lubrication system
Defective oil level switch or defective wiring harness

q
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the "Opera-
Leaking, crushed, clogged hydraulic piping

tion and Maintenance Manual" is not observed.
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure Q w

Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance w
Manual
Indicates pressure drop at low idle w
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve spring of regulator valve is fatigued, damaged q
Inspect oil filter directly q
Measured oil pressure is within standard value q
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
—
Remedy
Add
PC45MR-3, PC55MR-3 40-400 19

SEN04653-00 S-13 Oil level rises (Entry of coolant/fuel)
S-13 Oil level rises (Entry of coolant/fuel) 1
General causes why oil level rises Causes

q Coolant in oil (milky)
Clogged water pump breather hole

q Fuel in oil (smells diluted diesel fuel)
Defective nozzle holder sleeve

a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”.
Defect in fuel injection pump

Cracks inside cylinder block
Defective thermostat seat

Questions

Fuel must be added more frequently w Q
Coolant must be added more frequently Q Q Q Q
There is oil in coolant Q Q
Oil smells of diesel fuel w w Q
Exhaust gas color is white Q Q
When engine is started, drops of water come from muffler Q w
Check items
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or w
coolant spurts back
After water pump breather hole is cleaned, water flows out w

Troubleshooting
Leakage is detected by pressure test on cylinder head q

Inspect cylinder block directly q
Remove water pump and check it directly q
Remove fuel injection pump and check it directly q
There is defective contact on thermostat seat valve q
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
40-400 20 PC45MR-3, PC55MR-3

S-14 Coolant temperature becomes too high (overheating) SEN04653-00
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too high Causes

q Lack of cooling air (deformation, damage of fan)
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Drop in heat dissipation efficiency
Defective operation of thermostat
Slipping fan belt, worn fan pulley

q Problem in coolant circulation system
Clogged, crushed radiator fins

Clogged radiator core
Broken water pump
Lack of coolant
Questions
Suddenly overheated Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky
Fan belt tension is low w
When fan belt is turned, it has play w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w

Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting
When operation of thermostat is carried out, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
PC45MR-3, PC55MR-3 40-400 21

SEN04653-00 S-15 Abnormal noise is made
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes

Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

q
Defective inside of muffler (dividing board out of position)

q Abnormal combustion

Defective fuel injection pump (Seized rack or plunger)
q Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise
Broken dynamic valve system (valve, rocker arm)

before starting troubleshooting.
Excessive wear of piston ring, cylinder liner
Clogged or seized fuel injection nozzle

Improper gear train backlash
Removed, seized bushing
Degree of use of machine Operated for long period E
Questions
Condition of abnormal Gradually occurred Q Q

noise Suddenly occurred Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
When engine is cranked, interference sound is generated around turbocharger
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
cylinders is low w Q

Black Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Fuel injection rate of tested fuel injection pump is abnormal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Remedy
40-400 22 PC45MR-3, PC55MR-3

S-16 Vibration is excessive SEN04653-00
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes

q Defective parts (abnormal wear, breakage)

q Misalignment between engine and chassis
Stuck dynamic valve system (valve, rocker arm)

q Abnormal combustion
Loose engine mounting bolts, broken cushions

a If abnormal noise is made and vibration is excessive, carry out trouble-
Worn main bearing, connecting rod bearing

shooting for “S-15 Abnormal noise is made”, too.
Broken output shaft, parts in damper

Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Fuel injection rate of tested fuel injection pump is abnormal q
Inspect engine mounting bolts and cushions directly q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
PC45MR-3, PC55MR-3 40-400 23

SEN04653-00

©2008 KOMATSU
All Rights Reserved
40-400 24
SEN04654-00
PC45MR-3,
PC55MR-3

50 Disassembly and assembly1

100 General information on disassembly
and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 10
PC45MR-3, PC55MR-3 50-100 1

100 General information on disassembly and assembly
SEN04654-00 How to read this manual
How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The “Removal” section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q General tools that are necessary for removal
q Also the following information is described are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in the “Removal” section
tuted and should always be used are explained and listed below.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a: Know-how or precautions for work
2) Distinction of new and existing special [*1] : This mark shows that there are instructions or
tools precautions for installing parts.
6 : This mark shows the amount of oil or coolant
N: Tools newly developed for this
model. They respectively have a to be drained.
4 : Weight of part or component
new part number.
R: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other Installation
models. They can be used without q Except where otherwise instructed, installation
any modification. of parts is done in the r evers e order to
3) Circle mark Q in sketch column: removal.
q The sketch of the special tool is pre- q Instructions and precautions for installing parts
sented in the section of “Sketches of are shown with [*1] mark in the “Installation”
special tools”. Section, identifying which step the instructions
q This mark means part No. of special are intended for.
tools starting with 79 T- - q General tools that are necessary for installa-
* *** ****
and that they can not be supplied tion are described as [1], [2]•••etc. and their
from Komatsu in Japan (i.e. locally part names, part numbers and quantities are
made parts). not described.
q Marks shown in the “Installation” section stand
for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
50-100 2 PC45MR-3, PC55MR-3

How to read this manual SEN04654-00
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are deemed neces- q In “Disassembly” section, the work procedures,
sary for disassembly or assembly of parts precautions and know-how for carrying out
are described as A1,•••X1 etc. and their those procedures, and quantity of the oil and
part names, part numbers and quantities coolant drained are described.
are described in the special tool list. q General tools that are necessary for disassem-
q Also the following information is described bly are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used sembly” section are as follows.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a : Know-how or precautions for work
2) Distinction of new and existing special 6: Quantity of oil or coolant drained
tools
N : Tools newly developed for this
model. They respectively have a
new part number. Assembly
R : Tools with upgraded part numbers. q In “Assembly” section, the work procedures,
They are remodeled from already precautions and know-how for carrying out
available tools for other models. those procedures, and quantity of the oil and
Blank : Tools already available for other coolant added are described.
models. They can be used without q General tools that are necessary for assembly
any modification. are described as [1], [2]•••etc. and their part
3) Circle mark Q in sketch column: names, part numbers and quantities are not
q The sketch of the special tool is pre- described.
sented in the section of “Sketches of q The meanings of the symbols used in “Assem-
special tools”. bly” section are as follows.
k : Precautions related to safety in execution
q This mark means part No. of special
tools starting with 79 T- -
* *** ****
and that they can not be supplied
of work
a : This mark gives guidance or precautions
from Komatsu in Japan (i.e. locally when doing the procedure.
2 : Type of coating material
made parts).
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
PC45MR-3, PC55MR-3 50-100 3

SEN04654-00 Coating materials list
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
50-100 4 PC45MR-3, PC55MR-3

Coating materials list SEN04654-00
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

prevention
compound
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
PC45MR-3, PC55MR-3 50-100 5

SEN04654-00 Coating materials list
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
50-100 6 PC45MR-3, PC55MR-3

Special tool list SEN04654-00
Special tool list 1
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t.........Cannot be substituted, must always be installed (used).
q.........Extremely useful if available or, can be substituted with commercially available
part.
a New/Remodel: N .........Tools with new part numbers, newly developed for this model.
: R .........Tools with upgraded part numbers, remodeled from items already available for
other models.
:Blank:...Tools already available for other models, can be used without any modification.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
1 796T-126-1210 Wrench t 1 N Q Removal, installation of nut

790-101-5001 Push tool KIT t 1
790-101-5151 • Plate 1
2 Press fitting of oil seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5201 Push tool KIT q 1

Disassembly, assembly of
swing motor and swing 790-101-5271 • Plate 1
machinery assembly Press fitting of outer race
3 (small)
F 790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5331 • Plate 1
Press fitting of outer race
4 (large)
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Press fitting of bearing
Disassembly, assembly of 5 796-760-9110 Push tool t 1
(small)
swing motor and swing
Press fitting of bearing
machinery assembly 6 790-445-3810 Push tool t 1
(large)
790-101-5081 • Plate 1
1 Press fitting of bushing
Disassembly, assembly of L 790-101-5021 • Grip 1
idler assembly
01010-50816 • Bolt 1
2 791-430-3230 Installer t 1 Installation of floating seal
PC45MR-3, PC55MR-3 50-100 7

SEN04654-00 Special tool list
Necessity
Remodel
Sketch
New/
Q’ty
790-101-5081 • Plate 1
3 Press fitting of bushing
Disassembly, assembly of 790-101-5021 • Grip 1
track roller assembly
01010-50816 • Bolt 1
4 791-430-3230 Installer t 1 Installation of floating seal
L 790-101-5081 • Plate 1
Press fitting of ball bearing
5 and cap
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly, assembly of
carrier roller
790-101-5111 • Plate 1
6 Press fitting of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly, assembly of Disassembly, assembly of
recoil spring assembly M 792-371-1400 Sleeve t 1 recoil spring assembly
Disassembly, assembly of Disassembly and assem-
hydraulic pump assembly S 796T-13S-1010 Torque adapter q 1 N Q bly of mounting bolt for
hydraulic pump
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Disassembly, assembly
of center swivel joint T Separation of rotor and
790-101-2540 • Washer 1 swivel joint
assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
50-100 8 PC45MR-3, PC55MR-3

Special tool list SEN04654-00
Necessity
Remodel
Sketch
New/
Q’ty
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of

1 hydraulic cylinder assem-
790-101-1102 Hydraulic pump t 1 bly
Removal, installation of
2 790-330-1100 Wrench assembly t 1
cylinder head
Commercially Width across
available Socket t 1 flats: 41 mm
Commercially Width across
available Socket t 1 flats: 46 mm
Width across
790-302-1390 Socket t 1 flats: 46 mm,
long type
Removal,
Width across installation
3 790-302-1270 Socket t 1 flats: 50 mm of piston
Width across nut
790-302-1490 Socket t 1 flats: 50 mm,
long type
Width across
790-302-1280 Socket t 1 flats: 55 mm
Width across
790-302-1470 Socket t 1 flats: 55 mm,
long type
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 790-201-1731 • Push tool 1 Press fitting of bushing

Disassembly, assembly
of hydraulic cylinder U 790-201-1751 • Push tool 1
assembly
790-201-1741 • Push tool 1
790-201-1761 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 790-201-1540 • Plate 1 Press fitting of dust seal
790-201-1560 • Plate 1
790-201-1550 • Plate 1
790-201-1570 • Plate 1
6 790-720-1000 Expander q 1 Installation of piston ring
796-720-1640 Ring q 1
Boom, arm
07281-00909 Clamp q 1
796-720-1740 Ring q 1
7 Bucket
07281-00809 Clamp q 1
796-720-1650 Ring q 1
Swing, blade
07281-01029 Clamp q 1
Removal, installation of
operator’s cab glass X 2 793-498-1210 Lifter (Suction cup) t 2 Fixing of window glass
(stuck glass)
PC45MR-3, PC55MR-3 50-100 9

SEN04654-00 Sketches of special tools
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches
F1. Wrench
S. Torque adapter
50-100 10 PC45MR-3, PC55MR-3

Sketches of special tools SEN04654-00
PC45MR-3, PC55MR-3 50-100 11

SEN04654-00

©2008 KOMATSU
All Rights Reserved
50-100 12
SEN04655-00
PC45MR-3,
PC55MR-3


Removal and installation of fuel injection pump assembly.............................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 4
Removal and installation of hydraulic oil cooler assembly .............................................................................. 6
Removal and installation of engine and hydraulic pump assembly .............................................................. 10
PC45MR-3, PC55MR-3 50-200 1

SEN04655-00 Removal and installation of fuel injection pump assembly
Removal and installation of fuel 4. Make mark (7) on the gear case to record the
injection pump assembly 1 relative position of stamp line (5) of the fuel
injection pump body to stamp line (6) of the
Removal gear.

For details, see Testing and adjusting, “How to
open and close (tilt) floor”.
2. Loosen the fan belt and remove fan (1). [*1]

a Before removing fan (1), make a match
mark on it and mounting part.
5. Remove 4 fuel tubes (8). [*2]

a Check the installed position of the fuel
tube.
6. Disconnect fuel return hose (9).
7. Disconnect fuel hoses (10) and (11) and

engine stop solenoid connector.
3. Before removing fuel injection pump (2),
remove the front cover of the timing gear case 8. Disconnect cooling hoses (12).
and make match marks with paint on the
meshing parts of pump drive gear (3) and idle
gear (4).
9. Disconnect fuel control cable (13) from the fuel

injection pump.
50-200 2 PC45MR-3, PC55MR-3

Removal and installation of fuel injection pump assembly SEN04655-00
10. Remove mounting bolt (14) and disconnect Installation

lubrication tube (15).
q Carry out installation in the reverse order to
removal.
[*1]
a When installing the fan, line up the match
marks.
a Check that the identification mark (M) of the
fan is on outside.
q Sample of identification mark
11. Remove nut (16) from the end of the fuel injec-
tion pump drive shaft.
a Take care not to drop the nut into the
case.
a Never loosen mounting bolts (17) of pump
drive gear (3). (If the flange and pump drive
gear move from each other, it becomes
very difficult to adjust the injection timing.)
12. Using puller, push out the pump drive shaft
from the gear.
[*2]
a Referring to the following figure, install the fuel
tube.
a The cylinder of the engine on the flywheel side
is the No. 1 cylinder.
13. Remove 3 mounting nuts (18).
14. Remove the injection pump assembly (2).
[*3]
3 Nut at shaft end:
113 – 123 Nm {11.5 – 12.5 kgm}
[*4]
a Install the fuel injection pump temporarily, and
then tighten the nut at the shaft end first.
a Adjust the injection angle. For details, see
Testing and adjusting, “Testing and adjusting
fuel injection timing”.
PC45MR-3, PC55MR-3 50-200 3

SEN04655-00 Removal and installation of radiator assembly
Removal and installation of 6. Disconnect overflow hose (6) and radiator

radiator assembly 1 hose (7). [*1]
Removal 7. Disconnect air duct (8).

1. Open drain plug (1) to drain the coolant. a Place air duct (8) and air hose (9) as an
assembly on a place where they will not
6 Coolant: 8.5 l be obstacles.
2. Tilt open floor frame (2). For details, see Test- 8. Remove undercover (10) and disconnect hose
ing and adjusting, “How to open and close (tilt) (11). [*2]
floor”.
3. Remove cover (3).
4. Remove heater hose clamp (4).
5. Remove cover board (5).
50-200 4 PC45MR-3, PC55MR-3

Removal and installation of radiator assembly SEN04655-00
9. Disconnect fuel cooler (12). Installation

10. Remove plate (13). q Carry out installation in the reverse order to
removal.
11. Remove radiator assembly (14).
[*1], [*2]
q Refilling with coolant
a Add coolant through the coolant filler to
the specified level. Run the engine to cir-
culate the coolant through the system.
Then, check the coolant level again.
5 Coolant: 8.5 l
PC45MR-3, PC55MR-3 50-200 5

SEN04655-00 Removal and installation of hydraulic oil cooler assembly
Removal and installation of 5. Remove cover (5).

hydraulic oil cooler assembly 1
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Release the pressure inside the hydraulic tank.

For details, see Testing and adjusting, “Releas-
ing pressure inside the hydraulic tank”.
2. Open drain plug (1) to drain the coolant.

6 Coolant: 8.5 l
6. Open cover (3) and remove cover (4).
3. Loosen drain plug (2) to drain the hydraulic oil.

6 Hydraulic oil: 20 l
7. Remove cover (6) and 2 clamps (7) and move
the 2 heater hoses.
4. Tilt open the floor frame. For details, see Test-

ing and adjusting, “How to open and close (tilt)
floor”.
a If the machine has the operator cab, tilt
open the operator cab and floor frame
assembly.
50-200 6 PC45MR-3, PC55MR-3

Removal and installation of hydraulic oil cooler assembly SEN04655-00
9. Disconnect overflow hose (9) and radiator 13. Remove undercover (15) and disconnect radi-
upper hose (10). [*1] ator lower hose (16). [*2]
10. Disconnect air duct (11).

a Place air duct (11) and air hose (12) as an
assembly on a place where they will not
be obstacles.
11. Remove fan guard (13).
12. Remove all the mounting bolts of fan shroud

(14).
a At this time, the shroud cannot be
removed.
14. Disconnect fuel cooler (17).
PC45MR-3, PC55MR-3 50-200 7

SEN04655-00 Removal and installation of hydraulic oil cooler assembly
15. Disconnect 2 hoses (25) and (26).
18. Lift off radiator and hydraulic oil cooler assem-

16. Sling the radiator and hydraulic oil cooler bly (21).
assembly. a When removing the assembly, leave the
fan shroud.
17. Remove 1 each of mounting bolts (18) and a When removing the assembly, take care
(19) and 2 mounting bolts (20). [*3] not to damage the cores.
4 Radiator and hydraulic oil cooler
assembly: 35 kg
19. Remove radiator (23) and hydraulic oil cooler

(24) from shroud (22).
50-200 8 PC45MR-3, PC55MR-3

Removal and installation of hydraulic oil cooler assembly SEN04655-00
Installation

removal.
[*1], [*2]
3 Hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*3]
3 Mounting bolt
(18): 59 – 74 Nm {6 – 7.5 kgm}
(19), (20):
98 – 123 Nm {10 – 12.5 kgm}

5 Coolant: 8.5 l
q Refilling with oil (Hydraulic tank)

a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil
level again.
PC45MR-3, PC55MR-3 50-200 9

SEN04655-00 Removal and installation of engine and hydraulic pump assembly
Removal and installation of 4. Open cover (3) and remove cover (4).
engine and hydraulic pump
assembly 1
Removal

ing residual pressure from hydraulic tank”.
2. Open drain plug (1) to drain the coolant.

6 Coolant: 8.5 l
floor”.
assembly.

7. Remove cover (6) and 2 clamps (7) and move

the 2 heater hoses.
50-200 10 PC45MR-3, PC55MR-3

Removal and installation of engine and hydraulic pump assembly SEN04655-00
8. Remove 2 air cleaner mounting bolts (8). 15. Loosen alternator fixing bolt (15) and belt ten-
sion adjustment bolt (16) to remove alternator
belt (17).
9. Remove guard assembly (9).

4 Guard assembly: 45 kg
16. Remove fan guard (18).
17. Remove all the mounting bolts of fan shroud

(19).
10. Remove air cleaner assembly (10). [*1]

18. Remove fan pulley assembly (20).
12. Disconnect 2 heater hoses (12).
19. Remove fan shroud (19).
13. Disconnect radiator upper hose (13) from the
radiator.
14. Disconnect radiator lower hose (14) from the

water pump.
PC45MR-3, PC55MR-3 50-200 11

20. Disconnect fuel control cable (21).
21. Remove clamp (22).
22. Disconnect fuel hoses (23) and (24).
23. Remove fuel hose mounting clamps (25) and

(26).
27. Disconnect terminal (37) and connector (38)

from the alternator.
28. Remove clamp (39).
24. Disconnect wiring connectors (27) – (30).
29. Disconnect terminals (40) and (41) from the

starting motor.
25. Disconnect wiring connector (31).
26. Remove clamps (32) – (35) and move wiring

(36) toward the canopy.
50-200 12 PC45MR-3, PC55MR-3

30. Remove throttle cable clamp (42) and move 35. Sling the engine and hydraulic pump assem-
the cable aside. bly.
31. Disconnect hydraulic hoses (43) and (44). 36. Disconnect ground cable (51).
37. Remove 4 mounting nuts (52). [*6]
32. Disconnect hydraulic hoses (45) – (48).
33. Disconnect exhaust pipe (49). 38. Lift off engine and hydraulic pump assembly
(53).
a Check for undisconnected wiring and pip-
ing when removing the assembly.
a Take care of interference with the other
parts while removing the assembly.
4 Engine and hydraulic pump assembly:
250 kg
34. Disconnect suction hose and connector

assembly (50) from the hydraulic pump.
PC45MR-3, PC55MR-3 50-200 13

Installation

removal.
[*1]
3 Hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
3 Radiator hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*3]
a Adjust the alternator belt tension. For
details, see Testing and adjusting, “Testing
and adjusting alternator belt tension”.
[*4]
a Adjust the cable tension. For details, see
Testing and adjusting, “Adjusting fuel con-
trol lever”.
[*5]
2 Muffler bracket mounting bolt:
Adhesive (LT-2)
3 Muffler bracket mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
[*6]
2 Mounting nut: Adhesive (LT-2)
3 Mounting nut:
59 – 74 Nm {6 – 7.5 kgm}

5 Coolant: 8.5 l

level again.
5 Hydraulic oil: 20 l (EO10-DH)
q Bleeding air
a Bleed air. For details, see Testing and
adjusting, “Bleeding air from each part”.
50-200 14 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 50-200 15

SEN04655-00

©2008 KOMATSU
All Rights Reserved
50-200 16
SEN04656-00
PC45MR-3,
PC55MR-3


300 Power train
Removal and installation of swing motor and swing machinery assembly ..................................................... 2
Disassembly and assembly of swing motor and swing machinery assembly ................................................. 3
Removal and installation of swing circle assembly ......................................................................................... 8
PC45MR-3, PC55MR-3 50-300 1

300 Power train
SEN04656-00 Removal and installation of swing motor and swing machinery assembly
Removal and installation of swing Installation

motor and swing machinery q Carry out installation in the reverse order to
assembly 1 removal.
Removal [*1]
1. Remove the canopy and floor frame (opera- 3 Mounting bolt:
tor's cab and floor frame) assembly. For 98 – 123 Nm {10 – 12.5 kgm}
details, see “Removal and installation of floor
frame assembly”. q Refilling with oil (Hydraulic tank)
2. Disconnect hoses (1) – (5). level. Run the engine to circulate the oil
level again.
q Bleeding air
3. Remove all the mounting bolts and separate

the swing machinery from the frame, using
forcing screws [1] (2 pieces). [*1]
4. Lift off swing motor and swing machinery

assembly (6).
3 Swing motor and swing machinery
assembly: 45 kg
50-300 2 PC45MR-3, PC55MR-3

300 Power train
Disassembly and assembly of swing motor and swing machinery assembly SEN04656-00
Disassembly and assembly of 2. No. 1 sun gear

swing motor and swing machinery Remove No. 1 sun gear (2).
assembly 1 3. No. 1 planetary carrier and No. 2 sun gear
assembly
Special tools
1) Remove No. 1 planetary carrier and No. 2
sun gear assembly (3).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 796T-126-1210 Wrench t 1 N Q
790-101-5151 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5271 • Plate 1
3
F 790-101-5221 • Grip 1
01010-51225 • Bolt 1
2) Remove snap ring (4), thrust washer (5),
No. 1 planetary gear (6), needle roller
790-101-5331 • Plate 1 bearing (7), spacer (8), and thrust washer
4
790-101-5221 • Grip 1 (9).
01010-51225 • Bolt 1 3) Remove snap ring (10), and then remove
5 796-760-9110 Push tool t 1 No. 1 planetary carrier (11) from No. 2 sun
gear (10a).
6 790-445-3810 Push tool t 1
Disassembly
a Since an oil drain plug is not installed, prepare

an oil pan, etc. to receive oil flowing out of the
case during the disassembly work.
6 Swing machinery case: Approx. 1.3 l
1. Swing motor assembly

Set the swing motor and swing machinery
assembly to blocks [1] and remove swing
motor assembly (1).
PC45MR-3, PC55MR-3 50-300 3

300 Power train
SEN04656-00 Disassembly and assembly of swing motor and swing machinery assembly
4. No. 2 planetary carrier assembly 4) Remove bearing (21) from No. 2 planetary
1) Remove snap ring (12), thrust washer carrier (20).
(13), No. 2 planetary gear (14), needle
roller bearing (15), spacer (16), and thrust
washer (17).
5. Pinion shaft and bearing assembly

Remove bearing (25) and seal (26) from pinion
shaft (24).
2) Using tool F1, remove nut (18)
. 6. Swing machinery case

3) Remove No. 2 planetary carrier and bear- Remove outer races (27) and (28) and oil seal
ing assembly (19). (29) from swing machinery case (22).
a Using a press, etc., push the end of
pinion shaft (24) to remove the No. 2
pinion shaft and bearing assembly.
50-300 4 PC45MR-3, PC55MR-3

300 Power train
Assembly 2. Pinion shaft and bearing assembly

1. Swing machinery case 1) Install seal (26) to pinion shaft (24).
1) Using tool F2, press fit oil seal (29) to 2 Sliding surface of seal:
swing machinery case (22) until it is Grease (G2-LI)

stopped. 2) Using tool F5, press fit bearing (25) to pin-
a Install the oil seal with the spring up. ion shaft (24).
2 Press fitting surface of oil seal: q Press fitting force:
Gasket sealant (LG-6) 7.3 – 19.7 kN {0.74 – 2.0 ton}
a Take care that the gasket sealant will
not stick to the oil seal lip and the slid-
ing part of the shaft.
3) Set swing machinery case (22) to pinion

shaft and bearing assembly (23).
a Fill space (a) between the swing
2) Using tools F3 and F4, press fit outer machinery case and bearing with
races (28) and (27) to the swing machin- grease (G2-LI) to 40 – 60%.
ery case. a Take care not to damage the oil seal.
a Tool F3: Outer race (28)
Tool F4: Outer race (27)
a The figure shows outer race (28).
PC45MR-3, PC55MR-3 50-300 5

300 Power train
SEN04656-00 Disassembly and assembly of swing motor and swing machinery assembly
3. No. 2 planetary carrier assembly 4) Using tool F1, measure the starting torque
1) Using tool F6, press fit bearing (21) to No. of pinion shaft (24) and check that it is in
2 planetary carrier (20). the following range.
q Press fitting force: q Starting torque: Max. 13.2 Nm {1.35
2.94 – 11.18 kN {0.3 – 1.14 ton} kgm}
2) Set No. 2 planetary carrier and bearing 5) Install thrust washer (17), spacer (16),
assembly (19) to pinion shaft (24) and needle roller bearing (15), No. 2 planetary
press fit it with a press, etc. carrier (14), thrust washer (13), and snap
a Turning the case, press fit gradually. ring (12).
2 Spline: Grease (G2-LI) a Check that there is no play in the No.
q Press fitting force: 2 planetary gear.
4.90 – 18.8 kN {0.50 – 1.92 ton}
3) Using tool F1, tighten nut (18).

2 Nut: Adhesive (LT-2)
3 Nut: 392 – 441 Nm {40 – 45 kgm}
50-300 6 PC45MR-3, PC55MR-3

300 Power train
4. No. 1 planetary carrier and No. 2 sun gear 6. Filling with oil
assembly Add power train oil into the swing machinery
1) Install No. 1 planetary carrier (11) to No. 2 case.
5
sun gear (10a), and then install snap ring
Swing machinery case:
(10).
2) Install thrust washer (9), spacer (8), nee- Approx. 1.3 l (TO10)
dle roller bearing (7), No. 1 planetary gear
(6), thrust washer (5), and snap ring (4). 7. Swing motor assembly
a Check that there is no play in the No. Fit the O-ring and install swing motor assembly
1 planetary gear. (1).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
3) Install No. 1 planetary carrier and No. 2

sun gear assembly (3).
5. No. 1 sun gear

Install No. 1 sun gear (2).
PC45MR-3, PC55MR-3 50-300 7

300 Power train
SEN04656-00 Removal and installation of swing circle assembly
Removal and installation of swing Installation

circle assembly 1
Removal removal.
1. Remove the revolving frame assembly. For
details, see “Removal and installation of [*1]
revolving frame assembly”. 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
2. Remove 20 mounting bolts (1). [*1] 98 – 122.5 Nm {10 – 12.5 kgm}
(Target: 112 Nm {11.5 kgm})
3. Install the hanging bolts and lift off swing circle
assembly (2). [*2]
[*2]
4 Swing circle assembly: 65 kg a When installing the swing circle assembly,
set inner race soft zone (a) (mark of S)
and outer race soft zone (b) as shown
below.
2 Inner race tooth surface:
Grease (G2-LI)
50-300 8 PC45MR-3, PC55MR-3

300 Power train
Removal and installation of swing circle assembly SEN04656-00
PC45MR-3, PC55MR-3 50-300 9

SEN04656-00

©2008 KOMATSU
All Rights Reserved
50-300 10
SEN04657-00
PC45MR-3,
PC55MR-3


Removal and installation of track shoe assembly ........................................................................................... 2
Disassembly and assembly of idler assembly ................................................................................................ 3
Disassembly and assembly of recoil spring assembly .................................................................................... 5
Disassembly and assembly of track roller assembly ...................................................................................... 8
Disassembly and assembly of carrier roller assembly .................................................................................... 9
Removal and installation of revolving frame assembly ................................................................................. 10
PC45MR-3, PC55MR-3 50-400 1

SEN04657-00 Removal and installation of track shoe assembly
Removal and installation of track Installation

shoe assembly 1
Removal removal.
1. Swing the upper structure by 180° and raise
the machine by using the work equipment and [*1]
blade. a Adjust the track shoe tension. For details,
see Testing and adjusting, “Testing and
2. Loosen valve (1) to discharge grease and adjusting track shoe tension”.
loosen the track shoe tension. [*1]
k Since valve (1) may jump out because
of the high-pressure grease, do not
loosen it more than 1 turn.
3. Sling track shoe assembly (2) and pull it out

toward this side.
4 Rubber shoe: 190 kg
Double grouser shoe: 290 kg
Triple grouser shoe: 240 kg
Road liner: 290 kg
50-400 2 PC45MR-3, PC55MR-3

Disassembly and assembly of idler assembly SEN04657-00
Disassembly and assembly of

idler assembly 1
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5081 • Plate 1
1
L 790-101-5021 • Grip 1
01010-50816 • Bolt 1
2 791-430-3230 Installer t 1 3. Using tool L2, install floating seals (7) to sup-
ports (3) and (6).
a In this section, only the assembly procedure is a Remove all grease and oil from the con-
explained. tact surface of the O-ring and the floating
seal.
Assembly a Coat the sliding surface of the floating seal
1. Using tool L1, press fit 2 bushings (10) to idler with engine oil (EO30-CD) before install-
(9). ing, and be careful not to let any dirt or
dust stick to it.
2. Using tool L2, install 2 floating seals (8) to idler

(9). 4. Fit O-ring and install shaft (5) to support (6).
a Remove all grease and oil from the con-
tact surface of the O-ring and the floating
seal.
a Coat the sliding surface of the floating seal
with engine oil (EO30-CD) before install-
ing, and be careful not to let any dirt or
dust stick to it.
PC45MR-3, PC55MR-3 50-400 3

SEN04657-00 Disassembly and assembly of idler assembly
5. Install support and shaft assembly (4) to idler.
6. Fill inside of idler with engine oil.

5 Inside portion of idler:
Approx. 20 cc (EO30-CD)
7. Install support (3).

2 Mounting bolt: Thread tightener (LT-2)
8. Install bracket (2).

2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
9. Install cover (1).
50-400 4 PC45MR-3, PC55MR-3

Disassembly and assembly of recoil spring assembly SEN04657-00

recoil spring assembly 1
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
M 792-371-1400 Sleeve t 1
Disassembly
1. Piston
1) Remove valve (1).
2) Remove piston (2).
3) Release the hydraulic pressure slowly and

allow spring to extend, then remove stop-
per (5) and spring (6) from cylinder
assembly (7).
a Free length of spring: 302 mm
2. Recoil spring
1) Using tool M, set recoil spring to press.
k The recoil spring is under large
installed load, so be sure to set the
tool properly. Failure to do this is
dangerous.
2) Apply hydraulic pressure slowly to com-
press spring, then remove screw (3) and
remove nut (4).
a Compress the spring to a point where
the nut becomes loose.
a Installed load of spring:
Rubber shoe specification:
42.4 kN {4,326 kgm}
Steel, road liner specification:
26.9 kN {2,748 kgm}
PC45MR-3, PC55MR-3 50-400 5

SEN04657-00 Disassembly and assembly of recoil spring assembly
3. Cylinder Assembly
1) Remove snap ring (8), then remove 1. Cylinder
spacer (9) from cylinder (10). 1) Install O-ring (12) and backup ring (13) to
2) Remove dust seal (11). cylinder (10).
3) Remove O-ring (12) and backup ring (13). 2) Install dust seal (11).
3) Fit spacer (9) and secure with snap ring
(8).
2. Recoil spring
1) Assemble cylinder assembly (7), spring
(6), and stopper (5).
50-400 6 PC45MR-3, PC55MR-3

Disassembly and assembly of recoil spring assembly SEN04657-00
2) Using tool M, set recoil spring to press. a After assembling the recoil spring, check
k The recoil spring is under large that the out-of-parallel between surface
installed load, so be sure to set the (a) of cylinder (7) and surface (b) of stop-
tool properly. Failure to do this is per (5) is less than 0.5 mm.
dangerous.
3) Apply hydraulic pressure slowly to com-
press spring, then fit nut (4) and install
screw (3).
a Installed height of spring:
Rubber shoe specification: 202.2 mm
238.2 mm
a Installed load of spring:
Rubber shoe specification:
42.4 kN {4,326 kgm}
26.9 kN {2,748 kgm}
3. Piston
1) Tighten plug (1) temporarily.
a Grease will come out from grease
hole (c), so tighten completely, then
turn back approx. 2 turns.
2) Add approx. 120 cc of grease (G2-LI)
inside cylinder.
3) Assemble cylinder (2) and push in until
grease comes out from grease hole (c).
4) When grease comes out, tighten valve (1).
a After tightening the valve, check that
the grease fitting is facing the outside
(just beside) of the chassis.
PC45MR-3, PC55MR-3 50-400 7

SEN04657-00 Disassembly and assembly of track roller assembly
Disassembly and assembly of track 3. Set floating seal (4) in collars (1) and (2) by
roller assembly 1 using tool L4.
a Clean the O-ring and the O-ring contact
Special tools surface to degrease completely and dry
them.
a Apply engine oil (EO30-CD) to the floating
New/Remodel
Symbol
seal sliding surface and keep it free from
Necessity
Part No. Part name
dust.
Sketch
Q'ty
790-101-5081 • Plate 1
3
L 790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 791-430-3230 Installer t 1
a In this section, only the assembly procedure is

explained.
Assembly
1. Press fit two pieces of bushing (7) in roller (6)
using tool L3.
4. Set the O-ring and install shaft (3) in the roller.
5. Set collar (2) on the roller and fix it with a snap

ring.
6. Fill engine oil in the roller.

5 Roller inside:
Approx. 135 cc (EO30-CD)
7. Set collar (1) on the roller and fix it with a snap

ring.
2. Set two pieces of floating seal (5) in roller (6)

using tool L4.
a Clean the O-ring and the O-ring contact
surface to degrease completely and dry
them.
a Apply engine oil (EO30-CD) to the floating
seal sliding surface and keep it free from
dust.
50-400 8 PC45MR-3, PC55MR-3

Disassembly and assembly of carrier roller assembly SEN04657-00
Disassembly and assembly of 3. Fill the inside of the roller with grease.
3 Inside portion of roller:
carrier roller assembly 1
Approx. 30 cc of grease (Shell Alvania
Special tools Grease EP-2 or equivalent)
New/Remodel
4. Install shaft (3) to roller.
Symbol
Necessity
Part No. Part name
5. Using snap ring pliers, install snap ring (2).
Sketch
a Install the snap ring so that the edge on
Q'ty
the inside faces the tip of the shaft.
790-101-5081 • Plate 1
5
790-101-5021 • Grip 1
01010-50816 • Bolt 1
L
790-101-5111 • Plate 1
6
790-101-5021 • Grip 1
01010-50816 • Bolt 1
a In this section, only the assembly procedure is

explained.
Assembly
1. Using tool L5, press fit 2 ball bearings (6) to
roller (5). 6. Using tool L5, press fit cap (1).
2 Fill the ball portion of the bearing with a Cap press-fitting depth (a): 10 mm
grease (Shell Alvania Grease EP-2 or
equivalent).
2. Using tool L6, press fit dust seal (4) to roller

(5).
PC45MR-3, PC55MR-3 50-400 9

SEN04657-00 Removal and installation of revolving frame assembly
Removal and installation of 5. Sling the revolving frame assembly temporarily

revolving frame assembly 1 and remove mounting bolts (13). [*3]
a Leave 2 bolts each on the front and rear
Removal sides.
1. Remove the work equipment. For details, see
“Removal and installation of work equipment
assembly”.
2. Remove the canopy and floor frame (opera-

tor's cab and floor frame) assembly. For
details, see “Removal and installation of floor
frame assembly”.
3. Pull out pin (1) and remove boom cylinder

assembly (2). [*1]
4 Boom cylinder: 45 kg
6. Remove the remaining mounting bolts and lift

off revolving frame assembly (14).
a Balancing the revolving frame assembly
with lever blocks, etc., remove the remain-
ing mounting bolts.
a When removing the revolving frame
assembly, check that all the pipes have
been disconnected and take care not to
damage the center swivel joint.
4 Revolving frame assembly: 1,850 kg
4. Disconnect the hoses from the center swivel

joint and remove the lever. [*2]
q Hoses (3) – (11) and lever (12)
50-400 10 PC45MR-3, PC55MR-3

Removal and installation of revolving frame assembly SEN04657-00
Installation

removal.
[*1]
k When aligning the pin holes, never
insert your fingers in them.
2 Sliding surfaces of pin and swing
bracket:
Molybdenum disulfide grease (LM-P)
2 Greasing after installation:
Grease (Hyper white grease)
[*2]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
2 Revolving frame assembly mounting
bolt: Adhesive (LT-2)
3 Revolving frame assembly mounting
bolt: 117.6 – 137.2 Nm {12 – 14 kgm}

level again.
q Bleeding air
PC45MR-3, PC55MR-3 50-400 11

SEN04657-00

©2008 KOMATSU
All Rights Reserved
50-400 12
SEN04658-00
PC45MR-3,
PC55MR-3


500 Hydraulic system
Removal and installation of center swivel joint assembly ............................................................................... 2
Disassembly and assembly of center swivel joint assembly........................................................................... 4
Removal and installation of work equipment pump assembly ........................................................................ 8
Disassembly and assembly of control valve assembly ................................................................................. 10
Disassembly and assembly of hydraulic cylinder assembly ..........................................................................11
PC45MR-3, PC55MR-3 50-500 1

SEN04658-00 Removal and installation of center swivel joint assembly
Removal and installation of center 5. Disconnect hoses (7) – (15).

swivel joint assembly 1
6. Remove lever (16) from the center swivel joint.
Removal [*1]


floor”.
k Disconnect the cable from the negative
(–) terminal of the battery.
3. Remove left side cover (1).
7. Disconnect hoses (17) – (24).
4. Remove connector (2) from the bracket and

remove cover (3).
50-500 2 PC45MR-3, PC55MR-3

Removal and installation of center swivel joint assembly SEN04658-00
8. Disconnect hoses (25) and (26). Installation

9. Remove elbow (27) and the center swivel joint q Carry out installation in the reverse order to
assembly. removal.
[*1]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
153 – 190 Nm {15.5 – 19.5 kgm}

level again.
q Bleeding air
a Bleed air. For details, see Testing and adjust-
ing, “Bleeding air from each part”.
PC45MR-3, PC55MR-3 50-500 3

SEN04658-00 Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of 4. Remove dust seal (6), 3 plugs (7), and 4 plugs
center swivel joint assembly 1 (8) from swivel shaft (5).
5. Remove ring (10), O-ring (11), backup ring

Applicable machine model: PC45MR-3 (12), and 7 slipper seals (13) from rotor (9).
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
Disassembly
1. Remove bolts (1) and plate (2).
2. Remove O-ring (3) and snap ring (4).
3. Using tool T, pull rotor (9) out of swivel shaft (5)
50-500 4 PC45MR-3, PC55MR-3

Disassembly and assembly of center swivel joint assembly SEN04658-00
Assembly
1. Install O-ring (11), backup ring (12), and 7 slip-
per seals (13) to rotor (9).
2. Install dust seal (6) to swivel shaft (5).

2 Dust seal lip: Grease (G2-LI)
3. Install 3 plugs (7) and 4 plugs (8) to swivel

shaft (5).
a Degrease, clean, and dry the threaded
parts sufficiently.
a After installing, check that the plug ends
are lower than the shaft end.
3 Plug (8): 32 ± 13 Nm {3.3 ± 1.3 kgm}
4. Set swivel shaft (5) to the block. Using the

push tool and hitting with a plastic hammer,
etc., install rotor (9).
a Take care extremely not to damage the
slipper seals and O-ring.
2 Contact surfaces of rotor and swivel
shaft: Grease (G2-LI)
5. Install ring (10), snap ring (4), and O-ring (3).
6. Install plate (2).

3 Mounting bolt (1) :
66 ± 7 Nm {6.7 ± 0.7 kgm}
PC45MR-3, PC55MR-3 50-500 5

SEN04658-00 Disassembly and assembly of center swivel joint assembly
Applicable machine model: PC55MR-3 4. Remove dust seal (6), plug (7), and 4 plugs (8)
from swivel shaft (5).
Special tools
New/Remodel
5. Remove ring (10), O-ring (11), and 8 packings
Symbol
(13) from rotor (9).
Necessity
Part No. Part name
Sketch
Q'ty
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
Disassembly
1. Remove bolts (1) and plate (2).
2. Remove O-ring (3) and snap ring (4).
3. Using tool T, pull rotor (9) out of swivel shaft (5)
50-500 6 PC45MR-3, PC55MR-3

Disassembly and assembly of center swivel joint assembly SEN04658-00
Assembly
1. Install O-ring (11) and 8 packings (13) to rotor
(9).
2. Install dust seal (6) to swivel shaft (5).

2 Dust seal lip: Grease (G2-LI)
3. Install 1 plug (7) and 4 plugs (8) to swivel shaft

(5).
a Degrease, clean, and dry the threaded
parts sufficiently.
a After installing, check that the plug ends
are lower than the shaft end.
3 Plug (7):
16.8 – 22.6 Nm {1.71 – 2.3 kgm}
3 Plug (8):
16.7 – 24.5 Nm {1.7 – 2.5 kgm}
4. Set swivel shaft (5) to the block. Using the

push tool and hitting with a plastic hammer,
etc., install rotor (9).
a Take care extremely not to damage the
slipper seals and O-ring.
2 Contact surfaces of rotor and swivel
shaft: Grease (G2-LI)
5. Install ring (10), snap ring (4), and O-ring (3).
6. Install plate (2).

3 Mounting bolt (1) :
39.2 – 49 Nm {4 – 5 kgm}
PC45MR-3, PC55MR-3 50-500 7

SEN04658-00 Removal and installation of work equipment pump assembly
Removal and installation of work 5. Remove cover (4).

equipment pump assembly 1
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
S 796T-13S-1010 Torque adapter q 1 N Q
Removal
1. Release the pressure inside the hydraulic tank. 6. Remove throttle cable clamp (5) and move the
For details, see Testing and adjusting, “Releas- cable aside.
7. Disconnect hydraulic hoses (6) and (7).
8. Disconnect hydraulic hoses (8) – (11).
3. Tilt open floor frame (2). For details, see Test-

floor”.
assembly.
50-500 8 PC45MR-3, PC55MR-3

Removal and installation of work equipment pump assembly SEN04658-00
9. Disconnect suction hose and connector Installation

assembly (12) from the hydraulic pump.
removal.

level again.
6 Hydraulic oil: 20 l (EO10-DH)
q Bleeding air
a Bleed air. For details, see Testing and adjust-
ing, “Bleeding air from each part”.
10. Sling work equipment pump assembly (13) and
remove the 4 work equipment pump mounting
bolts with tool S.
11. Lift off work equipment pump assembly (13).
PC45MR-3, PC55MR-3 50-500 9

SEN04658-00 Disassembly and assembly of control valve assembly

control valve assembly 1
In this section, only the precautions for assembling

the control valve assembly are explained.
a Work in a clean indoor place where there is no

dirt and dust.
a Clean the parts in clear solvent, and then dry

them with compressed air.
a Replace a part having burrs with new one.
a Coat the sliding surfaces of each part with

engine oil before installing.
a Take care of the installed direction of each

spool.
a When tightening the plug of each spool, apply

a drop (about 0.02 g) of LOCTITE (No. 638) or
equivalent to it.
a Apply Sealend 242 or equivalent to the mating

faces.
a For tightening torque of each part, see Struc-

ture, function and maintenance standard,
“Control valve”.
50-500 10 PC45MR-3, PC55MR-3

Disassembly and assembly of hydraulic cylinder assembly SEN04658-00
Disassembly and assembly of a In this section, only the precautions for disas-
hydraulic cylinder assembly 1 sembly are described.
Special tools Disassembly

a When removing arm cylinder head (11) from
New/Remodel
cylinder (3), flatten the cylinder head side of
Symbol
Necessity
Part No. Part name washer (25) and washer caulking part (a) on
Sketch
the cylinder side.
Q'ty
790-502-1003 Cylinder repair stand t 1
1
790-101-1102 Hydraulic pump t 1
2 790-330-1100 Wrench assembly t 1
Commercially
available
Socket (Width across
flats: 41 mm) t 1
Commercially
available
flats: 46 mm) t 1
Socket
790-302-1390 (Width across flats: t 1
46 mm, long type)
3
790-302-1270
flats: 50 mm) t 1
Socket
50 mm, long type)
790-302-1280 Socket (Width across

flats: 55 mm) t 1
Socket
55 mm, long type)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
U 4
790-201-1731 • Push tool 1
790-201-1751 • Push tool 1
790-201-1741 • Push tool 1
790-201-1761 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 790-201-1540 • Plate 1
790-201-1560 • Plate 1
790-201-1550 • Plate 1
790-201-1570 • Plate 1
6 790-720-1000 Expander q 1
796-720-1640 Ring q 1
07281-00909 Clamp q 1
796-720-1740 Ring q 1
7
07281-00809 Clamp q 1
796-720-1650 Ring q 1
07281-01029 Clamp q 1
PC45MR-3, PC55MR-3 50-500 11

SEN04658-00 Disassembly and assembly of hydraulic cylinder assembly
Assembly 3. Cylinder head assembly

a The contents of this section are common to all 1) Using tool U4, press fit bushing (20) to cyl-
the cylinders, unless otherwise specified. inder head (14).
a Take care not to damage the packings, dust a Except boom cylinder
seals, O-rings, etc. 2) Using tool U5, press fit dust seal (18).
a Clean each part thoroughly. After assembling,
close the piping ports and pin inserting holes
so that dirt will not enter them.
a Do not insert each backup ring forcibly, but
warm it in water at 50 – 60°C and then insert it.
1. Cylinder
1) Press fit bushing (24) to cylinder (3).
2) Press fit 2 dust seals (23) to cylinder (3).
3) Using snap ring pliers, install snap ring

(17).
4) Install rod packing (19).
5) Install O-ring (15) and backup ring (16).
2. Piston rod
1) Press fit bushing (22) to piston rod (6).
2) Press fit 2 dust seals (21).
6) Install O-ring (12) and 2 backup rings (13).

a Boom cylinder only
50-500 12 PC45MR-3, PC55MR-3

7) Fit O-ring and install cylinder head assem- 4. Piston assembly

bly (11) to piston rod (6). 1) Install cushion plunger (10) to piston rod
(6).
a Boom cylinder only
2) Install piston ring (9) to piston (8).

3) Using tool U7, compress piston ring (9).
4) Install wear ring (7).
5) Install piston assembly (5) to piston rod

(6).
PC45MR-3, PC55MR-3 50-500 13

SEN04658-00 Disassembly and assembly of hydraulic cylinder assembly
6) Set piston rod assembly (2) to tool U1. 5. Piston rod assembly
7) Using tool U3, install piston nut (4). 1) Install piston rod assembly (2) to cylinder
a Width across flats of piston nut: (3).
(Unit: mm)
Model Boom Arm Bucket Swing
PC45MR-3 50 55 50 55
PC55MR-3 50 65(*) 50 55
a Use long-type sockets for the nuts

marked with *.
2 Piston nut: Thread tightener
(Loctite 262 or equivalent)
3 Piston nut:
(Unit: kNm {kgm})
Model Boom Arm Bucket
1.25 ± 0.13 1.67 ± 0.17 1.08 ± 0.11
PC45MR-3
{127 ± 12.7} {170 ± 17.0} {110 ± 11.0}
1.25 ± 0.13 2.30 ± 0.23 1.08 ± 0.11
PC55MR-3
{127 ± 12.7} {235 ± 23.5} {110 ± 11.0} 2) Set cylinder assembly (1) to tool U1.
3) Apply gasket sealant to the cylinder head
end (mating face to the lock washer).
(Arm cylinder only)
a Apply a string of gasket sealant about
1 mm in diameter around the surface
to be coated.
2 Cylinder head end face:
Gasket sealant (Threebond 1211)
4) Apply gasket sealant to the cylinder tube
mating face of the lock washer.
(Arm cylinder only)
a Apply a string of gasket sealant about
1 mm in diameter around the surface
to be coated.
2 Cylinder tube mating face of lock
washer:
Gasket sealant (Threebond 1211)
5) Install the rod subassembly and cylinder
tube and tighten them lightly and wipe off
the projected gasket sealant with a cloth.
(Arm cylinder only)
6) Using tool U2, tighten cylinder head.
3 Cylinder head:
(Unit: Nm {kgm})
Model Boom Arm Bucket
736 ± 73.6 785 ± 78.5 785 ± 78.5
PC45MR-3 {75 ± 7.5} {80 ± 8.0} {80 ± 8.0}
PC55MR-3 736
± 73.6 961 ± 96.1 863 ± 86.5
{75 ± 7.5} {98 ± 9.8} {88 ± 8.8}
50-500 14 PC45MR-3, PC55MR-3

7) After tightening to the specified torque,

bend 1 place each on the cylinder head
side and cylinder side.
(Arm cylinder only)
a Bending distance (t): Min. 2 mm
a Do not reuse a used lock washer.
6. Piping
Install cylinder piping.
3 Sleeve nut
Boom cylinder:
84 – 123 Nm {8.5 – 12.5 kgm}
Arm cylinder:
128 – 172 Nm {13 – 17.5 kgm}
Bucket cylinder:
84 – 123 Nm {8.5 – 12.5 kgm}
PC45MR-3, PC55MR-3 50-500 15

SEN04658-00

©2008 KOMATSU
All Rights Reserved
50-500 16
SEN04659-00
PC45MR-3,
PC55MR-3


600 Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC45MR-3, PC55MR-3 50-600 1

600 Work equipment
SEN04659-00 Removal and installation of work equipment assembly
Removal and installation of work 3. Sling boom cylinder (10) temporarily and
equipment assembly 1 remove the plate and head-side pin (11). [*1]
a Lower the boom cylinder onto a block, etc.
k Release the residual pressure in the hydrau-
lic circuit. For details, see Testing and adjust-
ing, “Releasing residual pressure from
hydraulic circuit.”
k Extend the boom cylinder and bucket cylin-
der to the stroke end and lower the work
equipment to the ground.
k Set the work equipment lock lever in the
LOCK position.
Removal
1. Disconnect connector (1) and remove the wir-
ing harness from the boom.
4. Sling the work equipment assembly tempo-

rarily.
5. Remove boom foot pin (12). [*2]
2. Disconnect 8 hoses (2) – (9).
6. Lift off work equipment assembly (13).

4 Work equipment assembly: 480 kg
50-600 2 PC45MR-3, PC55MR-3

600 Work equipment
Removal and installation of work equipment assembly SEN04659-00
Installation

removal.
[*1]
kWhen aligning the pin holes, never
2 Sliding surfaces of pin and boom:
Molybdenum disulfide grease (LM-G)
a Adjust clearance “a” between boom cylin-
der head (14) and boom (15) to 1 mm or
less with the shim.
q Set shim thickness: 1 mm
[*2]
kWhen aligning the pin holes, never
2 Sliding surfaces of pin and swing
bracket:
Molybdenum disulfide grease (LM-G)
• Refilling with oil (Hydraulic tank)

level again.
• Bleeding air
PC45MR-3, PC55MR-3 50-600 3

SEN04659-00

©2008 KOMATSU
All Rights Reserved
50-600 4
SEN04660-00
PC45MR-3,
PC55MR-3


Removal and installation of operator’s cab glass (stuck glass) ...................................................................... 2
Removal and installation of front window assembly ......................................................................................11
Removal and installation of floor frame assembly (Canopy specification) .................................................... 12
Removal and installation of operator cab and floor frame assembly (Operator cab specification) ............... 15
PC45MR-3, PC55MR-3 50-700 1

SEN04660-00 Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of operator’s cab glass (stuck glass) 1
a On the 5 faces of the operator's cab, including (1) Right sash window glass assembly
the ceiling, panes (1) – (9) are stuck. (Ceiling (2) Right front lower triangular window glass
(9) is a clear plate.) (3) Right rear window glass
a When replacing front window glass (8), remove (4) Rear window glass
front window assembly. (It is impossible to (5) Left rear window glass
replace only the front window glass while the (6) Door upper window glass
front window assembly is installed to the oper- (7) Door lower window glass
ator’s cab.) (8) Front window glass
a For the procedure for replacing the front win- (9) Clear plate
dow assembly, see “Removal and installation (10) Double-sided adhesive tape
of front window assembly”. (11) Center trim seal
50-700 2 PC45MR-3, PC55MR-3

Removal and installation of operator’s cab glass (stuck glass) SEN04660-00
a Precautions for removing and installing (The figure shows the operator's cab
glass of a wheel loader.)
q When removing and installing the glass,
be sure to put on protective goggles.
q When using primer or degreasing solvent,
take care of fire and ventilation extremely.
q If a shock is given to an edge of the glass,
the glass is broken easily. Handle the
glass with care.
q If primer, caulking material, or adhesive
gets in your eye, wash your eye with much
water, and then consult an eye doctor.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name a If the window glass is broken finely, it may
Sketch
be removed with knife [4] and a screw-
Q'ty
driver.
X 2 793-498-1210 Lifter (Suction cup) t 2 a Widening the cut with a screwdriver, cut
the adhesive and double-sided adhesive
Removal tape with knife [4].
a Remove the window glass to be replaced
according to the following procedure. (The figure shows the operator's cab of a
wheel loader.)
1. Using seal cutter [1], cut the adhesive between
broken window glass (12) and operator's cab
(metal sheet) (13).
2. Remove the window glass.
a When seal cutter is not available

1) Make holes on the adhesive and double-
sided adhesive tape with a drill and pass a
fine wire (piano wire, etc.) [2] through the
holes.
2) Grip both ends of the wire with pliers [3],
etc. (or hold them by winding them onto
something) and move the wire to the right
and left to cut the adhesive and double-
sided adhesive tape.
a Since the wire may be broken by the
frictional heat, apply lubricant to it.
PC45MR-3, PC55MR-3 50-700 3

Installation 3. Apply primer (15).

1. Using a knife and scraper [5], remove the a Since the primer has a large effect on the
remaining adhesive and double-sided adhe- adhesion of the glass, never apply a
sive tape from the metal sheets (glass sticking wrong primer. If you have applied a wrong
surfaces) of the operator's cab. primer by mistake, wipe it off with cleaning
a Remove the adhesive and double-sided solvent.
adhesive tape to a degree that they will a The using limit of primer is 4 months after
not affect adhesion of the new adhesive. the date of manufacture. Do not use
Take care not to scratch the painted sur- primer after this limit.
faces. (If the painted surfaces are a Use the primer within 2 hours after
scratched, adhesion will be lowered.) unpacking it.
a Even if the primer is packed again just
(The figure shows the operator's cab of a after it is unpacked, use it within 24 hours
wheel loader.) after it is unpacked for the first time. (Dis-
c a r d t h e p r i m e r 2 4 h o u r s a ft e r i t i s
packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accordingly,
leave the primer at the room tempera-
ture for a sufficient time.)
2) When reusing primer brush (16), wash it in
white gasoline.
2. Remove oil, dust, dirt, etc. from the sticking a After washing the brush, check it
surfaces of operator’s cab (13) and window again for dirt and foreign matter.
glass (14) with white gasoline. a Prepare respective brushes for the
a If the sticking surfaces are not cleaned paint primer and glass primer.
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
50-700 4 PC45MR-3, PC55MR-3

3) Evenly apply paint primer to the surfaces 4) Evenly apply glass primer to the sticking
to stick double-sided adhesive tapes (10) surfaces of window glass (14).
and the surfaces out of those surfaces on 2 Glass primer:
operator's cab (13) which will be coated SUNSTAR GLASS PRIMER 435-41
with the adhesive. a Do not apply the primer more than 2
2 Paint primer: times. (If it is applied more than 2
SUNSTAR PAINT PRIMER 435-95 times, its performance will be low-
a Do not apply the primer more than 2 ered.)
times. (If it is applied more than 2
times, its performance will be low-
ered.)
a Parts to be coated with primer: Apply

the primer to the sticking surfaces of
window glass (14) and all over dimen-
a Parts to be coated with primer: Apply sion (b) which will be on double-sided
the primer all over dimension (a). adhesive tape (10) and operator's cab
q Dimension to apply primer (a): 25 mm (13).
a Do not apply the primer to the
boarder about 5 mm wide between
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a After applying the primer, leave it for at

least 5 minutes (within 8 hours) to dry.
PC45MR-3, PC55MR-3 50-700 5

4. Stick double-sided adhesive tape (10) along Sliding sash

the inside edge of the glass sticking section. a Install the double-sided adhesive tape along
a The double-sided adhesive tape is used to the periphery of the sticking face of the sash.
stop the adhesive from flowing out, finish
the appearance neatly, apply the adhesive
evenly and stabilize its strength, and pro-
tect the glass until the adhesive is set.
a The double-sided adhesive tape is classi-
fied into 2 types by the sectional dimen-
sions. Use those types according to the
following table.
Double-sided Sectional size of double-

adhesive tape sided adhesive tape
For general use 5 mm thick × 7 mm wide
For front sash 5 mm thick × 5 mm wide

Sheet metal part
a Do not remove the release tape of the a Install the double-sided adhesive tape along
double-sided adhesive tape on the glass the edge of the sheet metal part.
sticking side before sticking the glass.
a When sticking the double-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take that the double-sided adhesive tape
will not float at each corner of the window
frame.
Pipe
a Install the double-sided adhesive tape from the
end of the round part of each corner of the
pipe.
a When sticking double-sided adhesive tape

around a frame, do not lap its finishing end
over the starting end, or you may make a
clearance of about 5 mm between them.
a Referring to the following, install the dou-
ble-sided adhesive tape to each glass
sticking part.
50-700 6 PC45MR-3, PC55MR-3

Front sash (Glass sticking side) 5. Apply adhesive.

q Right and left frames a The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
1) Break aluminum seal (18) of the outlet of
adhesive cartridge (17) and install the
nozzle.
q Bottom frame
q Dimension (c): 2.4 mm
2) Cut the tip of the adhesive nozzle (19) so

that dimensions (q) and (r) will be as fol-
lows.
q Dimension (q): 10 mm
q Dimension (r): 15 mm
Door (Glass sticking side)
a Install the double-sided adhesive tape along
the outer end of the door.
q (d): Inner, (e): Outer
PC45MR-3, PC55MR-3 50-700 7

3) Set adhesive cartridge (17) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
6. Install the sliding sash assembly.

1) Clean the sash sticking face on the cab
side and the sash flange sticking face with
cleaning solvent according to steps 1 and
4) Remove the release tape of the double- 2 above.
sided adhesive tape on the glass side. 2) Apply the primer according to step 3
5) Apply adhesive (20) to the outside of dou- above.
ble-sided adhesive tape (10) of the opera- a Use the right primer for the right sash.
tor's cab. a When sash has metallic shine:
2 Adhesive: Primer: SUNSTAR PRIMER GP-402
SUNSTAR PENGUINE SUPER 560 for sash
a When sash is painted black and does
not have metallic shine:
Primer: SUNSTAR PRIMER 435-95
for painted surface
a Do not apply the primer to the follow-
ing water draining area.
3) Install the double-sided adhesive tape
according to step 4 above.
a To drain water from around the sash,
avoid installing double-sided adhe-
sive tape (10) of the bottom side to
the area of dimension (v).
q Dimension (u): 150 mm, (v): 50 mm
a Apply adhesive (20) to dimensions (s)

and (t) of double-sided adhesive tape
(10) of operator's cab (13).
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (20) higher than dou-
ble-sided adhesive tape (10).
a Apply the adhesive evenly.
50-700 8 PC45MR-3, PC55MR-3

4) Apply the adhesive according to step 5 (The figure shows the operator's cab of
above. PC200-7.)
a Do not apply the adhesive to the
above water draining area.
5) Install sliding sash assembly (1) to opera-
tor's cab (13).
a Press the sash assembly firmly to
eliminate clearance from its periph-
ery.
a If the adhesive is projected, wipe it off
immediately before it is set.
a Make a clearance of the following

dimension in each corner joint of the
rear glass and fix the joint with caulk-
ing material (21).
q Dimension (w): 3 mm
2 Caulking material:
GE TOSHIBA SILICONE TOSSEAL
381
6) After installing the sliding sash assembly,

fix it with bands, etc. for about 10 hours.
7. Install the window glass and clear plate.

1) Clean the glass sticking face on the cab
side and the sticking face of the glass with
cleaning solvent according to steps 1 and
2 above.
2) Apply the primer according to step 3
above.
3) Install the double-sided adhesive tape
according to step 4 above.
4) Apply the adhesive according to step 5
above. 7) After sticking the glass, fix it with bands,
5) Stick the glass to the cab. etc. for about 10 hours.
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
6) After sticking the window glass, press all
around it until it is stuck to the double-
sided adhesive tape.
a Press the corners of the window glass
firmly, in particular.
a You can perform this work efficiently
by pulling the window glass from
inside of the operator's cab with lifter
X2.
PC45MR-3, PC55MR-3 50-700 9

8. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
a After installing front window glass (8),
install the center trim seal to its bot-
tom.
a When caulking, neatly arrange the
form of the adhesive at the right and
left ends with a rubber spatula.
2 Adhesive:
Sikaflex 256HV manufactured by
Sika Japan
a Apply caulking material all around the

glass to fill part (x) between the glass
and center trim seal.
50-700 10 PC45MR-3, PC55MR-3

Removal and installation of front window assembly SEN04660-00
Removal and installation of front 4. Remove bolts (4) and separate pull-up link (5)
window assembly 1 from the sash and set it up toward the ceiling.

and stop the engine.
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab. The procedure for removing
and installing the front window assembly (front
frame and front window glass) is explained
below.
Removal
1. Lower the front window assembly.
2. Remove wiper motor (1) and wiper blades (2). 5. Holding the handle, release the latch and
a Remove the coiled cable for the wiper remove the front window assembly (6).
from the sash and secure it in the opera-
tor's cab.
Installation
3. Remove rollers (3) (right and left) from the bot-
tom of the sash. q Carry out installation in the reverse order to
removal.
PC45MR-3, PC55MR-3 50-700 11

SEN04660-00 Removal and installation of floor frame assembly (Canopy specification)
Removal and installation of floor 2) Tilt up the floor frame.

frame assembly For details, see Testing and adjusting,
“How to open and close (tilt) floor”.
(Canopy specification) 1 3) Sling canopy (22) temporarily, and remove
8 mounting bolts (23).
Removal
1. Release the air pressure in the hydraulic tank.

2. Remove floor mat (1) and bar (2).
4) Lift off canopy (22).

4 Canopy assembly: 90 kg
3. Remove canopy according to the following pro-

cedure.
1) Remove roof (3).
50-700 12 PC45MR-3, PC55MR-3

Removal and installation of floor frame assembly (Canopy specification) SEN04660-00
5. Disconnect 4 work equipment PPC hoses (5) – 9. Disconnect connectors (12) – (15) at the front
(8). [*1] of the revolving frame.
6. Pull out fuel controller cable (9) disconnected 10. Sling the floor frame assembly.
from the e ngin e toward th e front of the
machine. [*2] 11. Disconnect wire (16) from the floor frame.
a Record the route of the cable.
12. Loosen 2 bolts (17) gradually and alternately to
7. Disconnect 4 travel PPC hoses (11). [*3] disconnect damper (18).
a Hose identification marks:
Right front: Black/Yellow
Right rear: Yellow/Green
Left front: Yellow/Brown
Left rear: Yellow/Orange
8. Disconnect 2 swing PPC hoses (10). [*4]

Right side: Blue/White
Left side: Red/White
13. Pull out pin (19).
14. Remove right and left bolts (20) and pull out
pin (21). [*5]
PC45MR-3, PC55MR-3 50-700 13

SEN04660-00 Removal and installation of floor frame assembly (Canopy specification)
15. Lift off floor frame assembly (22). Installation

a Check for undisconnected wiring and pip-
ing when removing the assembly. q Carry out installation in the reverse order to
a Take care of the balance while removing removal.
the assembly.
4 Floor frame assembly: 290 kg [*1]
a When connecting, check the identification
colors.
[*2]
trol lever”.
[*3], [*4]
marks and colors.
[*5]
k Do not insert your finger when positioning.

level again.
50-700 14 PC45MR-3, PC55MR-3

Removal and installation of operator cab and floor frame assembly (Operator cab specification) SEN04660-00
Removal and installation of 4. Disconnect the hoses according to the follow-

operator cab and floor frame ing procedure.
1) Tilt open operator cab and floor frame
assembly assembly (1). For details, see Testing and
(Operator cab specification) 1 adjusting, “How to open and close (tilt)
floor”.
Removal 2) Open and lock cover (2).
k Stop the machine on a level place, lower 3) Remove cover (3).
the work equipment to the ground, and set
the work equipment lock lever in the LOCK
position.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance. (Machine with air conditioner)
a Ask professional traders for collecting and fill-
4) Disconnect heater hose (4) and air condi-
ing operation of refrigerant (R134a).
tioner tube (5).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person. (Machine
with air conditioner)
1. Collect the refrigerant from the air conditioner

circuit. [*1]
(Machine with air conditioner)
2. Drain the coolant. [*2]
6 Coolant: 8.5 l

PC45MR-3, PC55MR-3 50-700 15

SEN04660-00 Removal and installation of operator cab and floor frame assembly (Operator cab specification)
6. Disconnect 4 work equipment PPC hoses (7) – 10. Disconnect connectors (14) – (17) at the front
(10). of the revolving frame.
7. Pull out fuel controller cable (11) disconnected 11. Sling the floor frame assembly.
from the engin e toward th e front of the
machine. [*4] 12. Disconnect wire (18) from the floor frame.
a Record the route of the cable.
13. Loosen 2 bolts (19) gradually and alternately to
8. Disconnect 4 travel PPC hoses (12). [*5] disconnect damper (20).
Right front: Black/Yellow
Right rear: Yellow/Green
Left front: Yellow/Brown
Left rear: Yellow/Orange
9. Disconnect 2 swing PPC hoses (13). [*6]

Right side: Blue/White
Left side: Red/White
50-700 16 PC45MR-3, PC55MR-3

Removal and installation of operator cab and floor frame assembly (Operator cab specification) SEN04660-00
14. Disconnect washer hose (21). Installation

a Pull out the washer hose about 3 cm from
the cabin frame and bind it with a string q Carry out installation in the reverse order to
etc. so that it will not return into the frame. removal.
15. Pull out pin (22). [*1]

a Charge the air conditioner circuit with
16. Remove right and left bolts (23) and pull out refrigerant (air conditioner gas: R134a).
pin (24). [*7] Charging capacity of refrigerant (Air condi-
tioner gas: R134a): 550 ± 50 g
[*2]
6 Coolant 8.5 l
[*3]
a Apply compressor oil (ND-OIL8) to the
threaded part of each refrigerant pipe and
tighten the pipe with double spanner.
3 M16 x 1.5 thread of tube:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
M24 x 1.5 thread of tube:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
17. Lift off operator cab and floor frame assembly
(25). [*4]
a Check for undisconnected wiring and pip- a When connecting, check the identification
ing when removing the assembly. colors.
a Take care of the balance while removing
the assembly. [*5]
4 Operator cab and floor frame assembly:
400 kg trol lever”.
[*6], [*7]
marks and colors.
[*8]
k Do not insert your finger when positioning.

level again.
PC45MR-3, PC55MR-3 50-700 17

SEN04660-00

©2008 KOMATSU
All Rights Reserved
50-700 18
SEN04661-00
PC45MR-3,
PC55MR-3


Removal and installation of air conditioner unit assembly (If equipped) ......................................................... 2
Removal and installation of KOMTRAX terminal ............................................................................................ 5
PC45MR-3, PC55MR-3 50-800 1

SEN04661-00 Removal and installation of air conditioner unit assembly (If equipped)
Removal and installation of air 2) Pull up the front window. When it stops
conditioner unit assembly moving backward, push up grips (2) until
they are locked securely.
(If equipped) 1
Removal
k Stop the machine on a level place, lower
the work equipment to the ground, and set
the work equipment lock lever in the LOCK
position.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant 3. Remove front window (lower side) (4).
(R134a) from air conditioner circuit in a Hold knobs (5) and pull up and remove the
advance. window, and then store it at the rear of the
a Ask professional traders for collecting and fill- operator's seat in the operator's cab.
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
1. Collect the refrigerant (gas) from the air condi-

tioner circuit. [*1]
2. Retract front window (upper side) (1) in the 4. Remove the floor mat and right PPC hose
ceiling. cover (6).
1) Hold right and left grips (2) in the opera-
tor's cab and pull them toward you, keep-
ing lock levers (3) down.
50-800 2 PC45MR-3, PC55MR-3

Removal and installation of air conditioner unit assembly (If equipped) SEN04661-00
5. Remove cover (7). 3) Remove 6 mounting bolts (14) and cover

(12).
6. Remove 3 mounting bolts (9) of right lever

stand (8) so that the stand will move. 9. Remove cover (16).
7. Remove air conditioner control panel (10) and

clamp of wiring harness (11).

For details, see Testing and adjusting, “How to
open and close (tilt) floor”.
1) Move the right lever stand backward. 11. Disconnect drain hose (17).
2) Remove 3 air outlets (13).
PC45MR-3, PC55MR-3 50-800 3

SEN04661-00 Removal and installation of air conditioner unit assembly (If equipped)
12. Disconnect 2 heater hoses (18) and 2 air con- Installation

ditioner tubes (19). [*2]
a Plug the hoses to prevent dirt from enter- q Carry out installation in the reverse order to
ing them. removal.
13. Remove 4 air conditioner unit assembly a When installing, check that the O-ring is fitted
mounting bolts (20). to each joint of the air conditioner hoses.
a Check that each O-ring is free from damage
and deterioration.
[*1]
a Charge the air conditioner circuit with refriger-
ant (R134a).
a Refrigerant (R134a): 550 ± 50 g
[*2]
a Apply compressor oil (ND-OIL8) to the
threaded part of each refrigerant pipe and
tighten the pipe with double spanner.
3 M16 x 1.5 thread of tube:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
14. Tilt down the floor frame. M24 x 1.5 thread of tube:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
15. Pull air conditioner unit assembly (21) toward
you and remove it and control panel together. q Refilling with coolant
a After pulling out the air conditioner unit a Add coolant through the coolant filler to
assembly halfway, disconnect connector the specified level. Run the engine to cir-
F11. culate the coolant through the system.
50-800 4 PC45MR-3, PC55MR-3

Removal and installation of KOMTRAX terminal SEN04661-00
Removal and installation of (Operator cab specification)

KOMTRAX terminal 1
Removal
1. Remove 4 bolts (1) and cover (2).

(Canopy specification)
3. Disconnect connectors (5) and (6).
4. Disconnect antenna cable (7).
5. Disconnect GPS antenna connector (8).
(Operator cab specification)
Installation
2. Remove 4 mounting bolts (3) and KOMTRAX q Carry out installation in the reverse order to
terminal (4). removal.
(Canopy specification)
PC45MR-3, PC55MR-3 50-800 5

SEN04661-00

©2008 KOMATSU
All Rights Reserved
50-800 6
SEN04618-01
PC45MR-3,PC55MR-3
SEN04618-01
HYDRAULIC EXCAVATOR
Shop Manual
PC45MR-3
PC55MR-3

90 Diagrams and Drawings

100 Hydraulic diagrams and drawings
Hydrauilc circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
PC45MR-3,PC55MR-3 90-100 1
SEN04618-01
90-100 2 PC45MR-3,PC55MR-3
Hydraulic circuit diagram Hydraulic circuit diagram
PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04618-01
PC45MR-3, PC55MR-3 90-100 3
PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3
SEN04618-01
PC45MR-3, PC55MR-3 90-100 5
PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3 (Auto-deceleration specification)
SEN04618-01
PC45MR-3, PC55MR-3 90-100 7
Hydrauilc circuit diagram SEN04618-01
PC45MR-3,PC55MR-3 90-100 9
SEN04618-01
©2009 KOMATSU
All Rights Reserved
90-100 10
SEN04619-02
PC45MR-3,PC55MR-3
SEN04619-02
HYDRAULIC EXCAVATOR
Shop Manual
PC45MR-3
PC55MR-3

90 Diagrams and Drawings

200 Electrical diagrams and drawings
Electrical circuit diagram (1/3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Connector list and stereogram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
PC45MR-3,PC55MR-3 90-200 1
SEN04619-02
90-200 2 PC45MR-3,PC55MR-3
Electrical circuit diagram (1/3) Electrical circuit diagram (1/3)
PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3
SEN04619-02
PC45MR-3, PC55MR-3 90-200 3
PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3
SEN04619-02
PC45MR-3, PC55MR-3 90-200 5
PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3
SEN04619-02
PC45MR-3, PC55MR-3 90-200 7
Connector list and stereogram
Connector list and stereogram PC45MR-3, PC55MR-3
PC45MR-3, PC55MR-3
Canopy specification Canopy specification
Address of stereogram
Connector Number
Model Component name Canopy Cab
No. of pins
specification
specification
A2 X 2 T ra ve lo ilp re ssu re sw itch L -1 L -1
D1 X 2 D io d e (fo r e n g in e sto p so le n o id ) K -9 K -9
D2 X 2 D io d e (C te rm in a lin p u t) S -8 T -9
F1 X 4 In te rm e d ia te co n n e cto r (B R , C circu its) M -7 M -7
F2 YAZAKI-Y 2 Intermediate connector (battery power supply circuit) M-7 M-7
F3 SWP 6 Intermediate connector (harness between floor and machine) L-8 L-8
F4 SWP 8 Intermediate connector (harness between floor and machine) L-8 L-8
F5 D T -T 2 P P C lo ck sw itch (le ft) T -6 T -5
F7 D T -T 4 W ip e r m o to r [C a b sp e cifica tio n ] — O -3
F8 M 2 Intermediate connector (cigarette lighter) [Cab specification] — P-8
F9 DT-T 2 Optional power supply [Canopy specification] R-9 —
F 11 KES1 3 H e a te r [C a b sp e cifica tio n ] — O -3
F 12 KES1 4 H e a te r sw itch [C a b sp e cifica tio n ] — T -4
F 13 M 2 H o rn sw itch O -6 O -5
F14 DT-T 2 PPC oil pressure lock switch [Canopy specification] O-5 —
F 15 A M P 0 70 20 M a ch in e m o n ito r O -7 O -6
F 16 KES0 2 S p e a ke r (rig h t) [C a b sp e cifica tio n ] — T -9
F 17 PA 9 R a d io [C a b sp e cifica tio n ] — O -6
F 18 KES0 2 S p e a ke r (le ft) [C a b sp e cifica tio n ] — T -5
F 19 S U M IT O M O 3 R o o m la m p [C a b sp e cifica tio n ] — Q -9
F20 SWP 12 Intermediate connector (main option harness) T-5 T-4
F21 DT-T 2 Revolving warning lamp [Canopy specification, if equipped] R-9 —
F21 M 2 Revolving warning lamp [Cab specification, if equipped] — Q-9
F22 M 2 Intermediate connector (additional working lamp) — R-9

[Cab specification]
F22A DT-T 2 Additional working lamp [Cab specification, if equipped] — Q-9
F22B DT-T 2 Additional working lamp [Cab specification, if equipped] — S-9
F22C DT-T 2 Additional working lamp [Cab specification, if equipped] — R-9
F23 M 3 Intermediate connector (radio) [Cab specification] — O-7
F24 M 3 Intermediate connector (wiper motor) [Cab specification] — Q-9
F 25 Te rm in a l 2 C ig a re tte lig h te r [C a b sp e cifica tio n ] — O -7
F26 KES1 4 Heater switch [Canopy specification, if equipped] T-5 —
F 27 KES1 3 H e a te r [C a n o p y sp e cifica tio n , if e q u ip p e d ] O -4 —
F 28 M 2 A la rm b u zze r O -6 O -4
F 29 — 10 W o rkin g la m p sw itch T -5 T -4
F 2 9A — 2 In te rm e d ia te co n n e cto r [C a b sp e cifica tio n ] — S -4
F 30 A M P 0 70 18 K O M TR A X S -8 T -9
F 32 A M P 0 70 12 K O M TR A X T -8 T -8
F 33 X 1 Te st co n n e cto r (m a le ) T -7 T -7
F 34 X 1 Te st co n n e cto r (fe m a le ) T -7 T -7
F 36 D T -T 3 R e sisto r (C A N circu it) S -8 S -9
F 37 D T -T 12 S e rvice co n n e cto r T -4 T -3
F 38 D T -T 2 S p e e d u p sw itch O -6 O -5
FB 1 — — F u se b o x T -3 T -3
Cab specification Cab specification
FU 1 — — F u se (1 0 A ) N -8 N -8
M1 YA ZA K I 2 H o rn M -7 M -7
M2 KES0 2 Windshield washer motor [Cab specification] E-9 E-9
M3 SWP 6 Intermediate connector (optional connector) M-1 M-1
M4 X 4 T V C syste m E -8 E -8
M5 — 2 F u sib le lin k (4 5 A ) B -4 , F -9 B -4 , F -9
M6 — 3 F u e lle ve lse n so r G -9 G -9
M8 D T -T 2 In te rm e d ia te co n n e cto r (tra ve la la rm ) D -8 D -8
M9 D T -T 2 E n g in e co o la n t te m p e ra tu re se n so r J-9 J-9
M 10 S U M IT O M O 3 A lte rn a to r I-9 I-9
M 11 D T -T 2 T V C so le n o id va lve L -6 L -6
M12 SWP 1 Air conditioner compressor [Cab specification] K-8 K-8
M 13 X 3 E n g in e sto p so le n o id L -7 L -7
M 14 X 2 F u e lp u m p L -5 L -5
M 15 S U M IT O M O 6 E n g in e sa fe ty re la y A -1 A -1
M 16 S U M IT O M O 2 E n g in e sa fe ty re la y A -1 A -1
M 17 D T -T 2 T ra ve lsp e e d u p so le n o id N -9 N -9
M 18 D T -T 2 P P C lo ck so le n o id M -9 M -9
M 19 — 2 E n g in e sto p so le n o id re la y B -1 B -1
M 20 — 1 E n g in e sto p so le n o id re la y A -1 A -1
M 21 — 1 E n g in e sto p so le n o id re la y B -1 B -1
M 22 KES 4 T im e r A -2 A -2
M 23 — 1 G lo w p lu g L -6 L -6
P1 D T -T 2 S o cke t M -7 M -7
R1 R e la y 5 S ta rtin g m o to r cu t re la y S -1 S -1
R2 R e la y 5 P P C lo ck so le n o id re la y S -1 S -1
R4 R e la y 5 T ra ve lsp e e d u p so le n o id re la y T -2 T -2
R6 R e la y 5 S ta rtin g m o to r cu t re la y (K O M T R A X ) T -2 T -2
R7 R e la y 5 A ir co n d itio n e r re la y [C a b sp e cifica tio n ] D -7 D -7
TF1 Te rm in a l 1 S ta rtin g sw itch (B te rm in a l) P -9 O -9
TF2 Te rm in a l 1 S ta rtin g sw itch (B R te rm in a l) O -8 O -8
TF3 Te rm in a l 1 S ta rtin g sw itch (A C C te rm in a l) O -8 O -8
TF4 Te rm in a l 1 S ta rtin g sw itch (C te rm in a l) O -8 O -9
TF5 Te rm in a l 1 S ta rtin g sw itch (R 1 te rm in a l) P -8 P -9
TF6 Te rm in a l 1 S ta rtin g sw itch (R 2 te rm in a l) P -8 P -8
TM 1 Te rm in a l 1 B a tte ry (+ te rm in a l) E -8 E -8
TM 2 Te rm in a l 1 A lte rn a to r (B te rm in a l) I-9 I-9
TM 3 Te rm in a l 1 E n g in e o ilp re ssu re sw itch L -5 L -5
TM 5 Te rm in a l 1 S ta rtin g m o to r (B te rm in a l) L -8 L -8
TM 6 Te rm in a l 1 S ta rtin g m o to r (S te rm in a l) L -8 L -8
TM 7 Te rm in a l 1 R e vo lvin g fra m e g ro u n d F -9 F -9
W 1 D T -T 2 In te rm e d ia te co n n e cto r (w o rkin g la m p ) B -3 , F -9 B -3 , F -9
W 2 D T -T 3 In te rm e d ia te co n n e cto r (in sta lle d to b o o m ) C -7 C -7
W3 DT-T 3 Additional working lamp [Canopy specification] F-9 —
SEN04619-02
PC45MR-3, PC55MR-3
90-200 9
SEN04619-02
PC45MR-3,PC55MR-3 90-200 11
SEN04619-02
©2009 KOMATSU
All Rights Reserved
90-200 12

SM PC45MR-3

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SEN04597-03

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 00

PC45MR-3, PC55MR-3 00-100 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04598-03

01 Specification ............................................................................................................................... SEN04601-00

10 Structure, function and maintenance standard........................................................................... SEN04603-01

20 Standrad value table................................................................................................................... SEN04613-00

30 Testing and adjusting ................................................................................................................. SEN04614-00

50 Disassembly and assembly........................................................................................................ SEN04616-00

00-100 2 PC45MR-3, PC55MR-3

400 Undercarriage and frame ...................................................................................................SEN04657-00

90 Diagrams and drawings..............................................................................................................SEN04617-02

PC45MR-3, PC55MR-3 00-100 3

10 Structure, function and maintenance standard

00-100 4 PC45MR-3, PC55MR-3

430 Hydraulic system, Part 3 SEN04609-00

20 Standard value table

30 Testing and adjusting

PC45MR-3, PC55MR-3 00-100 5

Removal and installation of KOMTRAX terminal .......................................................................................... 58

00-100 6 PC45MR-3, PC55MR-3

H-23 Large shock is made when machine stops swinging............................................................................ 35

50 Disassembly and assembly

PC45MR-3, PC55MR-3 00-100 7

Removal and installation of front window assembly...................................................................................... 11

90 Diagrams and drawings

00-100 8 PC45MR-3, PC55MR-3

PC45MR-3, PC55MR-3 00-100 9

PC45MR-3, PC55MR-3 Hydraulic excavator

Machine model Serial number

00 Index and Foreword

2. Preparation work 5) When raising a heavy component (heavier

15)Take care when removing or installing the

4. Precautions for sling work and making signals

8. Precautions for disconnecting and

How to read the shop manual

Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

60. Maintenance standard

Revision and distribution

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving standards are

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard

1. Standard size and tolerance

q Usually, the size of a hole and the size of the

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allowable