PDF Shop Manual Komatsu PC45MR-5E0 PC55MR-5E0 Hydraulic Excavator - 6 MB
This comprehensive shop manual covers the Komatsu PC45MR-5E0 and PC55MR-5E0 hydraulic excavators.
It is the definitive guide for service technicians, offering detailed instructions for testing, adjusting, troubleshooting, and repair.
With complete specifications and step-by-step procedures for every system, this manual is essential for maintaining the performance and reliability of your Komatsu mini-excavators.
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WENBM00230
Shop Manual
COMPACT HYDRAULIC EXCAVATOR
PC45MR-5E0 SERIAL NUMBERS F20001 and up
PC55MR-5E0 SERIAL NUMBERS F40001 and up
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00 INDEX AND FOREWORD ABBREVIATION LIST
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).
PC45MR-5E0, PC55MR-5E0 00-11
--- Page 4 ---
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kgf} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000kgf} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.
PC45MR-5E0, PC55MR-5E0 00-23
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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS
Introduction of parts for the disassembly of the face seal type hoses and tubes
Hose side Pipe joint side
Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
Introduction of parts for the disconnection of the taper seal type hoses and
tubes
Hose side Pipe joint side
Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
PC45MR-5E0, PC55MR-5E0 00-35
--- Page 6 ---
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
2. After inserting the hose in the mating adapter perfectly, pull
it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE
COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, turn lever (3) to the
right (clockwise).
3. While keeping the conditions of steps 1 and 2, pull out
whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
PC45MR-5E0, PC55MR-5E0 00-47
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METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PUSH
Method for disconnecting connector with lock to push (AMP-3)
While pressing lock (E), pull out connector (5) in the direction of
the arrow.
Method for connecting connector with lock to push (AMP-3)
Insert it straight until it clicks.
Method for disconnecting connector with lock to push (SUMITOMO-3)
While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.
Method for connecting connector with lock to push (SUMITOMO-3)
Insert it straight until it clicks.
Method for disconnecting connector with lock to push (SUMITOMO-4)
While pressing lock (D), pull out connector (4) in the direction
of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4)
Insert it straight until it clicks.
PC45MR-5E0, PC55MR-5E0 00-59
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00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE
Table of tightening torque for O-ring boss piping joints
REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread di- Width across Tightening torque (Nm {kgfm} )
Nominal No.
ameter (mm) flats (mm) Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs
REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread diam- Width across Tightening torque (Nm {kgfm} )
Nominal No.
eter (mm) flats (mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
PC45MR-5E0, PC55MR-5E0 00-71
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01 SPECIFICATIONS ABBREVIATION LIST
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).
PC45MR-5E0, PC55MR-5E0 01-3
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01 SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: PC45MR-5E0
PC45MR-5E0
Item Unit
Canopy specifications Cab specifications
Bucket capacity m³ 0.14
Machine weight
Rubber shoe specification kg 4750 4870
Steel shoe specification 4820 4940
Performance
Working ranges
Maximum digging depth mm 3625
Maximum vertical wall digging
mm 3070
depth
Maximum digging reach mm 6040
Maximum digging reach at
mm 5895
ground level
Maximum digging height mm 5730
Maximum dumping height mm 4000
Offset of bucket (Left side/right
mm 630/880
side)
Maximum raising distance of
mm 430
the blade
Maximum lowering distance of
mm 330
the blade
Maximum digging force kN {kg} 33.9 {3460} 33.9 {3460}
Continuous swing speed rpm 9.0 9.0
Swing operation max. slope angle Degrees 19.0 19.0
Travel speed (Lo/Hi)
Rubber shoe specification km/h 2.6/4.6 2.6/4.6
Steel shoe specification 2.4/4.3 2.4/4.3
Gradeability Degrees 30 30
Ground pressure
Rubber shoe specification kPa {kg/cm²} 26.6 {0.27} 27.3 {0.28}
Steel shoe specification 27.4 {0.28} 28.1 {0.29}
Dimensions
Overall length (for transport) mm 5330 5330
Overall width mm 1960 1960
Overall height (for transport) mm 2550 2590
Ground clearance of upper struc-
mm 608 608
ture bottom
Minimum ground clearance mm 290 290
PC45MR-5E0, PC55MR-5E0 01-15
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01 SPECIFICATIONS TABLE OF FUEL, COOLANT, AND LUBRICANTS
TABLE OF FUEL, COOLANT, AND LUBRICANTS
For details of notes (Note 1, Note 2...) in the table, see “Operation and Maintenance Manual”.
Ambient temperature
Recommended Komatsu
Reservoir Fluid type °C
Fluids
Min Max
EO10W30-LA (KES Die-
-20 40
sel Engine Oil)
EO15W40-LA CK4 (KES
Engine oil pan Engine oil -15 50
Diesel Engine Oil)
EO30-DH (KES Diesel
0 40
Engine Oil)
Final drive case Power train oil TO30 (KES) -30 50
HO56-HE (KES) -20 50
Hydraulic oil
Hydraulic system HO46-HM (KES) -10 50
Power train oil TO10 (KES) -10 50
Hyper grease (Note.1) G2-TE (KES) -20 50
Grease fitting
Lithium EP grease G2-LI (KES) -10 50
Non-Amine Engine Coolant
Cooling system AF-NAC (KES) -30 50
(AF-NAC) (Note.2)
EN 590 Class2 -30 20
Fuel tank Diesel fuel
EN 590 Grade D 0 50
Unit: ℓ
Places to supply oil, coolant, etc. Specified amount Refill capacity
Engine oil pan 8.1 7.5
Final drive case (each on right and left sides) 0.7 0.7
Hydraulic oil system 55 20
Cooling system 8.8 -
Fuel tank 65 -
PC45MR-5E0, PC55MR-5E0 01-27
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10 STRUCTURE AND FUNCTION FUNCTION OF NOx CONTROL SYSTEM
Machine monitor
Caution Failure code
Elapsed Message of Engine de-
Status lamp Failure code for Induce-
time (*1) NOx control Tone of au- ration (*4)
for abnor- ment strat-
system In- (Action lev- dible alert
mality (*2) egy status
formation el) (*3)
Red
Red AS00R3 (In-
Low-Level In- 3: EGR sys-
ducement 1 Torque re-
ducement tem inspec-
Intermittent- (NOx Con- duction rate:
2 64 hours tion and #B1675
(Inducement ly trol Device 25% or
mainte-
1) Abnormali- more
nance.
ty))
Red
Red
Torque: over
Red AS00R4 (In- 50% or
Severe In- Until abo- 4: Engine
ducement 2 more
ducement normality power is un- Continuous-
4 #B1675 (NOx control Engine
(Inducement is re- der heavy ly
Device Ab- speed re-
2) paired deration.
normality)) duction rate:
Min. 60%
Red
*1:Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage is started.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the ma-
chine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING.
*3:These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*4: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE
• The NOx control system continuously monitors its operation conditions and stores information on inappro-
priate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities. Those information are required by
the authorities. The abnormality counting spans 40 hours and it monitors the abnormalities that trigger In-
ducement.
PC45MR-5E0, PC55MR-5E0 10-11
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10 STRUCTURE AND FUNCTION AUTO-DECELERATION SYSTEM
AUTO-DECELERATION SYSTEM
AUTO-DECELERATION SYSTEM DIAGRAM
Input and output signals
a: CAN signal e: 1st throttle signal
b: CAN signal f: Fuel supply pump control signal
c: Oil pressure sensor signal g: Various sensor signals
d: Oil pressure switch signal
1: Machine controller 8: Oil pressure sensor
2: Engine controller 9: Main pump
3: Machine monitor 10: Control valve
4: Fuel control dial 10a: Merge-divider valve
5: Fuel supply pump 11: PPC lock solenoid valve
6: Various sensors 12: Swing motor
7: Oil pressure switch 12a: Swing parking brake
FUNCTION OF AUTO-DECELERATION SYSTEM
• When all the control levers are set to NEUTRAL positions while waiting for a dump truck or next work, the
engine speed decreases to the control speed automatically to improve the fuel economy and reduce the
noise.
• If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control
dial.
PC45MR-5E0, PC55MR-5E0 10-23
--- Page 14 ---
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
MACHINE MONITOR
FUNCTION OF MACHINE MONITOR
• The machine monitor has monitor display function and mode selection function.
• CPU (Central Processing Unit) is installed inside the machine monitor, and it processes, displays, and out-
puts the information.
• The monitor system monitors the machine state by obtaining the information with the sensors and switches
installed in various parts of the machine, processes the information instantly. It displays the information on
the machine monitor to inform the operator of the machine condition.
The followings are categories which contents displayed on the machine monitor are broadly divided into.
• Alarms when the machine has a trouble
• Machine state (engine coolant temperature, fuel level, etc.)
• The switches on the machine monitor have functions to control the machine.
PC45MR-5E0, PC55MR-5E0 10-35
--- Page 15 ---
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM
Input and output
Pin No. Signal name
signals
16 Service pressure sensor 2 Input
17 Starting switch ACC signal Input
18 (*1) -
19 (*1) -
20 (*1) -
21 Work equipment PPC pressure sensor Input