Komatsu Hydraulic Excavator Pc55Mr3 Shop Manual-21425K200225.pdf
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COVER

00 Index and foreword

	100 Index

		Composition of shop manual

		Table of contents

	200 Foreword and general information

		Safety notice

		How to read the shop manual

		Explanation of terms for maintenance standard

		Handling of electric equipment and hydraulic component

		Handling of connectors newly used for engines

		How to read electric wire code

		Precautions when carrying out work

		Method of disassembling and connecting push-pull type coupler

		Standard tightening torque table

		Conversion table

01 Specification

	100 Specification and technical data

		Specification dimension drawing

		Working range drawing

		Specifications

		Weight table

		Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard

	100 Engine and cooling system

		PTO

		Cooling system

	200 Power train

		Power train

		Swing circle

		Swing machinery

	300 Undercarriage and frame

		Track frame

		Idler cushion

		Idler

		Track roller

		Carrier roller

		Sprocket

		Track shoe

	410 Hydraulic system, Part 1

		Hydraulic components layout drawing

		Hydraulic tank, filter

		Center swivel joint

		Travel motor

		Hydraulic cylinder

		Solenoid valve

		Multi-control valve

	420 Hydraulic system, Part 2

		Hydraulic pump

		Control valve

		Anti-drop valve

	430 Hydraulic system, Part 3

		CLSS

		Operation for each function and valve

		Swing motor

		PPC valve

	500 Work equipment

		Work equipment

		Dimensions of each part of work equipment

	600 Cab and its attachments

		Floor

	700 Electrical system

		Engine control system

		Electrical control system

		Auto-deceleration function

		Attachment proportional switch, breaker operation switch, work mode selection, flow control function

		KOMTRAX system

		Component parts of system

		Monitor system

		Sensors

20 Standard value table

	100 Standard service value table

		Standard service value table for engine related parts

		Standard service value table for chassis related parts

30 Testing and adjusting

	100 Testing and adjusting

		Tools for testing, adjusting, and troubleshooting

		Testing engine speed

		Testing exhaust gas color

		Testing and adjusting valve clearance

		Testing compression pressure

		Testing engine oil pressure

		Testing and adjusting fuel injection timing

		Testing and adjusting alternator belt tension

		Testing and adjusting air conditioner compressor belt tension

		Adjusting fuel control lever

		Testing clearance in swing circle bearings

		Testing and adjusting track shoe tension

		Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits

		Testing and adjusting LS differential pressure

		Adjusting PC valve

		Testing and adjusting control pump circuit oil pressure

		Testing solenoid valve output pressure

		Testing PPC valve output pressure

		Adjusting PPC valve

		Testing swing holding brake release pressure

		Testing and adjusting travel deviation

		Testing oil leakage from work equipment cylinder

		Bleeding air from each part

		Releasing residual pressure from hydraulic circuit

		Releasing residual pressure from hydraulic tank

		Pressurizing hydraulic tank

		How to open and close (tilt) floor

		Inspection procedures for diode

		Function and flow of operator and service mode

		How to start operation of KOMTRAX terminal

		Lamp display of KOMTRAX terminal

		Removal and installation of KOMTRAX terminal

		Preparation work for troubleshooting of electrical system

40 Troubleshooting

	100 General information on troubleshooting

		Points to remember when troubleshooting

		Sequence of events in troubleshooting

		Checks before troubleshooting

		Classification and procedures of troubleshooting

		Information contained in troubleshooting table

		Connection table for connector pin numbers

		T- branch box and T- branch adapter table

	110 Failure code table and fuse locations

		User code and failure code list

		Fuse locations

	120 General information on troubleshooting

		Points to remember when troubleshooting

		Sequence of events in troubleshooting

		Checks before troubleshooting

		Classification and procedures of troubleshooting

		Information contained in troubleshooting table

		Connection table for connector pin numbers

		T- branch box and T- branch adapter table

	130 Troubleshooting by failure code

		Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller

		Failure code [DBH1KK] Unswitched power supply error

		Failure code [DBH2KK] Solenoid power supply error

		Failure code [DBH5KP] 5V sensor power supply output 0 error

		Failure code [DBH6KP] 5V sensor power supply output 1 error

		Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit)

		Failure code [DDWLKB] Breaker switch error (Hot short circuit)

		Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)

		Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)

		Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error

		Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault)

		Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit)

		Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)

		Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)

		Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)

		Failure code [D1E0KB] Motor power supply relay error (Ground fault)

		Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)

		Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)

		Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)

		Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)

		Failure code [DY10MA] Fuel control motor operation error

		Failure code [D1E0KA] Fuel control motor power supply relay contactsticking  (NC side)

		Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)

		Failure code [DXEAKA] EPC valve (port A side) error (Disconnection)

		Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)

		Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit)

	200 Troubleshooting of electrical system (E-mode)

		Before carrying out troubleshooting of electrical system

		E-1 Engine does not start

		E-2 Engine does not stop

		E-3 When starting switch is turned ON, any item does not operate

		E-4 When starting switch is turned ON, some items do not operate

		E-5 Alarm buzzer is abnormal

		E-6 Engine oil pressure caution is turned ON

		E-7 Charge level caution is turned ON

		E-8 Preheating system does not operate or preheater does not become hot

		E-9 Coolant temperature gauge is abnormal

		E-10 Fuel level gauge is abnormal

		E-11 Service meter does not operate while engine is running

		E-12 2nd travel speed is not selected

		E-13 Working lamp does not light up

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

		E-15 Windshield wiper does not operate

		E-16 Windshield washer does not operate

		E-17 Defective air conditioner

		E-18 KOMTRAX system does not operate normally

	300 Troubleshooting of hydraulic and mechanical system (H-mode)

		Information contained in troubleshooting table

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

		H-2 Engine speed lowers extremely or engine stalls

		H-3 Whole work equipment, travel system, swing system, and blade do not work

		H-4 Abnormal sound comes out from around hydraulic pump

		H-5 Fine control performance or response is low

		H-6 Speed or power of boom is low

		H-7 Speed or power of arm is low

		H-8 Speed or power of bucket is low

		H-9 Speed or power of boom swing is low

		H-10 Work equipment does not move singly

		H-11 Work equipment hydraulic drift is large

		H-12 Time lag of work equipment is large

		H-13 In compound operation of work equipment, speed of part loaded more is low

		H-14 Machine deviates during travel

		H-15 Travel speed or travel power is low (while work equipment is normal)

		H-16 Machine is not steered well or steering power is low

		H-17 Travel speed does not change

		H-18 Travel motor does not work

		H-19 Speed or power of swing is low

		H-20 Machine does not swing

		H-21 Swing acceleration performance is low

		H-22 Machine overruns when it stops swinging

		H-23 Large shock is made when machine stops swinging

		H-24 When upper structure stops swinging, it makes large sound

		H-25 Hydraulic drift of swing is large

		H-26 Speed or power of blade is low

		H-27 Blade does not move

		H-28 Hydraulic drift of blade is large

	400 Troubleshooting of engine (S-mode)

		Method of using troubleshooting charts

		S-1 Starting performance is poor

		S-2 Engine does not start

		S-3 Engine does not pick up smoothly

		S-4 Engine stops during operations

		S-5 Engine does not rotate smoothly

		S-6 Engine lacks output (or lacks power)

		S-7 Exhaust smoke is black (incomplete combustion)

		S-8 Oil consumption is excessive (or exhaust smoke is blue)

		S-9 Oil becomes contaminated quickly

		S-10 Fuel consumption is excessive

		S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)

		S-12 Oil pressure drops

		S-13 Oil level rises (Entry of coolant

		S-14 Coolant temperature becomes too high (overheating)

		S-15 Abnormal noise is made

		S-16 Vibration is excessive

50 Disassembly and assembly

	100 General information on disassembly and assembly

		How to read this manual

		Coating materials list

		Special tool list

		Sketches of special tools

	200 Engine and cooling system

		Removal and installation of fuel injection pump assembly

		Removal and installation of radiator assembly

		Removal and installation of hydraulic oil cooler assembly

		Removal and installation of engine and hydraulic pump assembly

	300 Power train

		Removal and installation of swing motor and swing machinery assembly

		Disassembly and assembly of swing motor and swing machinery assembly

		Removal and installation of swing circle assembly

	400 Undercarriage and frame

		Removal and installation of track shoe assembly

		Disassembly and assembly of idler assembly

		Disassembly and assembly of recoil spring assembly

		Disassembly and assembly of track roller assembly

		Disassembly and assembly of carrier roller assembly

		Removal and installation of revolving frame assembly

	500 Hydraulic system

		Removal and installation of center swivel joint assembly

		Disassembly and assembly of center swivel joint assembly

		Removal and installation of work equipment pump assembly

		Disassembly and assembly of control valve assembly

		Disassembly and assembly of hydraulic cylinder assembly

	600 Work equipment

		Removal and installation of work equipment assembly

	700 Cab and its attachments

		Removal and installation of operator?s cab glass (stuck glass)

		Removal and installation of front window assembly

		Removal and installation of floor frame assembly (Canopy specification)

		Removal and installation of operator cab and floor frame assembly (Operator cab specification)

	800 Electrical system

		Removal and installation of air conditioner unit assembly (If equipped)

		Removal and installation of KOMTRAX terminal

90 Diagrams and Drawings

	100 Hydraulic diagrams and drawings

		Hydraulic circuit diagram

	200 Electrical diagrams and drawings

		Electrical circuit diagram (1

		Electrical circuit diagram (2

		Electrical circuit diagram (3

		Connector list and stereogram

		Related circuit diagram of proportional swithch



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