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