SEN06574-14
COMPACT HYDRAULIC EXCAVATOR
PC45MR -5 PC55MR -5 SERIAL NUMBERS
PC45MR- 30001 PC55MR- 20001
and up
00 Index and Foreword
PC45MR-5, PC55MR-5
00-1
Index
00 Index and Foreword
Index 00 Index and Foreword .................................................................................................................................. 00-1 Abbreviation List ....................................................................................................................................00-11 Foreword, Safety, Basic Information...................................................................................................... 00-17 How to Read the Shop Manual ...................................................................................................... 00-17 Safety Notice for Operation ............................................................................................................ 00-19 Precautions to Prevent Fire............................................................................................................ 00-28 Procedures If Fire Occurs .............................................................................................................. 00-30 Precautions When You Discard Waste Materials............................................................................ 00-31 Precautions When You Handle Hydraulic Equipment ..................................................................... 00-32 Precautions When You Disconnect and Connect Pipings............................................................... 00-35 Precautions When You Handle Electrical Equipment ..................................................................... 00-42 Precautions When You Handle Fuel System Equipment ................................................................ 00-44 Precautions When You Handle Intake System Equipment ............................................................. 00-45 Practical Use of KOMTRAX ........................................................................................................... 00-46 Disconnect and Connect Push-Pull Type Coupler .......................................................................... 00-47 Precautions for Disconnection and Connection of Connectors ....................................................... 00-51 Disconnect and Connect Deutsch Connector ................................................................................. 00-55 How to Disconnect and Connect Slide Lock Type Connector ......................................................... 00-56 Disconnect and Connect Connector with Lock to Pull .................................................................... 00-58 Disconnect and Connect Connector with Lock to Push .................................................................. 00-59 Disconnect and Connect Connector with Housing to Rotate .......................................................... 00-61 How to Read the Codes for Electric Cable ..................................................................................... 00-62 Explanation of Terms for Maintenance Standard ............................................................................ 00-66 Standard Tightening Torque Table.................................................................................................. 00-69 Conversion Table ........................................................................................................................... 00-76 01 Specification.............................................................................................................................................. 01-1 Table of Contents .................................................................................................................................... 01-2 Abbreviation List ..................................................................................................................................... 01-3 Specifications.......................................................................................................................................... 01-9 Specification Drawing....................................................................................................................... 01-9 Working Range Drawings............................................................................................................... 01-13 Specifications................................................................................................................................. 01-15 Weight Table .................................................................................................................................. 01-23 Table of Fuel, Coolant, and Lubricants ........................................................................................... 01-27 10 Structure and Function .............................................................................................................................. 10-1 Table of Contents .................................................................................................................................... 10-2 Abbreviation List ..................................................................................................................................... 10-4 Boot-up System .................................................................................................................................... 10-10 Layout Drawing of Boot-up System ................................................................................................ 10-10 System Operating Lamp System.................................................................................................... 10-12 Battery Disconnect Switch.............................................................................................................. 10-14 Engine System...................................................................................................................................... 10-15 Layout Drawing of Engine System ................................................................................................. 10-15 Engine Control System .................................................................................................................. 10-16 Auto-Deceleration System.............................................................................................................. 10-20 Overheat Prevention System ......................................................................................................... 10-22 Automatic Idle Stop System ........................................................................................................... 10-24 Component Parts of Engine System .............................................................................................. 10-26 Cooling System..................................................................................................................................... 10-27 Layout Drawing of Cooling System ................................................................................................ 10-27 Control System ..................................................................................................................................... 10-29 Layout Drawing of Control System ................................................................................................. 10-29 Machine Monitor System................................................................................................................ 10-30 KOMTRAX System ........................................................................................................................ 10-31 Component Parts of Control System .............................................................................................. 10-32 Hydraulic System .................................................................................................................................. 10-48 00-2
PC45MR-5, PC55MR-5
00 Index and Foreword
Index
Layout Drawing of Hydraulic System.............................................................................................. 10-48 CLSS ............................................................................................................................................. 10-50 Engine and Pump Combined Control System ................................................................................ 10-53 Component Parts of Hydraulic System........................................................................................... 10-56 Work Equipment System......................................................................................................................10-116 Layout Drawing of Work Equipment System .................................................................................10-116 Structure of Valve Control .............................................................................................................10-120 PPC Lock System .........................................................................................................................10-122 Work Equipment and Travel Automatic Lock System ....................................................................10-124 Attachment Oil Flow Adjuster System ...........................................................................................10-125 Component Parts of Work Equipment System ..............................................................................10-127 Swing System ......................................................................................................................................10-143 Layout Drawing of Swing System..................................................................................................10-143 Component Parts of Swing System...............................................................................................10-144 Travel System ......................................................................................................................................10-154 Layout Drawing of Travel System..................................................................................................10-154 System Diagram of Travel Control System....................................................................................10-156 Component Parts of Travel System...............................................................................................10-158 Undercarriage and Frame ....................................................................................................................10-169 Layout Drawing of Undercarriage..................................................................................................10-169 Idler Cushion.................................................................................................................................10-170 Work Equipment ..................................................................................................................................10-171 Structure of Work Equipment ........................................................................................................10-171 Function of Work Equipment .........................................................................................................10-172 Work Equipment Clearance Adjustment Shim...............................................................................10-173 CAB Related Parts ...............................................................................................................................10-174 ROPS CAB ...................................................................................................................................10-174 Tilt Type Floor ...............................................................................................................................10-175 20 Standard Value Table ................................................................................................................................ 20-1 Table of Contents .................................................................................................................................... 20-2 Abbreviation List ..................................................................................................................................... 20-3 Standard Value Table for Engine ............................................................................................................. 20-9 Standard Value Table for Engine: PC45MR-5................................................................................... 20-9 Standard Value Table for Engine: PC55MR-5..................................................................................20-11 Standard Value Table for Machine......................................................................................................... 20-13 Standard Value Table for Machine: PC45MR-5 .............................................................................. 20-13 Standard Value Table for Machine: PC55MR-5 .............................................................................. 20-25 Machine Posture and Procedures to Measure Performance .......................................................... 20-37 30 Testing and Adjusting ................................................................................................................................ 30-1 Table of Contents .................................................................................................................................... 30-2 Abbreviation List ..................................................................................................................................... 30-5 Precautions Before Work .......................................................................................................................30-11 Related Information on Testing and Adjusting ....................................................................................... 30-12 Tools for Testing and Adjusting....................................................................................................... 30-12 Sketch of Tools for Testing and Adjusting ....................................................................................... 30-16 Engine and Cooling System .................................................................................................................. 30-18 Examine Engine Speed.................................................................................................................. 30-18 Examine Exhaust Gas Color .......................................................................................................... 30-20 Examine and Adjust Valve Clearance............................................................................................. 30-22 Examine Compression Pressure .................................................................................................... 30-24 Examine Engine Oil Pressure ........................................................................................................ 30-26 Bleed Air from Fuel System............................................................................................................ 30-28 Examine Fuel Circuit for Leakage .................................................................................................. 30-30 Handle Cylinder Cut-out Mode Operation....................................................................................... 30-31 Examine and Adjust Alternator Belt Tension................................................................................... 30-32 Examine and Adjust Air Conditioner Compressor Belt Tension ...................................................... 30-33 Power Train........................................................................................................................................... 30-35 Examine Swing Circle Bearing Clearance ...................................................................................... 30-35 PC45MR-5, PC55MR-5
00-3
Index
00 Index and Foreword
Undercarriage and Frame ..................................................................................................................... 30-36 Examine and Adjust Track Tension ................................................................................................ 30-36 Hydraulic System .................................................................................................................................. 30-38 Release Remained Pressure in Hydraulic Circuit ........................................................................... 30-38 Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits ............... 30-44 Examine and Adjust Swing and Blade Circuit Oil Pressure ............................................................ 30-55 Examine and Adjust Oil Pressure in Control Circuit........................................................................ 30-62 Adjust Oil Pressure in Pump PC Control Circuit ............................................................................. 30-66 Examine and Adjust Oil Pressure in Pump LS Control Circuit ........................................................ 30-68 Examine Outlet Pressure of Solenoid Valve ................................................................................... 30-72 Examine PPC Valve Outlet Pressure.............................................................................................. 30-75 Adjust Play of Work Equipment and Swing PPC Valves ................................................................. 30-80 Examine Swing Parking Brake Release Pressure .......................................................................... 30-81 Examine and Adjust Travel Deviation............................................................................................. 30-83 Examine Parts Which Cause Hydraulic Drift of Work Equipment.................................................... 30-86 Examine Oil Leakage ..................................................................................................................... 30-88 Bleed Air from Hydraulic System.................................................................................................... 30-91 Pressurize Hydraulic Tank.............................................................................................................. 30-94 CAB Related Parts ................................................................................................................................ 30-95 How to Open and Close Floor Unit................................................................................................. 30-95 Electrical System .................................................................................................................................30-105 Set and Operate Machine Monitor.................................................................................................30-105 How to Start Up KOMTRAX Terminal ............................................................................................30-156 Handle Voltage Circuit of Engine Controller ..................................................................................30-160 Examine Diodes............................................................................................................................30-161 Pm Clinic..............................................................................................................................................30-162 Pm Clinic Service ..........................................................................................................................30-162 40 Troubleshooting ........................................................................................................................................ 40-1 Table of Contents .................................................................................................................................... 40-2 Abbreviation List ..................................................................................................................................... 40-6 Precautions Before Work ...................................................................................................................... 40-12 Related Information to Troubleshooting................................................................................................. 40-13 General Troubleshooting Points ..................................................................................................... 40-13 Sequence of Events in Troubleshooting ......................................................................................... 40-14 Checks Before Troubleshooting ..................................................................................................... 40-16 Inspection Procedure Before Troubleshooting................................................................................ 40-18 Test in Accordance with Testing Procedure .................................................................................... 40-20 Preparation for Troubleshooting of Electrical System ..................................................................... 40-54 Procedure for Troubleshooting ....................................................................................................... 40-58 Symptom and Troubleshooting Numbers ....................................................................................... 40-61 Information Shown in Troubleshooting Table.................................................................................. 40-65 Connector List and Layout ............................................................................................................. 40-67 Connector Contact Identification (For 4D88E-7 Engine)................................................................. 40-83 T-Branch Box and T-Branch Adapter Table .................................................................................... 40-87 Fuse Location Table ....................................................................................................................... 40-93 Precautions When You Clean and Replace KDPF (KCSF and KDOC)........................................... 40-97 Failure Code Table ......................................................................................................................... 40-99 Troubleshooting by Failure Code (Display of Code) .............................................................................40-109 Failure Code [989L00]...................................................................................................................40-109 Failure Code [989M00]..................................................................................................................40-110 Failure Code [989N00] .................................................................................................................. 40-111 Failure Code [AQ20R1].................................................................................................................40-112 Failure Code [B@BCNS]...............................................................................................................40-113 Failure Code [D19JKZ]..................................................................................................................40-114 Failure Code [D811MC].................................................................................................................40-117 Failure Code [D862KA] .................................................................................................................40-118 Failure Code [D8ALKA].................................................................................................................40-119 Failure Code [D8ALKB].................................................................................................................40-121 00-4
PC45MR-5, PC55MR-5
00 Index and Foreword
Index
Failure Code [D8AQKR] ................................................................................................................40-123 Failure Code [DAF0KT].................................................................................................................40-125 Failure Code [DAF0MB] ................................................................................................................40-126 Failure Code [DAF0MC] ................................................................................................................40-127 Failure Code [DAF3KK].................................................................................................................40-128 Failure Code [DAF9KQ] ................................................................................................................40-130 Failure Code [DAFGMC] ...............................................................................................................40-131 Failure Code [DAFLKA].................................................................................................................40-132 Failure Code [DAFLKB].................................................................................................................40-134 Failure Code [DAFQKR]................................................................................................................40-136 Failure Code [DB2QKR] ................................................................................................................40-137 Failure Code [DBH0MC] ...............................................................................................................40-141 Failure Code [DBH2KK] ................................................................................................................40-142 Failure Code [DBH5KP] ................................................................................................................40-145 Failure Code [DBH5KP] ................................................................................................................40-147 Failure Code [DBH9KQ] ................................................................................................................40-149 Failure Code [DBHLKA] ................................................................................................................40-151 Failure Code [DBHLKB] ................................................................................................................40-153 Failure Code [DBHQKR] ...............................................................................................................40-155 Failure Code [DDNRKA] ...............................................................................................................40-160 Failure Code [DDNRKY] ...............................................................................................................40-162 Failure Code [DDNS00] ................................................................................................................40-164 Failure Code [DDWLKA] ...............................................................................................................40-166 Failure Code [DDWLKB] ...............................................................................................................40-168 Failure Code [DFB1KZ].................................................................................................................40-170 Failure Code [DFB3L8] .................................................................................................................40-172 Failure Code [DFB5KZ].................................................................................................................40-174 Failure Code [DHS1MA]................................................................................................................40-176 Failure Code [DHS5MA]................................................................................................................40-178 Failure Code [DKULKA] ................................................................................................................40-180 Failure Code [DKULKB] ................................................................................................................40-182 Failure Code [DKULKY] ................................................................................................................40-184 Failure Code [DV00KB].................................................................................................................40-186 Failure Code [DV20KB].................................................................................................................40-187 Failure Code [DW43KA] ................................................................................................................40-189 Failure Code [DW43KB] ................................................................................................................40-191 Failure Code [DW43KY] ................................................................................................................40-193 Failure Code [DW4CKY] ...............................................................................................................40-194 Failure Code [DXA8KA] ................................................................................................................40-196 Failure Code [DXA8KB] ................................................................................................................40-198 Failure Code [DXE7KA] ................................................................................................................40-200 Failure Code [DXE7KB] ................................................................................................................40-202 Failure Code [DXE7KY] ................................................................................................................40-204 Failure Code [DXEAKA] ................................................................................................................40-206 Failure Code [DXEAKB] ................................................................................................................40-208 Failure Code [DXEAKY] ................................................................................................................40-210 Troubleshooting of Electrical System (E-Mode)....................................................................................40-212 E-1 Engine Does Not Start (Engine Does Not Crank)....................................................................40-212 E-2 Engine Does Not Start (Fuel Feed Pump System)..................................................................40-218 E-3 Automatic Preheating System Does Not Operate ...................................................................40-220 E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...............40-222 E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs.......................40-225 E-6 Charge Level Monitor Comes On in Red While Engine is in Operation...................................40-226 E-7 Fuel Level Monitor Comes On in Red While Engine Runs ......................................................40-227 E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation ...........40-228 E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation .........................40-229 E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum .........................................40-230 E-11 Display of Fuel Gauge is Different from Actual Fuel Level.....................................................40-232 PC45MR-5, PC55MR-5
00-5
Index
00 Index and Foreword
E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum ...............40-233 E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..........40-234 E-14 Some Areas of Machine Monitor Screen are Not Shown ......................................................40-235 E-15 Function Switch Does Not Operate.......................................................................................40-236 E-16 Auto-Decelerator is Not Operated or Canceled with Lever....................................................40-237 E-17 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed ..40-238 E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change .............40-239 E-19 Alarm Buzzer Does Not Sound .............................................................................................40-241 E-20 Alarm Buzzer Cannot be Canceled.......................................................................................40-242 E-21 Service Meter is Not Shown, While Starting Switch is in OFF Position .................................40-243 E-22 Service Mode Cannot be Selected........................................................................................40-244 E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move....................................40-245 E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock.....................................40-247 E-25 Alarm Does Not Sound During Travel ...................................................................................40-249 E-26 Travel Alarm Does Not Stop When Machine Stops...............................................................40-251 E-27 Horn Does Not Sound...........................................................................................................40-252 E-28 Horn Does Not Sound (For Proportional Lever Spec) ...........................................................40-254 E-29 Horn Does Not Stop .............................................................................................................40-256 E-30 Horn Does Not Stop (For Proportional Lever Spec) ..............................................................40-258 E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec)......................................40-260 E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec) ...............40-264 E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate ................................40-268 E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate..................40-270 E-35 Travel Indicator is Not Shown Correctly with Monitoring Function.........................................40-272 E-36 Swing or Arm IN is Not Shown Normally in Monitoring Function ...........................................40-273 E-37 Work Equipment is Not Shown Normally in Monitoring Function...........................................40-274 E-38 KOMTRAX System Does Not Operate Normally...................................................................40-276 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).......................................................40-277 Information Shown in Troubleshooting Table (H-Mode) .................................................................40-277 H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate .................................................40-278 H-2 All Work Equipment or Travel Does Not Operate....................................................................40-279 H-3 Travel or Blade Does Not Operate..........................................................................................40-280 H-4 Swing or Blade Does Not Operate..........................................................................................40-281 H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low...................................40-282 H-6 All Work Equipment and Travel Speed or Power is Low .........................................................40-283 H-7 Travel and Blade Speed or Power is Low ...............................................................................40-284 H-8 Swing and Blade Speed or Power is Low ...............................................................................40-285 H-9 Fine Control Performance or Response is Unsatisfactory.......................................................40-286 H-10 Unusual Noise is Heard from Around Hydraulic Pump..........................................................40-287 H-11 Engine Speed Drops Largely or Engine Stops ......................................................................40-288 H-12 All Work Equipment Speed or Power is Low.........................................................................40-290 H-13 All Work Equipment and Blade Speed or Power is Low........................................................40-291 H-14 Blade Does Not Operate ......................................................................................................40-292 H-15 All Work Equipment Do Not Operate ....................................................................................40-293 H-16 All Work Equipment or Blade Do Not Operate ......................................................................40-294 H-17 Speed or Power of Boom is Low ..........................................................................................40-295 H-18 Arm Speed or Power is Low .................................................................................................40-297 H-19 Bucket Speed or Power is Low.............................................................................................40-298 H-20 Blade Speed or Power is Low...............................................................................................40-299 H-21 Boom Swing Speed or Power is Low....................................................................................40-301 H-22 Work Equipment Does Not Move in Single Operation...........................................................40-302 H-23 Hydraulic Drift of Boom is Large ...........................................................................................40-303 H-24 Hydraulic Drift of Arm is Large..............................................................................................40-304 H-25 Hydraulic Drift of Bucket is Large..........................................................................................40-305 H-26 Hydraulic Drift of Blade is Large ...........................................................................................40-306 H-27 Time Lag of Work Equipment is Large ..................................................................................40-308 H-28 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 40-309 H-29 Machine Does Not Travel Straight ........................................................................................40-310 00-6
PC45MR-5, PC55MR-5
00 Index and Foreword
Index
H-30 Machine Does Not Move Off Straight ...................................................................................40-312 H-31 Machine is Not Steered Correctly or Steering Power is Low .................................................40-313 H-32 Travel Speed is Low .............................................................................................................40-315 H-33 Two Sides of Crawlers Do Not Move ....................................................................................40-317 H-34 One of Tracks Does Not Run................................................................................................40-318 H-35 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast .................................40-320 H-36 Upper Structure Does Not Swing to Right and Left...............................................................40-321 H-37 Upper Structure Swings Only to Right or Left .......................................................................40-323 H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions...............................40-325 H-39 Swing Acceleration or Swing Speed is Low in Only One Direction .......................................40-327 H-40 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left).........40-328 H-41 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) .40-329 H-42 Shock is Large When Upper Structure Stops Swing Operation ............................................40-330 H-43 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation.....................40-331 H-44 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) ..............................40-332 H-45 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) ...........................40-333 Troubleshooting of Engine (S-Mode)....................................................................................................40-334 Information Shown in Troubleshooting Table (S-Mode) .................................................................40-334 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position..............................40-335 S-2 Engine Cranks but No Exhaust Smoke Comes Out ................................................................40-336 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)......40-337 S-4 Engine Startability is Unsatisfactory........................................................................................40-338 S-5 Engine Does Not Pick Up Smoothly........................................................................................40-340 S-6 Engine Stops During Operation ..............................................................................................40-342 S-7 Engine Runs Rough or is Not Stable ......................................................................................40-343 S-8 Engine Lacks Power ...............................................................................................................40-344 S-9 KDPF Becomes Clogged in a Short Time ...............................................................................40-346 S-10 Engine Oil Consumption is Excessive...................................................................................40-347 S-11 Oil Becomes Dirty Quickly.....................................................................................................40-348 S-12 Fuel Consumption is Excessive ............................................................................................40-349 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant.............................................................40-350 S-14 Oil Pressure Drops ...............................................................................................................40-351 S-15 Fuel Mixes Into Engine Oil ....................................................................................................40-353 S-16 Water Mixes Into Engine Oil (Milky) ......................................................................................40-354 S-17 Coolant Temperature Increases Too High (Overheating) ......................................................40-355 S-18 Unusual Noise is Heard ........................................................................................................40-356 S-19 Vibration is Excessive...........................................................................................................40-357 S-20 Air Cannot be Bled from Fuel Circuit.....................................................................................40-358 50 Disassembly and Assembly ...................................................................................................................... 50-1 Table of Contents .................................................................................................................................... 50-2 Abbreviation List ..................................................................................................................................... 50-5 Precautions Before Work .......................................................................................................................50-11 Related Information on Disassembly and Assembly.............................................................................. 50-12 How to Read This Manual .............................................................................................................. 50-12 Coating Materials List..................................................................................................................... 50-13 Special Tool List ............................................................................................................................. 50-18 Sketches of Special Tools .............................................................................................................. 50-23 Engine and Cooling System .................................................................................................................. 50-24 Remove and Install Supply Pump Assembly .................................................................................. 50-24 Remove and Install Starter Assembly ............................................................................................ 50-31 Remove and Install Radiator Assembly.......................................................................................... 50-33 Remove and Install Hydraulic Oil Cooler Assembly........................................................................ 50-40 Remove and Install Engine and Main Pump Assembly .................................................................. 50-47 Remove and Install Fuel Tank Assembly........................................................................................ 50-60 Remove and Install KDPF Assembly.............................................................................................. 50-65 Disassemble and Assemble KDPF Assembly ................................................................................ 50-69 Power Train........................................................................................................................................... 50-70 Remove and Install Travel Motor and Final Drive Assembly........................................................... 50-70 PC45MR-5, PC55MR-5
00-7
Index
00 Index and Foreword
Disassemble and Assemble Final Drive Assembly ......................................................................... 50-74 Remove and Install Swing Motor and Swing Machinery Assembly................................................. 50-83 Disassemble and Assemble Swing Machinery Assembly ............................................................... 50-85 Remove and Install Swing Circle Assembly ................................................................................... 50-92 Undercarriage and Frame ..................................................................................................................... 50-93 Disassemble and Assemble Recoil Spring Assembly..................................................................... 50-93 Separate and Connect Track Assembly ......................................................................................... 50-96 Disassemble and Assemble Idler Assembly ................................................................................... 50-98 Disassemble and Assemble Track Roller Assembly......................................................................50-101 Disassemble and Assemble Carrier Roller Assembly....................................................................50-104 Remove and Install Revolving Frame Assembly ...........................................................................50-107 Remove and Install Counterweight Assembly ...............................................................................50-110 Hydraulic System .................................................................................................................................50-118 Remove and Install Center Swivel Joint Assembly ........................................................................50-118 Disassemble and Assemble Center Swivel Joint Assembly...........................................................50-122 Remove and Install Hydraulic Tank Assembly ...............................................................................50-125 Remove and Install Main Pump Assembly ....................................................................................50-131 Remove and Install Accumulator Assembly ..................................................................................50-137 Disassemble and Assemble Work Equipment PPC Valve Assembly .............................................50-143 Disassemble and Assemble Travel PPC Valve Assembly .............................................................50-146 Work Equipment ..................................................................................................................................50-149 Remove and Install Blade Assembly .............................................................................................50-149 Remove and Install Work Equipment Assembly ............................................................................50-151 Disassemble and Assemble Work Equipment Cylinder Assembly.................................................50-155 CAB Related Parts ...............................................................................................................................50-164 Remove and Install Operator CAB Assembly (CAB Specification) ................................................50-164 Remove and Install Floor Frame Assembly (Canopy Specification) ..............................................50-171 Remove and Install Operator Cab Glass (Adhered Glass) ............................................................50-177 Remove and Install Front Window Assembly ................................................................................50-187 Remove and Install Air Conditioner Unit Assembly .......................................................................50-190 Remove and Install Operator Seat ................................................................................................50-199 How to Remove and Install Seat Belt ............................................................................................50-201 Electrical System .................................................................................................................................50-202 Remove and Install Engine Controller Assembly...........................................................................50-202 Remove and Install Machine Controller Assembly ........................................................................50-204 Remove and Install Machine Monitor Assembly ............................................................................50-207 Remove and Install KOMTRAX Terminal Assembly ......................................................................50-210 60 Maintenance Standard .............................................................................................................................. 60-1 Table of Contents .................................................................................................................................... 60-2 Abbreviation List ..................................................................................................................................... 60-3 Engine and Cooling System .................................................................................................................... 60-9 Maintenance Standard for PTO........................................................................................................ 60-9 Maintenance Standard for Cooling System .................................................................................... 60-10 Power Train............................................................................................................................................60-11 Maintenance Standard for Swing Circle ..........................................................................................60-11 Maintenance Standard for Swing Machinery .................................................................................. 60-12 Maintenance Standard for Sprocket ............................................................................................... 60-14 Undercarriage and Frame ..................................................................................................................... 60-15 Maintenance Standard for Track Frame and Idler Cushion ............................................................ 60-15 Maintenance Standard for Idler ...................................................................................................... 60-16 Maintenance Standard for Track Roller .......................................................................................... 60-18 Maintenance Standard for Carrier Roller ........................................................................................ 60-19 Maintenance Standard for Track Shoes ......................................................................................... 60-20 Maintenance Standard for Triple Shoes ......................................................................................... 60-22 Maintenance Standard for Road Liner............................................................................................ 60-23 Maintenance Standard for Rubber Shoes ...................................................................................... 60-24 Hydraulic System .................................................................................................................................. 60-25 Maintenance Standard for Hydraulic Tank...................................................................................... 60-25 00-8
PC45MR-5, PC55MR-5
00 Index and Foreword
Index
Maintenance Standard for Main Pump ........................................................................................... 60-26 Maintenance Standard for PC-EPC Valve ...................................................................................... 60-28 Maintenance Standard for Swing Motor ......................................................................................... 60-29 Maintenance Standard for Travel Motor ......................................................................................... 60-31 Maintenance Standard for Control Valve ........................................................................................ 60-32 Maintenance Standard for Work Equipment and Swing PPC Valve................................................ 60-44 Maintenance Standard for Blade PPC Valve .................................................................................. 60-47 Maintenance Standard for Boom Swing PPC Valve ....................................................................... 60-49 Maintenance Standard for Travel PPC Valve ................................................................................. 60-51 Maintenance Standard for Attachment PPC Valve ......................................................................... 60-54 Maintenance Standard for Center Swivel Joint............................................................................... 60-56 Work Equipment ................................................................................................................................... 60-57 Maintenance Standard for Work Equipment Linkage...................................................................... 60-57 Maintenance Standard for Boom Cylinder...................................................................................... 60-68 Maintenance Standard for Arm Cylinder......................................................................................... 60-70 Maintenance Standard for Bucket Cylinder .................................................................................... 60-72 Maintenance Standard for Blade Cylinder ...................................................................................... 60-74 Maintenance Standard for Boom Swing Cylinder ........................................................................... 60-75 80 Appendix ................................................................................................................................................... 80-1 Table of Contents .................................................................................................................................... 80-2 Abbreviation List ..................................................................................................................................... 80-3 Precautions Before Work ........................................................................................................................ 80-9 Air Conditioner System ......................................................................................................................... 80-10 Precautions for Refrigerant ............................................................................................................ 80-10 Air Conditioner Component .............................................................................................................80-11 Specifications of Air Conditioner .................................................................................................... 80-12 Structure and Function of Refrigeration Cycle ................................................................................ 80-13 Outline of Refrigeration Cycle ........................................................................................................ 80-14 Component Parts of Air Conditioner System ......................................................................................... 80-16 Air Conditioner Unit ........................................................................................................................ 80-16 Compressor ................................................................................................................................... 80-18 Condenser ..................................................................................................................................... 80-20 Receiver Drier ................................................................................................................................ 80-22 Information Shown in Troubleshooting Table......................................................................................... 80-23 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) ............................. 80-24 A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) ................. 80-27 A-3 Troubleshooting for Temperature Control Function ......................................................................... 80-31 A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System) ............. 80-34 A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems) ........ 80-38 A-6 Troubleshooting for Hot Water Circuit System ................................................................................ 80-39 A-7 Unusual Noise is Heard from Air Conditioner Related Parts ........................................................... 80-40 A-8 Water Leaks from Air Conditioner Related Parts............................................................................. 80-41 A-9 Troubleshooting for Fresh/Recirc Air Changeover .......................................................................... 80-42 Precautions for Disconnection and Connection of Air Conditioner Piping .............................................. 80-43 Handle Compressor Oil......................................................................................................................... 80-45 90 Circuit Diagrams........................................................................................................................................ 90-1 Table of Contents .................................................................................................................................... 90-2 Abbreviation List ..................................................................................................................................... 90-3 Hydraulic Circuit Diagram........................................................................................................................ 90-9 Symbols Used in Hydraulic Circuit Diagram ..................................................................................... 90-9 Hydraulic Circuit Diagram............................................................................................................... 90-13 Hydraulic Circuit Diagram (Quick Coupler Specifications) (1/2) ...................................................... 90-15 Hydraulic Circuit Diagram (Quick Coupler Specifications) (2/2) ...................................................... 90-17 Electrical Circuit Diagram ...................................................................................................................... 90-19 Symbols Used in Electric Circuit Diagram ...................................................................................... 90-19 Electrical Circuit Diagram (Canopy Spec) (1/5) .............................................................................. 90-23 Electrical Circuit Diagram (Canopy Spec) (2/5) .............................................................................. 90-25 Electrical Circuit Diagram (Canopy Spec) (3/5) .............................................................................. 90-27 PC45MR-5, PC55MR-5
00-9
Index
00 Index and Foreword
Electrical Circuit Diagram (Canopy Spec) (4/5) .............................................................................. 90-29 Electrical Circuit Diagram (Canopy Spec) (5/5) .............................................................................. 90-31 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (1/5) ................. 90-33 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (2/5) ................. 90-35 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (3/5) ................. 90-37 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (4/5) ................. 90-39 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (5/5) ................. 90-41 Electrical Circuit Diagram (Cab Spec) (1/6).................................................................................... 90-43 Electrical Circuit Diagram (Cab Spec) (2/6).................................................................................... 90-45 Electrical Circuit Diagram (Cab Spec) (3/6).................................................................................... 90-47 Electrical Circuit Diagram (Cab Spec) (4/6).................................................................................... 90-49 Electrical Circuit Diagram (Cab Spec) (5/6) .................................................................................... 90-51 Electrical Circuit Diagram (Cab Spec) (6/6).................................................................................... 90-53 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (1/6) ....................... 90-55 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (2/6) ....................... 90-57 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (3/6) ....................... 90-59 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (4/6) ....................... 90-61 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (5/6) ....................... 90-63 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (6/6) ....................... 90-65 Index ....................................................................................................................................................................1
00-10
PC45MR-5, PC55MR-5
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, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
00-11
Abbreviation List
Abbreviation
Actual word spelled out
00 Index and Foreword
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
00-12
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
00 Index and Foreword
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
00-13
Abbreviation List
00 Index and Foreword
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
00-14
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
00 Index and Foreword
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
00-15
Abbreviation List
00 Index and Foreword
Abbreviation S/T STRG
Actual word spelled out Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
00-16
PC45MR-5, PC55MR-5
00 Index and Foreword
How to Read the Shop Manual
Foreword, Safety, Basic Information How to Read the Shop Manual •
Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
•
The materials and specifications are subject to change without notice.
•
Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
•
Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
•
The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
•
•
For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
•
For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
•
For details of the switches, see the “Operation and Maintenance Manual”.
All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual. REMARK The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same as the terminology in the shop manual.
Composition of the Shop Manual This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword This section describes the index, foreword, safety, and basic information.
01 Specification This section describes the specifications of the machine.
10 Structure and Function This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
PC45MR-5, PC55MR-5
00-17
How to Read the Shop Manual
00 Index and Foreword
50 Disassembly and Assembly This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effectively. Symbol
Item
Remark
Danger
This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
Warning
This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
Caution
This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This signal indicates the weight of parts and components, and items which requires great attention to a selection of wires and working posture for slinging work.
Tightening torque
This signal indicates the tightening torque for portions which requires special care in assembling work.
Coat
This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolant
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining
This signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal Word Signal word for notice and remark describes the following. Symbol
Item
Remark
NOTICE
Notice
If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.
REMARK
Remark
This signal word contains useful information to know.
Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
00-18
PC45MR-5, PC55MR-5
00 Index and Foreword
Safety Notice for Operation
Safety Notice for Operation •
Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
•
The symbol mark
is indicated for such matters that require special precautions. The work indicated with
should be performed according to the instructions with special attention. Should a this warning mark hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.
Safety Considerations •
Well organized work place
•
Correct work clothes
•
Observance of work standard
•
Enforcement of hand signals
•
Prohibition against unlicensed persons operating and handling the machine
•
Safety check before starting work
•
Wear of dust glasses (for cleaning or grinding work)
•
Wear of welding goggles and protectors (for welding work)
•
Being in good physical condition, and good preparation
•
Always be alert and careful.
General Precautions k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this manual before operation. •
Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.
•
Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.
•
Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
•
Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.
PC45MR-5, PC55MR-5
00-19
Safety Notice for Operation
00 Index and Foreword
•
Always wear the protective eyeglasses when hitting parts with a hammer.
•
Always wear the protective eyeglasses when grinding parts with a grinder, etc.
•
When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals. Hang “UNDER REPAIR” warning tag in the operator's compartment Before starting work.
•
Only the approved personnel can do the work in a closed environment or in a prohibited area.
•
Work and operation which require license or qualification should be performed by qualified workers.
•
Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
•
Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.
•
Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.
•
When you work in high places, use a platform.
•
Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
•
Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
•
Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
•
When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
•
If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.
,&
Precautions for Preparatory Work •
Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.
•
Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” warning tag on them.
•
When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
•
Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately. ,&
00-20
PC45MR-5, PC55MR-5
00 Index and Foreword
Safety Notice for Operation
Precautions During Work •
For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position. REMARK Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.
•
For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).
•
Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
•
When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
•
The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
PC45MR-5, PC55MR-5
00-21
Safety Notice for Operation
00 Index and Foreword
•
Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
•
When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
•
When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.
•
When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.
•
When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
•
Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.
•
Install the disassembled parts again to the original position. Replace the damaged parts or the parts that cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that they do not touch and give damage to other parts when you operate the machine. REMARK
,&
When you replace the removed or disassembled parts with new ones, refer the parts book to find out the part number. •
When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.
•
When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
•
Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
•
Check that the measuring tools are correctly installed when measuring hydraulic pressure.
•
Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.
•
If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.
•
When removing the soot filter from the KDPF for cleaning purposes, soot ash remaining in the filter may scatter. Wear gloves, anti-dust masks, eye protection and other protective equipment.
•
When transporting a KDPF unit with a soot filter for maintenance or cleaning, fix it firmly in the package to prevent soot ash scattering during transport.
•
Soot ash removed from the soot filter may be considered as industrial waste.
00-22
PC45MR-5, PC55MR-5
00 Index and Foreword
Safety Notice for Operation
Adequate provision must be assured for the containment of the material once it is removed. Disposal should be performed in accordance with local laws and regulations.
,&
Precautions for Slinging Work and When You Make Signals •
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.
k Do not do the work while the lifted load is in the range where it possibly falls. It is not allowed to
go in the range where the lifted load possibly falls.
k Do not move a load over a person. k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly. •
When you lift or fix the machine, see “Operation and Maintenance Manual” or “Field Assembly Instruction”. k Do not lift or fix the machine by the positions where the name plate is not attached.
•
When you lift the machine for the disassembly and assembly, follow the instructions on the Disassembly and Assembly.
•
Check the slings before starting sling work.
•
Keep putting on gloves during sling work. (Put on leather gloves, if available.)
•
Measure the weight of the load by the eye and check its center of gravity.
•
Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
•
Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a dangerous accident. •
Hanging angle must be 60 ° or smaller as a rule.
•
When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.
PC45MR-5, PC55MR-5
00-23
Safety Notice for Operation
00 Index and Foreword
REMARK When slinging a load with 2 or more ropes, the force subjected 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 various hanging angles. When the 2 ropes sling a load vertically, 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), reduced 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 When You Use Mobile Crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions When You Use Overhead Traveling Crane k When raising a heavy component (heavier than 25 kg), use a hoist or crane.
00-24
PC45MR-5, PC55MR-5
00 Index and Foreword
Safety Notice for Operation
REMARK Weight of component whose weight is heavier than 25 kg is shown with symbol sembly”. •
in “Disassembly and As-
Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items. •
Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.
•
Observe the signals for sling work.
•
Operate the hoist at a safe place.
•
Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.
•
Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
•
Do not raise or lower a load while the crane is moving longitudinally or laterally.
•
Do not drag a sling.
•
When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
•
Consider the travel route in advance and lift up a load to a safe height.
•
Place the control switch in a position where it is not an obstacle to work and passage.
•
After operating the hoist, do not swing the control switch.
•
Remember the position of the main switch so that you can turn off the power immediately in an emergency.
•
If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition.
•
If you find an obstacle around the hoist, stop the operation.
•
After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
Select Wire Ropes Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below. REMARK The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope. Wire Rope (JIS G3525 6x37-A Type) (Standard Z Twist Wire Ropes Without Galvanizing) Nominal diameter of rope (mm)
Allowable load (kN {t} )
10
8.8 {0.9}
12
12.7 {1.3}
14
17.3 {1.7}
16
22.6 {2.3}
18
28.6 {2.9}
20
35.3 {3.6}
25
55.3 {5.6}
30
79.6 {8.1}
40
141.6 {14.4}
50
221.6 {22.6}
60
318.3 {32.4}
PC45MR-5, PC55MR-5
00-25
Safety Notice for Operation
00 Index and Foreword
Precautions When You Disconnect Air Conditioner Piping NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses. REMARK • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite. •
When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.
Precautions for Air Conditioner Piping •
When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
•
Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
•
Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
•
When removing the O-rings, use a soft tool so that the piping is not damaged.
•
Check that the O-ring is not damaged or deteriorated.
•
Apply compressor oil for refrigerant (R134a) to O-ring. REMARK Do not apply oil to the threaded portion of a bolt, nut or union. Manufacturer
Part name
DENSO
ND-OIL8
VALEO THERMAL SYSTEMS
ZXL100PG (PAG46 or equivalent)
SANDEN
SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
00-26
PC45MR-5, PC55MR-5
00 Index and Foreword
Safety Notice for Operation
REMARK • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see Others, “Precautions for Disconnection and Connection of Air Conditioner Piping”.
PC45MR-5, PC55MR-5
00-27
Precautions to Prevent Fire
00 Index and Foreword
Precautions to Prevent Fire Fire Caused by Fuel, Oil, Coolant or Window Washer Fluid Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following. •
Do not smoke or use any open flame near fuel or other flammable substances.
•
Shut down the engine before adding fuel.
•
Do not leave the machine when adding fuel or oil.
•
Tighten all the fuel and oil caps securely.
•
Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.
•
After adding fuel or oil, wipe up any spilled fuel or oil.
•
Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.
•
When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.
•
Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
•
Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
•
When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
,&
,&
Fire Caused by Accumulated or Attached Flammable Objects •
Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
•
To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
Fire Caused by Electrical System Short circuits in the electrical system can cause fire. Always observe the following. •
Keep all the electric wiring connections clean and securely tightened.
•
Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
Fire from Pipings Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
Fire Caused by High Temperature Exhaust Gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (regeneration), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not bring any flammable materials close to exhaust pipe outlet.
00-28
PC45MR-5, PC55MR-5
00 Index and Foreword
•
Precautions to Prevent Fire
When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration. See the Operation and Maintenance Manual for the setting procedure.
Explosion Caused by Light •
When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.
•
When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual.
PC45MR-5, PC55MR-5
00-29
Procedures If Fire Occurs
00 Index and Foreword
Procedures If Fire Occurs •
Turn the starting switch to OFF position to stop the engine.
•
Use the handrails and steps to get off the machine.
•
Do not jump off the machine. You may fall and suffer serious injury.
•
The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled. Do not breathe the fumes.
•
After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on your body. Be sure to wear rubber gloves when handling the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton work gloves, wear rubber gloves under them.
00-30
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Discard Waste Materials
Precautions When You Discard Waste Materials To prevent pollution, pay full attention to the way to dispose of waste materials. •
Always drain the oil from your machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.
•
Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. •
When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products.
PC45MR-5, PC55MR-5
00-31
Precautions When You Handle Hydraulic Equipment
00 Index and Foreword
Precautions When You Handle Hydraulic Equipment Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
Select an Applicable Workplace •
In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.
Disassembly and Maintenance Work in the Field k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hydraulic equipment is performed. k Release the remaining pressure from the hydraulic circuit always before performing the work. •
In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.
•
Perform disassembling and maintenance work in the dust proof area.
Seal Openings (Prevention of Flowing Out of Oil) Plug the openings of the piping and the device which have been removed to prevent foreign material from entering and oil from flowing out. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment. Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.
00-32
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Handle Hydraulic Equipment
Preventing Intrusion of Foreign Materials While You Refill •
During refilling with the hydraulic oil, do not let water enter the electrical components.
•
Clean the oil filler port and its around, refilling pump, oil jug, or etc.
•
Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage.
Replace Hydraulic Oil While Its Temperature is High •
The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.
•
Old hydraulic oil needs to be drained as much as possible when replacing. NOTICE Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened. REMARK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.
Do Not Use the Hydraulic Oil and Lubricating Oil Again Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine. If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing Operation •
Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.
•
Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.
Cleaning Operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine.
PC45MR-5, PC55MR-5
00-33
Precautions When You Handle Hydraulic Equipment
00 Index and Foreword
REMARK The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device.
00-34
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Disconnect and Connect Pipings
Precautions When You Disconnect and Connect Pipings When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and assembly” of the components, observe the following precautions.
Precautions for Removal and Disassembly Work •
If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.
•
After disconnecting the hoses or tubes, plug them to prevent dust from entering.
•
When draining oil, prepare a container with sufficient capacity.
•
Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.
•
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
•
Attach the tags to wires and hoses so that installation is done to the correct installing positions.
•
Check the thickness and number of shims when storing shims.
•
When hoisting the components, prepare the slings with sufficient strength.
•
When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
•
Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.
•
To disconnect the face seal type hose from the cylinder tube, loosen the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only.Check after disconnecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient. NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
•
After disconnecting the piping or removing a pipe joint, install the following plugs. NOTICE When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions. REMARK The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.
PC45MR-5, PC55MR-5
00-35
Precautions When You Disconnect and Connect Pipings
00 Index and Foreword
Introduction of Parts for the Disassembly of the Face Seal Type Hoses and Tubes
Hose side
Pipe joint side
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
Nominal No.
O-ring (3)
Introduction of Parts for the Disconnection of the Taper Seal Type Hoses and Tubes
Hose side
Pipe joint side
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
Nominal No.
00-36
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Disconnect and Connect Pipings
Introduction of Parts for the Disconnection of the Split Flange Type Hoses and Tubes
Nomi nal No.
Bolt pitch (mm) a
b
Flange (1)
04
38.1
17.5
07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05
42.9
19.8
07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06
47.6
22.2
07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10
52.4
26.2
07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7
30.2
07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
66.7
31.8
07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9
35.8
07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
79.4
36.5
07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8
42.8
07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
96.8
44.5
07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24
88.9
50.8
07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30
106.4
62
07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34
120.6
69.8
07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40
130.2
77.8
07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50
152.4
92
07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645
12
14
20
Hose side
Tube side Split flange (2)
Sleeve head (3)
O-ring (4)
Bolt (5)
Washer (6)
Introduction of Parts for the Removal of O-Ring Boss Type Joint
PC45MR-5, PC55MR-5
00-37
Precautions When You Disconnect and Connect Pipings
00 Index and Foreword
Nominal No.
Plug (1)
O-ring (2)
08
07040-10807
07002-10823
10
07040-11007
07002-11023
12
07040-11209
07002-11223
14
07040-11409
07002-11423
16
07040-11612
07002-11623
18
07040-11812
07002-11823
20
07040-12012
07002-12034
24
07040-12412
07002-12434
30
07041-13012
07002-13034
33
07040-13316
07002-13334
36
07041-13612
07002-13634
42
07040-14220
07002-14234
52
07040-15223
07002-15234
Introduction of Parts for the Removal of Taper Pipe Thread Type Joint
Plug (1)
Nominal No.
Nominal thread size
Square head type (A)
Hexagonal socket head (B)
01
R1/8
07042-00108
07043-00108
02
R1/4
07042-00211
07043-00211
03
R3/8
07042-00312
07043-00312
04
R1/2
07042-00415
07043-00415
06
R3/4
07042-00617
07043-00617
10
R1
07042-01019
07043-01019
12
R11/4
07042-01222
07043-01222
14
R11/2
07042-01422
07043-01422
20
R2
07042-02026
07043-02026
Precautions for Installation and Assembly Work •
Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
•
Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
00-38
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Disconnect and Connect Pipings
•
Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
•
Bend the cotter pins and lock plates securely.
•
When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to the threaded portion.
•
When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dust or damage.
•
Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
•
Apply engine oil to the rotating parts and sliding surface.
•
Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
•
After installing the snap ring, check that the snap ring is settled in the ring groove completely.
•
When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them securely.
•
Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.
•
When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
•
As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. REMARK If the threaded portion is difficult to degrease, you may use a seal tape. When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end. NOTICE If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.
•
To connect the face seal type hose to the cylinder tube, tighten the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point at the same time as shown in the following figure. Use the grip strength only.Check after connecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient. NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
NOTICE When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure. 1. Start the engine, and run it at low idle. 2.
Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.
3.
Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times.
PC45MR-5, PC55MR-5
00-39
Precautions When You Disconnect and Connect Pipings
00 Index and Foreword
NOTICE After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure.
Precautions at the End Time of Work Refilling of coolant or water or oil, greasing, and adding of DEF •
For machines with urea SCR system, fill DEF to the specified level before starting the engine.
•
Supply the specified amount of grease to the work equipment parts.
•
When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
•
When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.
•
If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system. See “TESTING AND ADJUSTING”.
Testing installed condition of cylinder heads and manifolds •
Check the cylinder head and intake and exhaust manifold mountings for looseness.
•
If there is any looseness, retighten the part. REMARK For the tightening torques, see “Disassembly and Assembly”.
Test engine piping for damage and looseness Intake and exhaust system Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion. If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion. If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion. If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage. REMARK When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.) • KDPF • DEF mixing tube • SCR assembly • KDOC muffler • Muffler • Exhaust pipe • KDPF & SCR Ass'y • Parts which connects the above, or etc.
00-40
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Disconnect and Connect Pipings
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there is any damage, replace the part. Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the installation portion. If there is any looseness, retighten the part.
Check of function of muffler in exhaust system REMARK When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.) • KDPF • DEF mixing tube • SCR assembly • KDOC muffler • Muffler • Exhaust pipe • KDPF & SCR Ass'y • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair KDPF or muffler, referring to “Troubleshooting” and “Disassembly and Assembly”.
PC45MR-5, PC55MR-5
00-41
Precautions When You Handle Electrical Equipment
00 Index and Foreword
Precautions When You Handle Electrical Equipment To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.
Handle Wiring Harnesses and Connectors •
Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.
•
Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by 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 and maintenance of the wiring harnesses.
•
If DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact. Be careful not to spill it over electrical equipment, wiring harness and connectors since DEF is strongly corrosive to metal.
Main Causes of Failure in Wiring Harness Defective contact of connectors (defective contact between male and female connectors) 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 connectors are 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 disconnecting the connectors approximately 10 times.
Defective crimping or soldering of connectors The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.
00-42
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Handle Electrical Equipment
Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.
Water entering the connector by high-pressure jetting 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. Do not spray water directly on the connector. If the connector is waterproof, intruded water is hardly drained. Once water enters into the connector, water goes through pins to cause short-circuit. Drying the drenched connector or take appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a connector If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through resulting in defective contact. If any oil, grease, dirt or dust is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air, and wash it with electrical contact restorer. NOTICE • When wiping the jointed portion of the connector, do not apply excessive force or deform the pins. • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.
PC45MR-5, PC55MR-5
00-43
Precautions When You Handle Fuel System Equipment
00 Index and Foreword
Precautions When You Handle Fuel System Equipment The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an Applicable Workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Seal the Opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment. Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
How to Clean Parts When Dirt is Stuck If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions When You Replace Fuel Filter Cartridge Be sure to use the Komatsu genuine fuel filter cartridge. NOTICE The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
00-44
PC45MR-5, PC55MR-5
00 Index and Foreword
Precautions When You Handle Intake System Equipment
Precautions When You Handle Intake System Equipment The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an Applicable Workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Seal the Opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it.
PC45MR-5, PC55MR-5
00-45
Practical Use of KOMTRAX
00 Index and Foreword
Practical Use of KOMTRAX Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers. When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently. Large-sized models are equipped with KOMTRAX Plus which can use more detailed information. REMARK (KOMTRAX may not be installed to the machine in some countries or areas.)
Advantage to Use KOMTRAX •
The location where the machine is working at can be checked on the map in a personal computer.
•
Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.
•
The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
•
Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.
•
Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is utilized as an advice tool for the user and operator.
•
KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.
How to Make a Full Use of KOMTRAX Making use of KOMTRAX enables the following activities. •
•
Quick response to a request for immediate repair 1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user. 2.
To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
3.
To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
Proactive maintenance 1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag. 2. To check the condition of the machine with the customer and to make a plan to visit. 3.
•
To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
Practice of periodic maintenance and periodic inspection service 1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over. 2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer. 3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to Operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.
00-46
PC45MR-5, PC55MR-5
00 Index and Foreword
Disconnect and Connect Push-Pull Type Coupler
Disconnect and Connect Push-Pull Type Coupler REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. • Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
How to Disconnect and Connect Type 1 Push-Pull Type Coupler Disconnection 1.
Hold adapter (1), and push hose joint (2) into mating adapter (3). REMARK • Push it in approximately 3.5 mm. • Do not hold rubber cap portion (4).
2.
While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.
3.
Hold hose adapter (1) or hose (5), and pull it out. REMARK Provide an oil container to receive a quantity of hydraulic oil which may flow out.
Connection 1.
Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4).
PC45MR-5, PC55MR-5
00-47
Disconnect and Connect Push-Pull Type Coupler
2.
00 Index and Foreword
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 problem.
How to Disconnect and Connect 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.
00-48
PC45MR-5, PC55MR-5
00 Index and Foreword
Disconnect and Connect Push-Pull Type Coupler
Connection 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.
How to Disconnect and Connect Type 3 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, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.
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-5, PC55MR-5
00-49
Disconnect and Connect Push-Pull Type Coupler
00 Index and Foreword
Connection 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.
00-50
PC45MR-5, PC55MR-5
00 Index and Foreword
Foreword, Safety, Basic Information
Precautions for Disconnection and Connection of Connectors Disconnect Connectors 1.
Hold the connectors when disconnecting. When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel. NOTICE Do not pull the connectors with one hand. REMARK If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.
2.
When removing a connector from a clip •
Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.
•
When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers. NOTICE If the connector is pried up and down or to the right or left, it may break the housing.
3.
Action to be taken after removing connectors After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion. NOTICE Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.
Connect Connectors 1.
Check the connector visually. •
Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
PC45MR-5, PC55MR-5
00-51
Foreword, Safety, Basic Information
00 Index and Foreword
•
Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
•
Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE • If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur. • If there is any damage or breakage, replace the connector. 2.
Connecting the connector securely Position connector (1) correctly, and fit it in securely. REMARK If the connector is lock stopper type, insert it until it clicks.
3.
Correct the protrusion of the boot and misalignment of the wiring harness.
•
If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position. REMARK If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.
•
If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.
Dry Wiring Harness REMARK If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
00-52
PC45MR-5, PC55MR-5
00 Index and Foreword
1.
Foreword, Safety, Basic Information
Disconnect the connector and wipe off the water with a dry cloth. NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.
2.
Dry the inside of the connector with a dryer. If water enters inside the connector, use a dryer to dry the connector. NOTICE Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.
3.
Perform a continuity test on the connector. After drying, leave the wiring harness disconnected, connect T-adapter(1), and perform a continuity test to check for any short circuits between pins caused by water or etc. REMARK After the connector is completely dried, blow the contact restorer, and reassemble them.
Handle Controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.
PC45MR-5, PC55MR-5
00-53
Foreword, Safety, Basic Information
00 Index and Foreword
NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine. • Do not leave things on the controller. • Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector. • Do not leave the controller in a place where it is exposed to rain. • Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).
Precautions for Troubleshooting Electrical Circuits •
Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
•
Before performing troubleshooting, check all the related connectors for loose connection. REMARK Check the related connectors for their performance by disconnecting and connecting them several times.
•
Be sure to connect all the disconnected connectors before proceeding to the next step. NOTICE If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.
•
When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit.
00-54
PC45MR-5, PC55MR-5
00 Index and Foreword
Foreword, Safety, Basic Information
Disconnect and Connect Deutsch Connector Disconnect DEUTSCH Connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
Connect DEUTSCH Connector 1.
Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)
2.
In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.
PC45MR-5, PC55MR-5
00-55
Foreword, Safety, Basic Information
00 Index and Foreword
How to Disconnect and Connect Slide Lock Type Connector How to Disconnect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2) 1.
Slide lock (L1) to the right.
2.
While pressing lock (L2), pull out connector (1) toward you. REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
How to Connect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2) Insert it straight until it clicks.
How to Disconnect Slide Lock Type Connector (FRAMATOME-24) 1.
Slide down lock (red) (L1).
00-56
PC45MR-5, PC55MR-5
00 Index and Foreword
2.
Foreword, Safety, Basic Information
While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure.
How to Connect Slide Lock Type Connector (FRAMATOME-24) Insert it straight until it clicks.
PC45MR-5, PC55MR-5
00-57
Foreword, Safety, Basic Information
00 Index and Foreword
Disconnect and Connect Connector with Lock to Pull How to Disconnect Connector with Lock to Pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
How to Connect Connector with Lock to Pull Insert the connector securely until it “clicks”.
00-58
PC45MR-5, PC55MR-5
00 Index and Foreword
Foreword, Safety, Basic Information
Disconnect and Connect Connector with Lock to Push How to Disconnect Connector with Lock to Push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. • 114 series
•
107 series
REMARK If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
How to Connect Connector with Lock to Push (BOSCH-3) Insert it straight until it clicks.
PC45MR-5, PC55MR-5
00-59
Foreword, Safety, Basic Information
00 Index and Foreword
How to Disconnect Connector with Lock to Push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.
How to Connect Connector with Lock to Push (AMP-3) Insert it straight until it clicks.
How to Disconnect 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.
How to Connect Connector with Lock to Push (SUMITOMO-3) Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (SUMITOMO-4) While pressing lock (D), pull out connector (4) in the direction of the arrow.
How to Connect Connector with Lock to Push (SUMITOMO-4) Insert it straight until it clicks.
00-60
PC45MR-5, PC55MR-5
00 Index and Foreword
Foreword, Safety, Basic Information
Disconnect and Connect Connector with Housing to Rotate How to Disconnect Connector with Housing to Rotate Turn housing (H1) to the left, and pull it out. REMARK Housing (H1) is left on the wiring harness side.
Connect Connector with Housing to Rotate 1.
Insert the connector to the end while aligning its groove to the other.
2.
Turn housing (H1) clockwise until it clicks.
PC45MR-5, PC55MR-5
00-61
How to Read the Codes for Electric Cable
00 Index and Foreword
How to Read the Codes for Electric Cable In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol. AEX
0.85 L
Type, symbol, and material of wire are shown in (Table 1). (Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on the diagram.) Indicates size of wire by nominal No. Sizes (Nominal Nos.) are shown in (Table 2). Indicates color of wire by color code. Color codes are shown in (Table 3).
Type, Symbol, and Material AV and AVS are different in only thickness and outside diameter of the coating. The conductors of CAVS and AVSS are round compressed conductors. And the outside diameter of the conductor and the thickness of the coating are different from those of AV and AVS. As for AEX, the thickness and outside diameter of the coating are similar to those of AV, but the coating material is different from that of AV and AVS. (Table 1) Type
Symbol
Low-voltage wire for automobile
AV
Thin-cover low-voltage wire for automobile
Conductor material
Insulator material
Temperature range (°C) in use
Example of use For large current wiring (nominal No. 5 and above)
General wiring
AVS -30 to +60
(nominal No. 3 and lower)
(Type 1) Thin-cover low-voltage wire for automobile
Soft polyvinyl chloride CAVS
(nominal No. 1.25 and lower)
(Type 2) Ultra-thin-cover low-voltage power supply AVSS for automobiles Heat-resistant low-voltage wire for automobile
Annealed copper for electric appliance -40 to +80
For industrial vehicles (for forklift trucks) Nominal No.0.5f to 2f General wiring for extremely cold weather specification
AEX
Heat-resistant ultra-thin lowAESS voltage elecX trical wire for automobiles
00-62
For mid- to small-size excavators
Heat-resistant crosslinked polyethylene
Wiring at high-temperature place -50 to +110 Extremely cold area and heat resistance specifications Thin-cover wiring
PC45MR-5, PC55MR-5
00 Index and Foreword
How to Read the Codes for Electric Cable
Dimensions
(Table 2) Nominal No.
Coating D
Conductor
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of strands
20
7
30
11
50
16
37
26
58
41
65
Diameter of strand
0.18
0.32
0.18
0.32
0.18
0.32
0.26
0.32
0.26
0.32
0.32
Cross-sectional area (mm2)
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
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
-
AV
Standard
-
-
-
-
-
-
-
4.6
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
50
84
41
70
85
108
127
169
217
Diameter of strand
0.45
0.45
0.80
0.80
0.80
0.80
0.80
0.80
0.80
Cross-sectional area (mm2)
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
-
-
-
-
-
-
-
-
-
AV
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Coating D
Conductor
Nominal No.
Conductor
0.5f
0.5
0.75f
0.85
1.25f
1.25
Number of strands
-
7
-
11
-
16
Diameter of strand
-
round compression
-
round compression
Cross-sectional area (mm2)
-
0.56
-
0.88
-
1.29
d (approx.)
-
0.9
-
1.1
-
1.4
PC45MR-5, PC55MR-5
round compression
00-63
Coating D
How to Read the Codes for Electric Cable
00 Index and Foreword
Nominal No.
0.5f
0.5
0.75f
0.85
1.25f
1.25
CAVS Standard
-
1.6
-
1.8
-
2.1
Nominal No.
Coating D
Conductor
AVSS
0.5f
0.75f
1.25f
2f
Number of strands
19
19
37
37
Diameter of strand
0.19
0.23
0.21
0.26
Cross-sectional area (mm2)
0.54
0.79
1.28
2
d (approx.)
1
1.2
1.5
1.8
Standard
1.6
1.8
2.1
2.6
0.5f
0.75f
1.25f
2f
Number of strands
19
19
37
37
Diameter of strand
0.19
0.23
0.21
0.26
Cross-sectional area (mm2)
0.5387
0.7894
1.282
1.964
d (approx.)
1
1.2
1.5
1.8
Standard
1.6
1.8
2.1
2.6
Nominal No.
Coating D
Conductor
AESSX
REMARK “f” of nominal No. denotes “flexible”.
Color Code Table (Table 3) Color Code
00-64
Color of wire
Color Code
Color of wire
B
Black
LgW
Light green and White
Br
Brown
LgY
Light green and Yellow
BrB
Brown and Black
LR
Blue and Red
BrR
Brown and Red
LW
Blue and White
BrW
Brown and White
LY
Blue and Yellow
BrY
Brown and Yellow
O
Orange
Ch
Charcoal
P
Pink
Dg
Dark green
R
Red
G
Green
RB
Red and Black
GB
Green and Black
RG
Red and Green
GL
Green and Blue
RL
Red and Blue
Gr
Gray
RW
Red and White
GR
Green and Red
RY
Red and Yellow
PC45MR-5, PC55MR-5
00 Index and Foreword
Color Code
How to Read the Codes for Electric Cable
Color of wire
Color Code
Color of wire
GW
Green and White
Sb
Sky Blue
GY
Green and Yellow
Y
Yellow
L
Blue
YB
Yellow and Black
LB
Blue and Black
YG
Yellow and Green
Lg
Light green
YL
Yellow and Blue
LgB
Light green and Black
YR
Yellow and Red
LgR
Light green and Red
YW
Yellow and White
REMARK 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 indicates that the background is “Green” and marking is “White”.
Circuit Type and Color Code Type of wire
AVS, AV, CAVS, AVSS
AEX,AESSX
Charge
R
WG
-
-
-
-
R
-
Ground
B
-
-
-
-
-
B
-
Start
R
-
-
-
-
-
R
-
Light
RW
RB
RY
RG
RL
-
O
-
Instrument
Y
YR
YB
YG
YL (*1)
YW (*1)
Y
Gr
Signal
G
GW
GR
GY
GB
GL (*1)
G
Br
L
LW
LR
LY
LB
-
L
-
Br
BrW (*2)
BrR (*2)
BrY (*2)
BrB (*2)
-
-
-
Lg
LgR (*2)
LgY (*1)
LgB (*2)
LgW (*1)
-
-
-
O (*1)
-
-
-
-
-
-
-
Gr
-
-
-
-
-
-
-
P
-
-
-
-
-
-
-
Sb
-
-
-
-
-
-
-
Dg (*1)
-
-
-
-
-
-
-
Ch (*1)
-
-
-
-
-
-
-
Type of circuit
Others
*1: This item is not set to AVSS. *2: This item is not set to 0.75f to 2f of AVSS.
PC45MR-5, PC55MR-5
00-65
Explanation of Terms for Maintenance Standard
00 Index and Foreword
Explanation of Terms for Maintenance Standard The maintenance standard section shows the judgment criteria whether the equipment or parts should be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.
Standard Dimension and Tolerance •
The finished dimension of a part is slightly different from one to another actually.
•
A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the part.
•
The dimension set as the standard is called the standard dimension and the allowable range of difference from this standard dimension is called “tolerance”.
•
An indication example of a standard dimension and tolerance is shown in the following table. (The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side)
Example: Standard dimension
Tolerance -0.022
120
-0.126
•
The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/ lower limit of tolerance).” Example) 120 (-0.022/ -0.126)
•
Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is determined by the tolerance.
•
A dimension indication example of a shaft and hole is shown in the following table. (The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension
60
00-66
Tolerance Shaft
Hole
-0.030
+0.046
-0.076
0
PC45MR-5, PC55MR-5
00 Index and Foreword
Explanation of Terms for Maintenance Standard
Standard Clearance and Standard Value •
The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.
•
When some parts are repaired, the clearance is generally adjusted to the standard clearance.
•
The values indicating performance and function of new products or equivalent are called “standard value”, which is indicated by a range or a target value.
•
When some parts are repaired, the value of performance/ function is set to the standard value.
Standard Interference •
When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called “interference”.
•
Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is “standard interference”.
•
After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.
Allowable Limit, Allowable Value, or Allowable Dimension •
The dimension of parts changes due to the wear or deformation while they are used. When the dimension changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.
•
If a part is worn to the repair limit, it must be replaced or repaired.
•
The performance and function of products lower while they are used. A value with which the product can be used without causing a problem is called “allowable value” or “allowable dimension”.
•
A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgment must be made in consideration of the operating condition and customer's requirement.
Allowable Clearance •
Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called “allowable clearance”.
•
If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable Interference •
The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called “allowable interference”.
•
The allowable interference shows the repair limit of the part of smaller tolerance.
PC45MR-5, PC55MR-5
00-67
Explanation of Terms for Maintenance Standard
•
00 Index and Foreword
The parts whose interferences are out of the allowable interference must be replaced or repaired.
00-68
PC45MR-5, PC55MR-5
00 Index and Foreword
Standard Tightening Torque Table
Standard Tightening Torque Table Table of Tightening Torque for Bolts and Nuts REMARK Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.
Thread diameter (mm) 6
8
10
12 14 16
Width across flats (mm) 10 (*2) 10 13 (*2) 12 17 (*1, *2) 14 19 (*1, *2) 17 22 24 (*1) 22
Tightening torque (Nm {kgfm} ) 11.8 to 14.7 {1.2 to 1.5}
27 to 34 {2.8 to 3.5}
59 to 74 {6 to 7.5}
98 to 123 {10 to 12.5} 153 to 190 {15.5 to 19.5} 235 to 285 {23.5 to 29.5}
18
27
320 to 400 {33 to 41}
20
30
455 to 565 {46.5 to 58}
22
32
610 to 765 {62.5 to 78}
24
36
785 to 980 {80 to 100}
27
41
1150 to 1440 {118 to 147}
30
46
1520 to 1910 {155 to 195}
33
50
1960 to 2450 {200 to 250}
36
55
2450 to 3040 {250 to 310}
39
60
2890 to 3630 {295 to 370}
*1: Split flange bolt *2: Flanged bolt REMARK Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in the table below.
PC45MR-5, PC55MR-5
00-69
Standard Tightening Torque Table
Thread diameter (mm)
00 Index and Foreword
Width across flats (mm)
Tightening torque (Nm {kgfm} )
6
10
5.9 to 9.8 {0.6 to 1.0}
8
12
13.7 to 23.5 {1.4 to 2.4}
10
14
34.3 to 46.1 {3.5 to 4.7}
12
17
74.5 to 90.2 {7.6 to 9.2}
REMARK Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt Nominal size threads per inch
A
B
Tightening torque (Nm {kgfm} )
Tightening torque (Nm {kgfm} )
Range
Target
Range
Target
9.8 to 14.7 {1 to 1.5}
12.7 {1.3}
2.9 to 3.9 {0.3 to 0.4}
3.43 {0.35}
5/
16-18UNC
24.5 to 34.3 {2.5 to 3.5}
29.4 {3}
6.9 to 8.8 {0.7 to 0.9}
7.8 {0.8}
3/ -16UNC 8
44.1 to 58.8 {4.5 to 6}
52.0 {5.3}
9.8 to 14.7 {1 to 1.5}
11.8 {1.2}
7/
16-14UNC
73.5 to 98.1 {7.5 to 10}
86.3 {8.8}
19.6 to 24.5 {2 to 2.5}
21.6 {2.2}
1/ -13UNC 2
108 to 147 {11 to 15}
127 {13}
29.4 to 39.2 {3 to 4}
34.3 {3.5}
9/
16-12UNC
157 to 216 {16 to 22}
186 {19}
44.1 to 58.8 {4.5 to 6}
51.0 {5.2}
5/ -11UNC 8
226 to 294 {23 to 30}
265 {27}
63.7 to 83.4 {6.5 to 8.5}
68.6 {7}
3/ -10UNC 4
392 to 530 {40 to 54}
461 {47}
108 to 147 {11 to 15}
127 {13}
7/ -9UNC 8
637 to 853 {65 to 87}
745 {76}
177 to 235 {18 to 24}
206 {21}
1/ -20UNC 4
00-70
PC45MR-5, PC55MR-5
00 Index and Foreword
Standard Tightening Torque Table
Type of bolt Nominal size threads per inch
A
B
Tightening torque (Nm {kgfm} )
Tightening torque (Nm {kgfm} )
Range
Target
Range
Target
1-8UNC
883 to 1196 {90 to 122}
1040 {106}
245 to 333 {25 to 34}
284 {29}
11/8-7UNC
1187 to 1608 {121 to 164}
1393 {142}
333 to 451 {34 to 46}
392 {40}
11/4-7UNC
1598 to 2157 {163 to 220}
1873 {191}
451 to 608 {46 to 62}
530 {54}
11/2-6UNC
2354 to 3177 {240 to 324}
2765 {282}
657 to 892 {67 to 91}
775 {79}
REMARK Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt Nominal size threads per inch
A
B
Tightening torque (Nm {kgfm} )
Tightening torque (Nm {kgfm} )
Range
Target
Range
Target
1/ -28UNF 4
14.7 to 19.6 {1.5 to 2}
17.7 {1.8}
3.9 to 4.9 {0.4 to 0.5}
4.41 {0.45}
5/
16-24UNF
34.3 to 39.2 {3.5 to 4}
34.3 {3.5}
7.8 to 9.8 {0.8 to 1}
8.8 {0.9}
3/ -24UNF 8
53.9 to 68.6 {5.5 to 7}
61.8 {6.3}
14.7 to 19.6 {1.5 to 2}
16.7 {1.7}
7/
16-20UNF
83.4 to 108 {8.5 to 11}
96.1 {9.8}
24.5 to 29.4 {2.5 to 3}
26.5 {2.7}
1/ -20UNF 2
127 to 167 {13 to 17}
147 {15}
34.3 to 49.0 {3.5 to 5}
41.2 {4.2}
9/
16-18UNF
186 to 245 {19 to 25}
216 {22}
49.0 to 68.6 {5 to 7}
58.8 {6}
5/ -18UNF 8
255 to 343 {26 to 35}
294 {30}
73.5 to 98.1 {7.5 to 10}
83.4 {8.5}
3/ -16UNF 4
441 to 598 {45 to 61}
520 {53}
127 to 167 {13 to 17}
147 {15}
7/ -14UNF 8
716 to 961 {73 to 98}
843 {86}
196 to 265 {20 to 27}
226 {23}
1-14UNF
1020 to 1373 {104 to 140}
1196 {122}
284 to 382 {29 to 39}
333 {34}
11/8-12UNF
1353 to 1844 {138 to 188}
1598 {163}
382 to 520 {39 to 53}
451 {46}
11/4-12UNF
1804 to 2432 {184 to 248}
2118 {216}
510 to 686 {52 to 70}
598 {61}
11/2-12UNF
2707 to 3658 {276 to 373}
3177 {324}
765 to 1030 {78 to 105}
892 {91}
PC45MR-5, PC55MR-5
00-71
Standard Tightening Torque Table
00 Index and Foreword
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.
Nominal No.
Thread di- Width across flats (mm) ameter (mm)
02
14
-
18
03, 04
20
05, 06
24
10, 12
33
14
42
Varies depending on type of connector.
Tightening torque (Nm {kgfm} ) Range
Target
35 to 63 {3.5 to 6.5}
44 {4.5}
59 to 98 {6.0 to 10.0}
78 {8.0}
84 to 132 {8.5 to 13.5}
103 {10.5}
128 to 186 {13.0 to 19.0}
157 {16.0}
363 to 480 {37.0 to 49.0}
422 {43.0}
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.
Nominal No.
00-72
Thread diam- Width across eter (mm) flats (mm)
Tightening torque (Nm {kgfm} ) 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-5, PC55MR-5
00 Index and Foreword
Nominal No.
Standard Tightening Torque Table
Tightening torque (Nm {kgfm} )
Thread diam- Width across eter (mm) flats (mm)
Range
Target
18
18
27
34.3 to 44.1 {3.5 to 4.5}
39.2 {4.0}
20
20
30
44.1 to 53.9 {4.5 to 5.5}
49.0 {5.0}
24
24
32
58.8 to 78.4 {6.0 to 8.0}
68.6 {7.0}
30
30
32
93.1 to 122.5 {9.5 to 12.5}
107.8 {11.0}
33
33
-
107.8 to 147.0 {11.0 to 15.0}
127.4 {13.0}
36
36
36
127.4 to 176.4 {13.0 to 18.0}
151.9 {15.5}
42
42
-
181.3 to 240.1 {18.5 to 24.5}
210.7 {21.5}
52
52
-
274.4 to 367.5 {28.0 to 37.5}
323.4 {33.0}
Table of Tightening Torque for Hose (Taper Seal Type and Face Seal Type) REMARK • Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified. • The table is applied to the threaded portion coated with engine oil (wet threaded portion).
Nominal No. of hose
Width across flats (mm)
02
19
Tightening torque (Nm {kgfm} )
Taper seal
Face seal Nominal size - Thread root diameter(mm) threads per inch (reference)
Range
Target
Thread size (mm)
34 to 54 {3.5 to 5.5}
44 {4.5}
-
34 to 63 {3.5 to 6.5}
44 {4.5}
14
22
54 to 93 {5.5 to 9.5}
74 {7.5}
-
24
59 to 98 {6.0 to 10.0}
78 {8.0}
04
27
84 to 132 {8.5 to 13.5}
05
32
06
36
(10)
41
(12) (14)
03
9/
16-18UN
14.3
-
-
16-16UN
17.5
18
-
-
103 {10.5}
22
13/ -16UN 16
20.6
128 to 186 {13.0 to 19.0}
157 {16.0}
24
1 -14UNS
25.4
177 to 245 {18.0 to 25.0}
216 {22.0}
30
13/16-12UN
30.2
177 to 245 {18.0 to 25.0}
216 {22.0}
33
-
-
240 to 300 {24.5 to 30.5}
270 {27.5}
-
17/16-12UN
36.5
46
197 to 294 {20.0 to 30.0}
245 {25.0}
36
-
-
55
246 to 343 {25.0 to 35.0}
294 {30.0}
42
-
-
PC45MR-5, PC55MR-5
11/
00-73
Standard Tightening Torque Table
00 Index and Foreword
Table of Tightening Torque for Face Seal Joints REMARK • The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine. • The table is applied to the threaded portion coated with engine oil (wet threaded portion). • Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
Outside diameter of adequate pipe (mm)
Width across flats (mm)
8
Tightening torque (Nm {kgfm} )
Face seal Nominal size threads per inch
Thread root diameter(mm) (reference)
Range
Target
19
14 to 16 {1.4 to 1.6}
15 {1.5}
9/
16-18UN
14.3
10
22
24 to 27 {2.4 to 2.7}
25.5 {2.6}
11/ -16UN 16
17.5
12
24 (27)
43 to 47 {4.4 to 4.8}
45 {4.6}
13/
16-16UN
20.6
15 (16)
30 (32)
60 to 68 {6.1 to 6.8}
64 {6.5}
1 -14UNS
25.4
22 (20)
36
90 to 95 {9.2 to 9.7}
92.5 {9.4}
13/16-12UN
30.2
Tightening Torque Table for Bolts and Nuts on 102, 107 and 114 Series Engines REMARK Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified. Thread diameter (mm)
Tightening torque (Nm {kgfm} )
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
-
Tightening Torque Table for 102, 107, and 114 Series Engines (Joint Bolts) REMARK Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.
00-74
PC45MR-5, PC55MR-5
00 Index and Foreword
Standard Tightening Torque Table
Thread diameter (mm)
Tightening torque (Nm {kgfm} )
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}
Tightening Torque Table for Tapered Screws on 102, 107, and 114 Series Engines (National Taper Pipe Thread (NPT)) REMARK Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified. Material of female screw
In cast iron or steel
In aluminum
Nominal thread size
Tightening torque (Nm {kgfm} )
Tightening torque (Nm {kgfm} )
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}
8
35±4 {3.57±0.41}
25±3 {2.55±0.31}
2
55±6 {5.61±0.61}
35±4 {3.57±0.41}
4
75±8 {7.65±0.82}
45±5 {4.59±0.51}
3/ 1/ 3/
PC45MR-5, PC55MR-5
00-75
Conversion Table
00 Index and Foreword
Conversion Table How to Use the Conversion Table The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below.
Examples to Use the Conversion Table to Change a Unit from mm to in. When converting 55 mm to in 1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A). 2.
Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3.
Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in 1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm. 2. Convert 55 mm to 2.165 in according to the preceding procedure. 3.
The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in (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) (A)
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
3.780
3.819
3.858
3.898
mm to in 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
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
00-76
PC45MR-5, PC55MR-5
00 Index and Foreword
Conversion Table
1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
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
kg to lb 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
ℓ to U.S.Gal 1 ℓ = 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
ℓ to U.K.Gal 1 ℓ = 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
PC45MR-5, PC55MR-5
00-77
Conversion Table
00 Index and Foreword
1 ℓ = 0.21997 U.K.Gal 0
1
2
3
4
5
6
7
8
9
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
kgfm to lbft 1 kgfm = 7.233 lbft 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
kgf/cm2 to lb/in2 1 kgf/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
00-78
PC45MR-5, PC55MR-5
00 Index and Foreword
Conversion Table
1 kgf/cm2 = 14.2233 lb/in2 0
1
2
3
4
5
6
7
8
9
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
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
Temperature Conversion of Fahrenheit to Celsius •
A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.
•
When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
•
When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius 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
PC45MR-5, PC55MR-5
00-79
Conversion Table
00 Index and Foreword
1 °C = 33.8 °F °C
°F
°C
°F
°C
°F
°C
°F
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
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
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
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
00-80
PC45MR-5, PC55MR-5
01 Specification
PC45MR-5, PC55MR-5
01-1
Table of Contents
01 Specification
Table of Contents Abbreviation List ............................................................................................................................................ 01-3 Specifications................................................................................................................................................. 01-9 Specification Drawing.............................................................................................................................. 01-9 Specification Drawing: PC45MR-5 ................................................................................................... 01-9 Specification Drawing: PC55MR-5 ..................................................................................................01-11 Working Range Drawings...................................................................................................................... 01-13 Working Range: PC45MR-5........................................................................................................... 01-13 Working Range: PC55MR-5........................................................................................................... 01-14 Specifications........................................................................................................................................ 01-15 Specifications: PC45MR-5 ............................................................................................................. 01-15 Specifications: PC55MR-5 ............................................................................................................. 01-19 Weight Table ......................................................................................................................................... 01-23 Weight Table: PC45MR-5............................................................................................................... 01-23 Weight Table: PC55MR-5............................................................................................................... 01-25 Table of Fuel, Coolant, and Lubricants .................................................................................................. 01-27
01-2
PC45MR-5, PC55MR-5
01 Specification
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
01-3
Abbreviation List
Abbreviation
Actual word spelled out
01 Specification
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
01-4
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
01 Specification
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
01-5
Abbreviation List
01 Specification
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
01-6
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
01 Specification
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
01-7
Abbreviation List
01 Specification
Abbreviation S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
01-8
Actual word spelled out
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
01 Specification
Specification Drawing
Specifications Specification Drawing Specification Drawing: PC45MR-5
Item
Unit
PC45MR-5 Canopy specification
Cab specification
Machine weight Rubber shoe specification
kg
Steel shoe specification Bucket capacity
m3
Engine model
-
4790
4910
4860
4930 0.14
Komatsu 4D88E-7 diesel engine
Engine rated horsepower •
Gross (SAE J1995)
•
ISO 14396
•
Net (ISO 9249/SAE J1349)
kW {HP} /min-1 {rpm}
29.1 {39.0}/ 2400 {2400} 29.1 {39.0}/ 2400 {2400} 28.3 {38.0}/ 2400 {2400}
A Overall length
mm
B Overall height
mm
C Overall width
mm
1960
D Shoe width
mm
400
E Tail swing radius
mm
1040
F Overall length of the track
mm
2520
G Distance between tumbler centers
mm
2000
mm
290
km/h
2.6/4.6
Minimum ground clearance
5330 2550
2590
Travel speed (Lo/Hi) Rubber shoe specification Steel shoe specification
PC45MR-5, PC55MR-5
2.4/4.3
01-9
Specification Drawing
01 Specification
Item
Unit
Continuous swing speed
min-1 {rpm}
PC45MR-5 Canopy specification
Cab specification 9.0 {9.0}
REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine.
01-10
PC45MR-5, PC55MR-5
01 Specification
Specification Drawing
Specification Drawing: PC55MR-5
Item
Unit
PC55MR-5 Canopy specification
Cab specification
Machine weight Rubber shoe specification
kg
Steel shoe specification Bucket capacity
m3
Engine model
-
5070
5190
5140
5260 0.16
Komatsu 4D88E-7 diesel engine
Engine rated horsepower •
Gross (SAE J1995)
•
ISO 14396
•
Net (ISO 9249/SAE J1349)
kW {HP} /min-1 {rpm}
29.1 {39.0}/ 2400 {2400} 29.1 {39.0}/ 2400 {2400} 28.3 {38.0}/ 2400 {2400}
A Overall length
mm
B Overall height
mm
C Overall width
mm
1960
D Shoe width
mm
400
E Tail swing radius
mm
1120
F Overall length of the track
mm
2520
G Distance between tumbler centers
mm
2000
mm
290
km/h
2.6/4.6
Minimum ground clearance
5550 2550
2590
Travel speed (Lo/Hi) Rubber shoe specification Steel shoe specification Continuous swing speed
PC45MR-5, PC55MR-5
2.4/4.3 min-1 {rpm}
9.0 {9.0}
01-11
Specification Drawing
01 Specification
REMARK • The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine.
01-12
PC45MR-5, PC55MR-5
01 Specification
Working Range Drawings
Working Range Drawings Working Range: PC45MR-5
Item
Unit
PC45MR-5
A
Maximum digging reach
mm
6040
B
Maximum digging depth
mm
3625
C
Maximum digging height
mm
5730 (5405)
D
Maximum vertical wall digging depth
mm
3070
E
Maximum dumping height
mm
4000 (3705)
F
Minimum swing radius of work equipment Minimum turning radius during boom swing
mm
2380 (2465) 1840 (1905)
G Maximum reach at ground level
mm
5895
H
Maximum raising distance of the blade
mm
430
I
Maximum lowering distance of the blade
mm
330
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 34639 and up).
PC45MR-5, PC55MR-5
01-13
Working Range Drawings
01 Specification
Working Range: PC55MR-5
Item
Unit
PC55MR-5
A
Maximum digging reach
mm
6220
B
Maximum digging depth
mm
3770
C
Maximum digging height
mm
5915 (5575)
D
Maximum vertical wall digging depth
mm
3030
E
Maximum dumping height
mm
4200 (3890)
F
Minimum swing radius of work equipment Minimum turning radius during boom swing
mm
2285 (2520) 1760 (1930)
G Maximum reach at ground level
mm
6075
H
Maximum raising distance of the blade
mm
430
I
Maximum lowering distance of the blade
mm
330
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 23282 and up).
01-14
PC45MR-5, PC55MR-5
01 Specification
Specifications
Specifications Specifications: PC45MR-5 Item Bucket capacity
Unit
PC45MR-5 Canopy specifications
m3
Cab specifications 0.14
Machine weight Rubber shoe specification
kg
Steel shoe specification
4790
4910
4860
4930
Performance Working ranges Maximum digging depth
mm
3625
Maximum vertical wall digging depth
mm
3070
Maximum digging reach
mm
6040
Maximum digging reach at ground level
mm
5895
Maximum digging height
mm
5730 (5405)
Maximum dumping height
mm
4000 (3705)
Offset of bucket (Left side/right side)
mm
630/880
Maximum raising distance of the blade
mm
430
Maximum lowering distance of the blade
mm
330
Maximum digging force
kN {kgf}
33.9 {3460}
33.9 {3460}
Continuous swing speed
min-1 {rpm}
9.0 {9.0}
9.0 {9.0}
Degrees
19.0
19.0
km/h
2.6/4.6
2.6/4.6
2.4/4.3
2.4/4.3
Degrees
30
30
kPa {kgf/cm2}
27.4 {0.28}
28.0 {0.29}
27.8 {0.28}
28.4 {0.29}
Swing operation max. slope angle Travel speed (Lo/Hi) Rubber shoe specification Steel shoe specification Gradeability Ground pressure Rubber shoe specification Steel shoe specification
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 34639 and up). Dimensions Overall length (for transport)
mm
5330
5330
Overall width
mm
1960
1960
Overall height (for transport)
mm
2550
2590
PC45MR-5, PC55MR-5
01-15
Specifications
01 Specification
PC45MR-5
Item
Unit
Ground clearance of upper structure bottom
mm
608
608
Minimum ground clearance
mm
290
290
Tail swing radius
mm
1040
1040
2380 (2465)
2380 (2465)
1840 (1905)
1840 (1905)
Minimum swing radius of work equipment Minimum turning radius during boom swing
Canopy specifications
Cab specifications
mm
Maximum height at minimum swing radius of work equipment
mm
4140 (3990)
4140 (3990)
Overall width of track
mm
1960
1960
Overall length of the track
mm
2520
2520
Distance between tumbler centers
mm
2000
2000
Distance between track centers
mm
1560
1560
Machine cab height
mm
1395
1395
Blade width x height
mm
1960 x 355
1960 x 355
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 34639 and up). Engine Model
-
4D88E-7
Type
-
No. of cylinders - bore x stroke
mm
4-88 x 90
Total piston displacement
ℓ {cc}
2.189 {2189}
4-stroke, water-cooled, in-line vertical, direct injection type
Performance Rated horsepower •
SAE J1995 (gross)
•
ISO 14396
•
ISO 9249/SAE J1349 (net)
29.1 {39.0}/ 2400 {2400} kW {HP} /min-1 {rpm}
29.1 {39.0}/ 2400 {2400} 28.3 {38.0}/ 2400 {2400}
Nm {kgfm} /min-1 {rpm}
137.3 {14.0}/ 1560 {1560}
Fuel consumption ratio at rated horsepower
g/kWh {g/HPh}
232 {173}
Maximum speed with no load
min-1 {rpm}
2550 {2550}
Minimum speed with no load
min-1 {rpm}
1225 {1225}
Maximum torque
Starting motor •
Serial No.: 4814 to 21759
–
12 V, 2.3 kW
•
Serial No.: 21453 and up
–
12 V, 1.7 kW
Alternator
-
12 V, 40 A
12 V, 55 A
Battery (*1)
-
12 V, 72 Ah x 1 pieces
12 V, 72 Ah x 1 pieces
01-16
PC45MR-5, PC55MR-5
01 Specification
Item Radiator core type
Specifications
Unit -
PC45MR-5 Canopy specifications
Cab specifications
V-shaped fin
*1: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine. Undercarriage Carrier roller
-
1 pieces on one side
Track roller
-
4 pieces on one side
Track shoe
-
Steel shoe
-
Assembly type triple grouser shoe, 39 pieces on each side
Rubber shoe
-
Rubber track
Hydraulic system Main pump Type x quantity
-
Variable displacement piston type x 1piece
Theoretical discharged volume
cm3/rev
22.3 x 2
Set pressure
MPa {kgf/cm2}
26.5 {270}
Swing and blade pump Type x quantity
-
Gear type x 1 piece
Theoretical discharged volume
cm3/rev
14.1
Set pressure
MPa {kgf/cm2}
21.6{220}
Pilot pump Type x quantity
-
Gear type x 1 piece
Theoretical discharged volume
cm3/rev
5.2
Set pressure
MPa {kgf/cm2}
3.14{32}
Control valve Type x quantity
-
8-spool type x 1 piece
Operating method
-
Hydraulic assist type
Travel motor Type x quantity
-
Variable displacement piston type x 2 pieces (With counterbalance valve, travel shaft brake)
Swing motor Type x quantity
-
Fixed displacement piston type x 1 piece (With brake valve, swing shaft brake)
Boom cylinder Type
-
Cylinder bore
mm
PC45MR-5, PC55MR-5
Double-acting piston type 90
01-17
Specifications
01 Specification
Item
Unit
PC45MR-5 Canopy specifications
Cab specifications
Piston rod diameter
mm
55
Stroke
mm
691 (668)
Max. distance between pins
mm
1739 (1716)
Min. distance between pins
mm
1048
Arm cylinder Type
-
Double-acting piston type
Cylinder bore
mm
80
Piston rod diameter
mm
50
Stroke
mm
649
Max. distance between pins
mm
1631
Min. distance between pins
mm
981.5
Bucket cylinder Type
-
Double-acting piston type
Cylinder bore
mm
70
Piston rod diameter
mm
45
Stroke
mm
580
Max. distance between pins
mm
1480
Min. distance between pins
mm
900
Boom swing cylinder Type
-
Double-acting piston type
Cylinder bore
mm
90
Piston rod diameter
mm
50
Stroke
mm
630
Max. distance between pins
mm
1573.5
Min. distance between pins
mm
943.5
Blade cylinder Type
-
Double-acting piston type
Cylinder bore
mm
110
Piston rod diameter
mm
50
Stroke
mm
140
Max. distance between pins
mm
642.5
Min. distance between pins
mm
502.5
Hydraulic tank
-
Box-shaped open type
Hydraulic oil filter
-
Tank return side
Hydraulic oil cooler
-
Air-cooled (V-fin)
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 34639 and up).
01-18
PC45MR-5, PC55MR-5
01 Specification
Specifications
Specifications: PC55MR-5 Item Bucket capacity
Unit
PC55MR-5 Canopy specifications
m3
Cab specifications 0.16
Machine weight Rubber shoe specification
kg
Steel shoe specification
5070
5190
5140
5260
Performance Working ranges Maximum digging depth
mm
3770
Maximum vertical wall digging depth
mm
3030
Maximum digging reach
mm
6220
Maximum digging reach at ground level
mm
6075
Maximum digging height
mm
5915 (5575)
Maximum dumping height
mm
4200 (3890)
Offset of bucket (Left side/right side)
mm
630/880
Maximum raising distance of the blade
mm
430
Maximum lowering distance of the blade
mm
330
Maximum digging force Continuous swing speed Swing operation max. slope angle
kN {kgf}
39.0 {3980}
39.0 {3980}
9.0 {9.0}
9.0 {9.0}
Degrees
19.0
19.0
km/h
2.6/4.6
2.6/4.6
2.4/4.3
2.4/4.3
Degrees
30
30
kPa {kgf/cm2}
28.9 {0.29}
29.6 {0.30}
29.3 {0.30}
30.0 {0.31}
min-1 {rpm}
Travel speed (Lo/Hi) Rubber shoe specification Steel shoe specification Gradeability Ground pressure Rubber shoe specification Steel shoe specification
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 23282 and up). Dimensions Overall length (for transport)
mm
5550
5550
Overall width
mm
1960
1960
Overall height (for transport)
mm
2550
2590
Ground clearance of upper structure bottom
mm
608
608
PC45MR-5, PC55MR-5
01-19
Specifications
Item
01 Specification
Unit
PC55MR-5 Canopy specifications
Cab specifications
Minimum ground clearance
mm
290
290
Tail swing radius
mm
1120
1120
2285 (2520)
2285 (2520)
1760 (1930)
1760 (1930)
Minimum swing radius of work equipment Minimum turning radius during boom swing
mm
Maximum height at minimum swing radius of work equipment
mm
4475 (4305)
4475 (4305)
Overall width of track
mm
1960
1960
Overall length of the track
mm
2520
2520
Distance between tumbler centers
mm
2000
2000
Distance between track centers
mm
1560
1560
Machine cab height
mm
1395
1395
Blade width x height
mm
1960 x 355
1960 x 355
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 23282 and up). Engine Model
-
4D88E-7
Type
-
No. of cylinders - bore x stroke
mm
4-88 x 90
Total piston displacement
ℓ {cc}
2.189 {2189}
4-stroke, water-cooled, in-line vertical, direct injection type
Performance Rated horsepower •
SAE J1995 (gross)
•
ISO 14396
•
ISO 9249/SAE J1349 (net)
29.1 {39.0}/ 2400 {2400} kW {HP} /min-1 {rpm}
29.1 {39.0}/ 2400 {2400} 28.3 {38.0}/ 2400 {2400}
Maximum torque
Nm {kgfm} /min-1 {rpm}
137.3 {14.0}/ 1560 {1560}
Fuel consumption ratio at rated horsepower
g/kWh {g/HPh}
232 {173}
Maximum speed with no load
min-1 {rpm}
2550 {2550}
Minimum speed with no load
min-1 {rpm}
1225 {1225}
Starting motor •
Serial No.: 4814 to 21759
-
12 V, 2.3 kW
•
Serial No.: 21453 and up
-
12 V, 1.7 kW
Alternator
-
12 V, 40 A
12 V, 55 A
Battery (*1)
-
12 V, 72 Ah x 1 piece
12 V, 72 Ah x 1 piece
01-20
PC45MR-5, PC55MR-5
01 Specification
Item Radiator core type
Specifications
Unit -
PC55MR-5 Canopy specifications
Cab specifications
V-shaped fin
*1: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine. Undercarriage Carrier roller
-
1 pieces on one side
Track roller
-
4 pieces on one side
Track shoe
-
Steel shoe
-
Assembly type triple grouser shoe, 39 pieces on each side
Rubber shoe
-
Rubber track
Hydraulic system Main pump Type x quantity
-
Variable displacement piston type x 1 piece
Theoretical discharged volume
cm3/rev
22.3 x 2
Set pressure
MPa {kgf/cm2}
26.5 {270}
Swing and blade pump Type x quantity
-
Gear type x 1 piece
Theoretical discharged volume
cm3/rev
14.1
Set pressure
MPa {kgf/cm2}
21.6 {220}
Pilot pump Type x quantity
-
Gear type x 1 piece
Theoretical discharged volume
cm3/rev
5.2
Set pressure
MPa {kgf/cm2}
3.14 {32}
Control valve Type x quantity
-
8-spool type x 1 piece
Operating method
-
Hydraulic assist type
Travel motor Type x quantity
-
Variable displacement piston type x 2 pieces (With counterbalance valve, travel shaft brake)
Swing motor Type x quantity
-
Fixed displacement piston type x 1 piece (With brake valve, swing shaft brake)
Boom cylinder Type
-
Cylinder bore
mm
PC45MR-5, PC55MR-5
Double-acting piston type 90
01-21
Specifications
Item
01 Specification
Unit
PC55MR-5 Canopy specifications
Cab specifications
Piston rod diameter
mm
55
Stroke
mm
691 (668)
Max. distance between pins
mm
1739 (1716)
Min. distance between pins
mm
1048
Arm cylinder Type
-
Double-acting piston type
Cylinder bore
mm
85
Piston rod diameter
mm
55
Stroke
mm
733
Max. distance between pins
mm
1821
Min. distance between pins
mm
1088
Bucket cylinder Type
-
Double-acting piston type
Cylinder bore
mm
75
Piston rod diameter
mm
50
Stroke
mm
580
Max. distance between pins
mm
1480
Min. distance between pins
mm
900
Boom swing cylinder Type
-
Double-acting piston type
Cylinder bore
mm
95
Piston rod diameter
mm
50
Stroke
mm
630
Max. distance between pins
mm
1573.5
Min. distance between pins
mm
943.5
Blade cylinder Type
-
Double-acting piston type
Cylinder bore
mm
110
Piston rod diameter
mm
50
Stroke
mm
140
Max. distance between pins
mm
642.5
Min. distance between pins
mm
502.5
Hydraulic tank
-
Box-shaped open type
Hydraulic oil filter
-
Tank return side
Hydraulic oil cooler
-
Air-cooled (V-fin)
*1: The value in parentheses is for the machines for the North America market (Applicable Serial Numbers: 23282 and up).
01-22
PC45MR-5, PC55MR-5
01 Specification
Weight Table
Weight Table Weight Table: PC45MR-5
k This weight table is provided for your reference when handling the components or when transport-
ing.
k This weight table shows the dry weight.
Unit: kg Item
PC45MR-5
Engine assembly
265
•
Engine
217
•
Engine mount
8
•
PTO
10
•
Main pump
29
Cooling assembly
32
Battery
24
Revolving frame
529
Floor frame assembly (*1)
163
Canopy (*1)
114
Handrail (*1)
6
Operator's cab assembly (including floor frame assembly) (*2)
426
Operator's seat
25
Fuel tank
6
Hydraulic tank
40
Control valve
50
Counterweight
622
Swing motor (including brake valve)
15
Swing circle
59
Swing machinery
26
Center swivel joint
18
Track frame assembly (excluding track shoes)
944
•
Track frame
551
•
Idler assembly
36 x 2
•
Recoil spring assembly
18 x 2
•
Carrier roller
3x2
•
Track roller
10 x 8
•
Travel motor (including reduction gear)
49 x 2
•
Sprocket
12 x 2
Track shoe assembly Rubber shoe (400 mm)
242 x 2
Road liner (400 mm)
269 x 2
PC45MR-5, PC55MR-5
01-23
Weight Table
01 Specification
Unit: kg Item Triple grouser shoe (400 mm)
PC45MR-5 274 x 2
Boom swing bracket assembly
101
Boom assembly
161
Arm assembly
94
Bucket link assembly
28
Bucket assembly (including side cutter)
101
Blade assembly
210
Boom cylinder assembly
46
Arm cylinder assembly
35
Bucket cylinder assembly
25
Boom swing cylinder assembly
35
Blade cylinder assembly
29
*1: Canopy specification *2: Cab specification
01-24
PC45MR-5, PC55MR-5
01 Specification
Weight Table
Weight Table: PC55MR-5
k This weight table is provided for your reference when handling the components or when transport-
ing.
k This weight table shows the dry weight.
Unit: kg Item
PC55MR-5
Engine assembly
265
•
Engine
217
•
Engine mount
8
•
PTO
10
•
Main pump
29
Cooling assembly
32
Battery
24
Revolving frame
529
Floor frame assembly (*1)
163
Canopy (*1)
114
Handrail (*1)
6
Operator's cab assembly (including floor frame assembly) (*2)
426
Operator's seat
25
Fuel tank
6
Hydraulic tank
40
Control valve
50
Counterweight
622
X-weight (additional counterweight)
235
Swing motor (including brake valve)
15
Swing circle
59
Swing machinery
26
Center swivel joint
18
Track frame assembly (excluding track shoes)
944
•
Track frame
551
•
Idler assembly
36 x 2
•
Recoil spring assembly
18 x 2
•
Carrier roller
3x2
•
Track roller
10 x 8
•
Travel motor (including reduction gear)
49 x 2
•
Sprocket
12 x 2
Track shoe assembly Rubber shoe (400 mm)
242 x 2
Road liner (400 mm)
269 x 2
Triple grouser shoe (400 mm)
274 x 2
PC45MR-5, PC55MR-5
01-25
Weight Table
01 Specification
Unit: kg Item
PC55MR-5
Boom swing bracket assembly
101
Boom assembly
176
Arm assembly
95
Bucket link assembly
28
Bucket assembly (including side cutter)
121
Blade assembly
210
Boom cylinder assembly
46
Arm cylinder assembly
46
Bucket cylinder assembly
29
Boom swing cylinder assembly
39
Blade cylinder assembly
29
*1: Canopy specification *2: Cab specification
01-26
PC45MR-5, PC55MR-5
01 Specification
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”.
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-5, PC55MR-5
01-27
10 Structure and Function
PC45MR-5, PC55MR-5
10-1
Table of Contents
10 Structure and Function
Table of Contents Abbreviation List ............................................................................................................................................ 10-4 Boot-up System ........................................................................................................................................... 10-10 Layout Drawing of Boot-up System ....................................................................................................... 10-10 System Operating Lamp System........................................................................................................... 10-12 System Diagram of System Operating Lamp System..................................................................... 10-12 Function of Operation Lamp System .............................................................................................. 10-12 Battery Disconnect Switch..................................................................................................................... 10-14 Function of Battery Disconnect Switch ........................................................................................... 10-14 Engine System............................................................................................................................................. 10-15 Layout Drawing of Engine System ........................................................................................................ 10-15 Engine Control System ......................................................................................................................... 10-16 System Diagram of Engine Control ................................................................................................ 10-16 Function of Engine Control System ................................................................................................ 10-17 Auto-Deceleration System..................................................................................................................... 10-20 System Diagram of Auto-Deceleration System............................................................................... 10-20 Function of Auto-Deceleration System ........................................................................................... 10-20 Operation of Auto-Deceleration System ......................................................................................... 10-21 Overheat Prevention System ................................................................................................................ 10-22 Overheat Prevention System Diagram ........................................................................................... 10-22 Function of Overheat Prevention System ....................................................................................... 10-23 Automatic Idle Stop System .................................................................................................................. 10-24 System Diagram of Automatic Idle Stop System ............................................................................ 10-24 Function of Automatic Idle Stop System......................................................................................... 10-24 Component Parts of Engine System ..................................................................................................... 10-26 PTO ............................................................................................................................................... 10-26 Cooling System............................................................................................................................................ 10-27 Layout Drawing of Cooling System ....................................................................................................... 10-27 Specifications of Cooling System ................................................................................................... 10-28 Control System ............................................................................................................................................ 10-29 Layout Drawing of Control System ........................................................................................................ 10-29 Machine Monitor System....................................................................................................................... 10-30 System Diagram of Machine Monitor System................................................................................. 10-30 KOMTRAX System ............................................................................................................................... 10-31 System Diagram of KOMTRAX System ......................................................................................... 10-31 Function of KOMTRAX System ...................................................................................................... 10-31 Component Parts of Control System ..................................................................................................... 10-32 Machine Monitor ............................................................................................................................ 10-32 KOMTRAX Terminal....................................................................................................................... 10-40 Machine Controller ......................................................................................................................... 10-42 Fuel Control Dial ............................................................................................................................ 10-46 Hydraulic System ......................................................................................................................................... 10-48 Layout Drawing of Hydraulic System..................................................................................................... 10-48 CLSS .................................................................................................................................................... 10-50 Structure of CLSS .......................................................................................................................... 10-50 Function of CLSS ........................................................................................................................... 10-51 Engine and Pump Combined Control System ....................................................................................... 10-53 Engine and Pump Combined Control System Diagram .................................................................. 10-53 Function of Engine and Pump Combined Control System .............................................................. 10-54 Component Parts of Hydraulic System.................................................................................................. 10-56 Hydraulic Tank ............................................................................................................................... 10-56 Main Pump..................................................................................................................................... 10-60 Control Valve.................................................................................................................................. 10-72 Work Equipment System.............................................................................................................................10-116 Layout Drawing of Work Equipment System ........................................................................................10-116 Structure of Valve Control ....................................................................................................................10-120 PPC Lock System ................................................................................................................................10-122 10-2
PC45MR-5, PC55MR-5
10 Structure and Function
Table of Contents
System Diagram of PPC Lock.......................................................................................................10-122 Function of PPC Lock System.......................................................................................................10-123 Work Equipment and Travel Automatic Lock System ...........................................................................10-124 Function of Work Equipment and Travel Automatic Lock System..................................................10-124 Operation of Lock Lever Automatic Lock System ..........................................................................10-124 Attachment Oil Flow Adjuster System ..................................................................................................10-125 Attachment Oil Flow Adjuster System Diagram .............................................................................10-125 Function of Attachment Oil Flow Adjuster System.........................................................................10-126 Component Parts of Work Equipment System .....................................................................................10-127 Work Equipment and Swing PPC Valve ........................................................................................10-127 Attachment PPC Valve ..................................................................................................................10-132 Blade PPC Valve...........................................................................................................................10-134 Boom Swing PPC Valve ................................................................................................................10-136 Bipartite Solenoid Valve ................................................................................................................10-138 Multi-Control Valve ........................................................................................................................10-141 Pilot Circuit Accumulator ...............................................................................................................10-142 Swing System .............................................................................................................................................10-143 Layout Drawing of Swing System.........................................................................................................10-143 Component Parts of Swing System......................................................................................................10-144 Swing Motor ..................................................................................................................................10-144 Swing Machinery...........................................................................................................................10-151 Swing Circle ..................................................................................................................................10-153 Travel System .............................................................................................................................................10-154 Layout Drawing of Travel System.........................................................................................................10-154 System Diagram of Travel Control System...........................................................................................10-156 Function of Travel Control System ................................................................................................10-156 Component Parts of Travel System......................................................................................................10-158 Travel Motor..................................................................................................................................10-158 Travel PPC Valve ..........................................................................................................................10-166 Center Swivel Joint .......................................................................................................................10-168 Undercarriage and Frame ...........................................................................................................................10-169 Layout Drawing of Undercarriage.........................................................................................................10-169 Specifications of Undercarriage ....................................................................................................10-169 Idler Cushion........................................................................................................................................10-170 Structure of Idler Cushion .............................................................................................................10-170 Specifications of Idler Cushion ......................................................................................................10-170 Work Equipment .........................................................................................................................................10-171 Structure of Work Equipment ...............................................................................................................10-171 Function of Work Equipment ................................................................................................................10-172 Work Equipment Clearance Adjustment Shim......................................................................................10-173 Function of Work Equipment Clearance Adjustment Shim ............................................................10-173 CAB Related Parts ......................................................................................................................................10-174 ROPS CAB ..........................................................................................................................................10-174 Structure of ROPS CAB ................................................................................................................10-174 Function of ROPS CAB.................................................................................................................10-174 Tilt Type Floor ......................................................................................................................................10-175 Structure of Tilt Type Floor ............................................................................................................10-175 Function of Tilt Type Floor.............................................................................................................10-175
PC45MR-5, PC55MR-5
10-3
Abbreviation List
10 Structure and Function
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
10-4
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
PC45MR-5, PC55MR-5
10 Structure and Function
Abbreviation
Actual word spelled out
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
PC45MR-5, PC55MR-5
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
10-5
Abbreviation List
10 Structure and Function
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
10-6
Mass Air Flow
PC45MR-5, PC55MR-5
10 Structure and Function
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
PC45MR-5, PC55MR-5
Urea SCR system
Electrical system
10-7
Abbreviation List
Abbreviation
TOPS
10 Structure and Function
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
10-8
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
10 Structure and Function
Abbreviation S/T STRG
Actual word spelled out Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
Abbreviation List
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
10-9
Layout Drawing of Boot-up System
10 Structure and Function
Boot-up System Layout Drawing of Boot-up System Chassis Part
1: Battery
3: KOMTRAX terminal
2: Machine monitor
4: Machine controller
10-10
PC45MR-5, PC55MR-5
10 Structure and Function
5: Battery disconnect switch
Layout Drawing of Boot-up System
7: Engine controller
6: System operating lamp
PC45MR-5, PC55MR-5
10-11
System Operating Lamp System
10 Structure and Function
System Operating Lamp System (Machine with system operating lamp)
System Diagram of System Operating Lamp System
1: Battery disconnect switch
6: Machine monitor
2: Battery
7: Engine controller
3: Fusible link
8: Machine controller
4: Fuse box
9: KOMTRAX terminal
5: System operating lamp
Function of Operation Lamp System System operating lamp is lit while any of controllers are in operation. To prevent the abnormal end of the disconnection of the battery power supply circuit while the controllers are in operation, check the operation state with this lamp. REMARK • Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and check that the system operating lamp goes off, then turn the battery disconnect switch to “OFF” position. • If the battery disconnect switch is turned “OFF” (the battery power supply circuit is OFF) while the system operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect switch while the system operating lamp is lit. • The system operating lamp goes off in 2 minutes after the starting switch is turned to “OFF” position. • The system operating lamp may be lit while the starting switch is in “OFF” position, because KOMTRAX terminal may maintain its communication under this condition.
On and Off of System Operation Lamp •
Voltage of 12 V is constantly applied to one side of system operating lamp (LED (Light Emitting Diode)).
•
When any controller is in operation, the controller outputs Low (0 V), and a current flows through the diode and the system operating lamp is lit.
•
When all controllers are stopped, the controller outputs High (12 V), and no current flows through the diode and the system operating lamp is not lit. REMARK The system operating lamp may look slightly luminous in the dark when it is not lit. It is due to the minute leakage of current and this is not an abnormal phenomenon.
•
When the starting switch is in “OFF” position, KOMTRAX terminal repeats the start and stop to maintain the periodic communication.
•
The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour.
10-12
PC45MR-5, PC55MR-5
10 Structure and Function
System Operating Lamp System
REMARK When you want to cut off the battery circuit for maintenance but the system operating lamp is still lit, turn the starting switch to “ON” position once, and then turn it to “OFF” position. The lamp goes off in a maximum of 2 minutes. After system operating lamp goes off, turn the battery disconnect switch immediately to “OFF” position. •
The engine controller transmits the operation signal to the machine controller during operation, and the machine controller indicates that the engine controller is in operation.
PC45MR-5, PC55MR-5
10-13
Battery Disconnect Switch
10 Structure and Function
Battery Disconnect Switch Function of Battery Disconnect Switch (O): OFF position (I): ON position •
•
Battery disconnect switch (1) is usually used in the following cases in the same purpose of disconnecting the cable from the negative terminal of the battery. •
When storing the machine for a long period (1 month or longer)
•
When servicing or repairing the electrical system
•
When performing electric welding
•
When handling the battery
•
When replacing the fuse, etc.
When battery disconnect switch (1) is at OFF position (the contact is opened), all the continuous power supplies for the components including the starting switch B terminal and controllers are all cut out. It is the same state as the time when the battery is not connected, and all the electrical system of the machine are out of operation.
NOTICE • Do not turn off battery disconnect switch (1) while system operating lamp (2) is lit. If battery disconnect switch (1) is turned off while system operating lamp (2) is lit, it may erase the data in the controller, and damage the controller seriously. • Do not turn off battery disconnect switch (1) while the engine is running or immediately after the engine is stopped. If battery disconnect switch (1) is turned off while the alternator is generating power, the generated current has nowhere to go. It leads to over-voltage in the electrical system of the machine, which may cause serious damage to the electrical system including the electric devices and controllers. REMARK • System operating lamp (2) lights up while the controller is in operation. It lights up when KOMTRAX terminal is performing communication, even if the starting switch is set to OFF position. • If battery disconnect switch (1) has been off for a long period, the machine monitor and the clock of the radio may return to the initial state. In this case, resetting is required.
10-14
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Engine System
Engine System Layout Drawing of Engine System
1: Alternator
7: Engine controller
2: Air cleaner
8: KDPF
3: Dust indicator
9: EGR valve
4: Flywheel
10: Fuel filter
5: EGR cooler
11: Engine oil filter
6: Starting motor
PC45MR-5, PC55MR-5
10-15
Engine Control System
10 Structure and Function
Engine Control System System Diagram of Engine Control
1: Battery disconnect switch (*1)
11: Starting motor cut-off relay (for PPC lock)
2: Battery
12: Starting motor cut-off relay (for personal code)
3: Fusible link
13: Fuel control dial
4: Fuse box
14: Starting motor relay
5: Fuse box
15: Starting motor
6: Starting switch
16: Fuel supply pump
7: Engine shutdown secondary switch
17: Various sensors
8: Engine controller
18: Machine monitor
9: Lock lever
19: KOMTRAX terminal
10: PPC lock switch
20: Machine controller
*1: Machine with battery disconnect switch
10-16
PC45MR-5, PC55MR-5
10 Structure and Function
Engine Control System
Function of Engine Control System Mechanism and Function to Start Engine
•
When starting switch (6) is turned to ON position, engine controller (8) sends a command current to fuel supply pump (16). Accordingly, a fail-safe mechanism is formed and the engine stops in case that the electric system has a failure.
•
When starting switch (6) is turned to START position while lock lever (9) is in LOCK position, the starting current is supplied to starting motor (15) and the engine starts. If lock lever (9) is in FREE position, starting motor cut-off relay (11) operates to cut off the starting current to starting motor (15) and the engine does not start, that is, a neutral safety mechanism.
•
Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18). Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting motor (15), thus the engine does not start.
PC45MR-5, PC55MR-5
10-17
Engine Control System
10 Structure and Function
Mechanism and Function of Engine Speed Control
•
Engine controller (8) sends the throttle signal of fuel control dial (13) to machine controller (20).
•
Machine controller (20) calculates a proper engine speed from the setting of the work equipment mode and the condition of the work equipment, and transmits it as the throttle signal to engine controller (8).
•
Upon receipt of the throttle signal from machine controller (20), engine controller (8) controls fuel supply pump (16).
Mechanism and Function to Stop Engine
When starting switch (6) is turned to OFF position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off, and the command current to fuel supply pump (16) is also cut off. Fuel supply pump (16) stops supplying fuel, the engine speed decreases, and the engine stops.
10-18
PC45MR-5, PC55MR-5
10 Structure and Function
Engine Control System
Mechanism and Function of Engine Stopping System with Engine Shutdown Secondary Switch
When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as that of the time when starting switch (6) is turned to OFF position, and the engine stops.
PC45MR-5, PC55MR-5
10-19
Auto-Deceleration System
10 Structure and Function
Auto-Deceleration System System Diagram of Auto-Deceleration System
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.
10-20
PC45MR-5, PC55MR-5
10 Structure and Function
Auto-Deceleration System
Operation of Auto-Deceleration System A: All work equipment control levers are in NEUTRAL B: Work equipment control lever is operated C: Speed which is set with fuel control dial D: Engine control speed (approximately 1225 min-1 {approximately 1225 rpm}) E: 4 seconds. F: Max. 2 seconds. G: Max. 1 second.
Operation When Control Lever is in Neutral The engine speed is decreased to approximately 1225 min-1 {approximately 1225 rpm} when all the control levers are kept in NEUTRAL for 4 seconds or more with the engine running at approximately 1225 min-1 {approximately 1225 rpm} or higher speed, and the engine control speed (approximately 1225 min-1 {approximately 1225 rpm}) is kept until any control lever is operated.
Operation When Control Lever is Operated The engine speed increases immediately to the speed being set with the fuel control dial when any control lever is operated while the engine speed is kept at the engine control speed (approximately 1225 min-1 {approximately 1225 rpm}).
PC45MR-5, PC55MR-5
10-21
Overheat Prevention System
10 Structure and Function
Overheat Prevention System Overheat Prevention System Diagram
Input and output signals a: PC-EPC valve drive signal
e: 1st throttle signal
b: Solenoid valve GND
f: Fuel supply pump control signal
c: CAN signal
g: Various sensor signals
d: CAN signal 1: Battery disconnect switch
11: Fuel control dial
2: Battery
12: Fuel supply pump
3: Fusible link
13: Various sensors
4: Starting switch
14: Main pump
5: Fuse box
14a: Servo
6: Resistor for PC-EPC valve
14b: LS valve
7: Machine controller
14c: PC valve
8: Engine controller
15: Control valve
9: Machine monitor
15a: Merge-divider valve
10: Pump secondary drive switch
16: PC-EPC valve
10-22
PC45MR-5, PC55MR-5
10 Structure and Function
Overheat Prevention System
Function of Overheat Prevention System This system prevents overheating by reducing the pump load and by lowering the engine speed, and protects engine and hydraulic components when coolant temperature becomes too high during operation. Operating condition Working mode: Travel (Hi mode)
Operation and remedy
→
Operating condition
→
•
Operation and remedy
→
Engine speed: Kept as it is
Coolant temperature: 100 °C or above
Pump discharged volume: Throttled
Operating condition
Operation and remedy
Working mode: All modes
Coolant temperature: Below 96 °C
Pump discharged volume: Throttled
Coolant temperature: 98 °C or above
Working mode: All modes
Engine speed: Kept as it is
Condition to cancel
Condition to cancel Coolant temperature: Below 100 °C →
→
Pump discharged volume: Throttled
•
Coolant temperature: Below 107 °C →
•
Warning lamp: Lit
Operating condition
When above condition is satisfied, it is restored to the state before operation (automatic restoration). Condition to cancel
Engine speed: Kept as it is
Coolant temperature: 107 °C or above
When above condition is satisfied, it is restored to the state before operation (automatic restoration).
Operation and remedy
When above condition is satisfied, it is restored to the state before operation (automatic restoration). Condition to cancel
Coolant temperature: Below 110 °C Working mode: All modes Coolant temperature: 110 °C or above
PC45MR-5, PC55MR-5
→
Engine speed: Low idle Warning lamp: Lit Alarm buzzer: Sounds
→
Fuel control dial: Return to Low idle (MIN) position. •
When above condition is satisfied, it is restored to the state before operation (manual restoration).
10-23
Automatic Idle Stop System
10 Structure and Function
Automatic Idle Stop System System Diagram of Automatic Idle Stop System
Input and output signals a: CAN signal
c: Lock lever signal
b: CAN signal 1: Lock lever
5: Engine controller
2: PPC lock switch
6: KOMTRAX terminal
3: Machine controller
7: Engine
4: Machine monitor
8: Coolant temperature sensor
Function of Automatic Idle Stop System •
Auto idle stop function stops the engine after a certain period of time passed and the operating conditions are satisfied when the auto idle stop function is enabled.
•
The engine stops when the machine controller judges the condition and outputs the engine stop signal with the auto idle stop function.
•
The operating time of the auto idle stop function can be set from the user menu or service menu on the machine monitor.
Condition of Automatic Idle Stop System Operation The auto idle stop function operates when all of the following conditions are satisfied at the same time. •
Engine is running.
•
Lock lever is in “LOCK” position.
•
Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”
•
Engine coolant temperature is high (60 °C or above)
•
Engine coolant temperature is not overheated (below 107 °C).
•
“Auto Idle Stop Timer Set” on machine monitor is not set.
•
Machine monitor is not set in service mode. (See “Setting time”.)
•
Regeneration of KDPF is not being performed.
•
None of the following failure codes is occurring.
Relevant failure codes are as follows.
10-24
PC45MR-5, PC55MR-5
10 Structure and Function
Failure code
Automatic Idle Stop System
Failure (displayed on screen)
B@BCNS
Eng Water Overheat
#B0118
Cooling water temperature sensor fault (High voltage)
#B0117
Cooling water temperature sensor fault (Low voltage)
DBHQKR
Controller Area Network 2 Defective Communication (Mcn Controller)
DB2QKR
CAN 2 Defective Communication (Engine Controller)
#B0123
Accelerator sensor 1 (Voltage high)
#B0122
Accelerator sensor 1 (Voltage low)
Setting Time Set the time for the auto idle stop function according to the following items. For setting of each item, see “Testing and Adjusting”. “Auto Idle Stop Timer Set”(Service Menu) Setting
Contents of setting
OFF
The auto idle stop function does not operate, and the related items are not displayed on service menu and user menu.
1 minute
In Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer Set menu, the selectable shortest time is 1 minute.
3 minutes
In Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer Set menu, the selectable shortest time is 3 minutes.
5 minutes
In Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer Set menu, the selectable shortest time is 5 minutes.
“Auto Idle Stop Time Fixing” (Service Menu) Setting
Contents of setting
Variable
In Auto Idle Stop Timer Set user menu, operator can select OFF or minimum set time in Auto Idle Stop Timer Set to maximum time of 60 minutes. (Default)
OFF
The auto idle stop function does not operate, and Auto Idle Stop Timer Set menu is not displayed.
Fix to “x” minutes.
In the Auto Idle Stop Timer Set menu, the operator can set the time up to “x” minutes (set time at left) in the auto idle stop setting time. (Cannot select OFF)
“Auto Idle Stop Time Fixing” (user menu) Setting OFF “y” minutes
Contents of setting Auto idle stop function does not operate. (Default) The engine stops “y” minutes (set time at left) after the lock lever is set to “LOCK” position.
NOTICE • When “Fix to x min.” is selected in the “Auto Idle Stop Time Fixing” menu, the screen changes to the operator screen automatically and the auto idle stop function operates 60 minutes after the lock lever is set to LOCK position, even when the Service menu is being used. • When performing work with the Service menu, always check the set value of the auto idle stop function.
PC45MR-5, PC55MR-5
10-25
Component Parts of Engine System
10 Structure and Function
Component Parts of Engine System PTO PTO Abbreviation for Power Take Off
Structure of PTO General View and Sectional View
1: Boss
4: Cover
2: Spring pin
5: Main pump
3: Rubber
Function of PTO •
PTO reduces the torsional vibration caused by the engine torque fluctuation. PTO also protects the drive system after the engine from the torsional vibration.
•
The power from the engine is transmitted through the flywheel to the coupling rubber (3). The coupling absorbs the torsional vibration, and the power is transmitted through the boss (1) to the main pump.
10-26
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Cooling System
Cooling System Layout Drawing of Cooling System
A: Oil cooler inlet
C: Radiator inlet
B. Oil cooler outlet
D: Radiator outlet
1: Oil cooler inlet plug
2: Shroud
PC45MR-5, PC55MR-5
10-27
Layout Drawing of Cooling System
10 Structure and Function
3: Radiator inlet hose
8: Radiator cap
4: Fan guard
9: Oil cooler
5: Radiator outlet hose
10: Reservoir tank
6: Oil cooler outlet plug
11: Fuel cooler
7: Radiator
12: Drain valve
Specifications of Cooling System Radiator Core type: CF90–4 Fin pitch: 3.5/2 mm Total heat dissipation area: 15.54 m2 Pressure valve cracking pressure: 88.3±14.7 kPa {0.9±0.15 kgf/cm2} Vacuum valve cracking pressure: 0 to 4.9 kPa {0 to 0.05 kgf/cm2}
Hydraulic Oil Cooler Core type: V-shaped fin Fin pitch: 3.5/2 mm Total heat dissipation area: 6.75 m2
Fuel Cooler Core type: Drawn cup Fin pitch: 3.0/2 mm Total heat dissipation area: 0.2 m2
10-28
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Control System
Control System Layout Drawing of Control System Chassis Part
1: Fuel control dial
4: Machine controller
2: KOMTRAX GPS antenna
5: KOMTRAX communication antenna
3: KOMTRAX terminal
6: Machine monitor
PC45MR-5, PC55MR-5
10-29
Machine Monitor System
10 Structure and Function
Machine Monitor System System Diagram of Machine Monitor System
a: Power supply
c: Sensor signal and switch signal
b: CAN signal 1. Machine monitor
4: Engine controller
2: Battery
5: KOMTRAX terminal
3: Machine controller
6: Sensors and switches
10-30
PC45MR-5, PC55MR-5
10 Structure and Function
KOMTRAX System
KOMTRAX System System Diagram of KOMTRAX System
KOMTRAX system consists of KOMTRAX terminal, communication antenna, and GPS antenna
Function of KOMTRAX System •
KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees the information in the office and supplies various services to the customers.
•
KOMTRAX system can transmits the following information. •
Positional information
•
Working information
•
Alarm and failure information
•
Fuel consumption information
•
Maintenance information
•
Machine working condition information
REMARK To provide the services, you need to establish radio station for KOMTRAX separately.
PC45MR-5, PC55MR-5
10-31
Component Parts of Control System
10 Structure and Function
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 outputs 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.
10-32
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Control System
REMARK • It consists of display and function switches. The display adopts LCD (Liquid Crystal Display), and the function switches part is flat sheet switch. • If there is any abnormality in the machine monitor, controller, or wiring between the machine monitor and controller, the machine monitor does not display correctly. • An LCD panel sometimes shows black spots (spots that remain unlit) and bright spots (spots that do not go off) as one of the characteristics. When there are fewer than 10 black or white spots, this is not a failure or a defect. • The battery voltage may drop sharply when the engine is started depending on the ambient temperature and battery condition. In this case, the display may disappear a while, but it is not an abnormal phenomenon. • When the machine monitor is used continuously, blue bright spots may appear on the black background, but it is neither failure nor malfunction. The background color of the display is usually blue or white, so the blue bright spots will not be a problem. (Red, green, blue are used for display of the white.) • For the following items, see “Operation and Maintenance Manual”. •
Screen display
•
Guidance icons, function switches
Input and Output Signals of Machine Monitor 070-12P “F15” Pin No.
Signal name
Input and output signals
1
Continuous power supply (12 V)
2
Ground (return)
3
Starting switch (ACC)
Input
4
Starting motor cut-off relay (for personal code)
Output
5
External buzzer
Output
6
Continuous power supply (12 V)
Input
7
Ground (return)
8
Engine shutdown secondary switch
Input
9
External starting signal
Input
10
System operating lamp
Output
11
CAN0_H (with built-in terminating resistor 120 Ω)
Input and output
12
CAN0_L (with built-in terminating resistor 120 Ω)
Input and output
PC45MR-5, PC55MR-5
Input -
-
10-33
Component Parts of Control System
10 Structure and Function
Gauges and Meters Shown on Machine Monitor Gauge
Item to be displayed
Range and method for display
Range
Temperature
Monitor background
Engine coolant temperature gauge
W1
110 °C
Red
W2
107 °C
Red
(*1)
W3
105 °C
Blue
W4
86 °C
Blue
W5
59 °C
White
Range
Quantity
Monitor background
F1
56.0 ℓ
Blue
F2
46.0 ℓ
Blue
F3
33.6 ℓ
Blue
F4
17.2 ℓ
Blue
F5
13.7 ℓ
Red
Fuel gauge (*1)
Segment ECO gauge
Green
1 to 8
Orange
9, 10
(*2)
Service meter
•
Indicates corresponding temperature range.
•
Alarm buzzer sounds when the temperature exceeds 110 °C.
•
If the background color of monitor is white, perform warm-up operation.
Indicates the remaining quantity.
Load level Indicates instantaneous fuel consumption (average of fuel consumption by 3 Light to seconds) in 10 steps. medium (Displayed when Operation Record → Configurations → ECO Gauge on user menu is set to ON.) Heavy
00000.0 h to 99999.9 h
•
12-hour display (AM/PM)
•
24 hour display
Fuel consumption gauge
•
1 day
•
Split Time
(*2)
•
None
Clock
Remarks
Indicates accumulated engine operating hours. (Press F2 switch to change to clock display.) Displays the time. (Press F2 switch to change to service meter display.) Indicates average fuel consumption. (Display can be switched by selecting another item in Operation Record → Configurations → Average Fuel Consumption Display on user menu.)
*1: The gauge disappears if the gauge signal is not available due to an open circuit in the CAN communication line. *2: Display can be switched by selecting another item in “Operation Record” → “Configurations” on the user menu.
10-34
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Control System
Caution Lamps Shown on Machine Monitor Range and method for display Symbol
Item to be displayed
Range
Caution lamp display (background color)
Min. 107 °C
Lit (red)
L02
Min. 60 °C, below 107 °C
Lit (blue)
-
Engine coolant temperature Below 60 °C
Fuel level
Battery charge
Lit (white)
Lit (red)
-
Min. 13.8 ℓ
Lit (blue)
-
(below specified voltage)
Lit (red)
(when pressure is below the specified pressure) When maintenance due time is over
Maintenance due time warning
When maintenance notice time is over
Caution lamp background color changes depending on the temperature detected.
•
Alarm buzzer sounds when the temperature exceeds 110 °C.
•
If the background color of caution lamp is white, perform warm-up operation.
•
The background color of caution lamp changes depending on the fuel level.
•
Caution lamp lights up and alarm buzzer sounds when an abnormality is detected while engine is running.
•
Caution lamp lights up and alarm buzzer sounds when an abnormality is detected while engine is running.
•
The display changes depending on how long it has passed since the maintenance due time was over.
•
After starting switch is turned to ON position, caution lamp lights up when condition is satisfied for lighting up, and then it goes out in 30 seconds.
•
Caution lamp lights up when an abnormality is detected in machine system.
•
When the background color of caution lamp is red, the warning buzzer sounds.
L03
When it is abnormal Engine oil pressure
•
-
Below 13.8 ℓ
When charging was faulty
Remarks
Action level display
Lit (red)
L03
Lit (red)
-
Lit (yellow)
-
When action level L04 or L03 is detected
Lit (red)
L04 or L03
When action level L01 is detected
Lit (yellow)
(*1)
State of system
PC45MR-5, PC55MR-5
L01 (*2)
10-35
Component Parts of Control System
10 Structure and Function
Range and method for display Symbol
Item to be displayed
State of engine system
State of hydraulic system
State of KDPF system
KDPF soot accumulation
(background color)
When action level L04 or L03 is detected
Lit (red)
When action level L01 is detected
Lit (yellow)
When action level L04 or L03 is detected
Lit (red)
When action level L01 is detected
Lit (yellow)
When action level L04 or L03 is detected
Lit (red)
When action level L01 is detected
Lit (yellow)
When action level L04 or L03 is detected
Lit (red)
When action level L01 is detected
Lit (yellow)
Remarks
Action level display •
Caution lamp lights up when an abnormality is detected in engine system.
•
When the background color of caution lamp is red, the warning buzzer sounds.
•
Caution lamp lights up when abnormality is detected in hydraulic system.
•
When the background color of caution lamp is red, the warning buzzer sounds.
•
Caution lamp lights up when an abnormality is detected in KDPF system.
•
When the background color of caution lamp is red, the warning buzzer sounds.
•
Caution lamp lights up when soot is accumulated in KDPF or when purifying function detects an abnormality.
•
When the background color of caution lamp is red, the warning buzzer sounds.
•
Caution lamp lights up and warning buzzer sounds when engine overrun is detected.
•
Caution lamp lights up when abnormality is detected in the machine.
•
When the background color of caution lamp is red, the warning buzzer sounds.
L04 or L03 L01 (*2) L04 or L03 L01 (*2) L04 or L03 L01 (*2) L03
L01 (*2)
Engine Overrun
When engine overruns
Lit (red)
L02
Seat belt caution lamp
Seat belt is not fastened
-
-
When action level L04 is detected
Lit (red)
L04
When action level L03 is detected
Lit (red)
L03
When action level L02 is detected
Lit (red)
L02
When action level L01 is detected
Lit (yellow)
Action level
10-36
Range
Caution lamp display
L01 (*2)
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Control System
*1: Maintenance notice time can be changed on “Maintenance Mode Setting” of SERVICE MODE. *2: These items are lit for 2 seconds, and then go out.
Pilot Lamps Shown on Machine Monitor Symbol
Item to be displayed
Preheating
Aftertreatment devices regeneration
•
Operates automatically when temperature is low. (The lamp is lit for approximately 15 seconds at maximum.)
•
Goes out after engine is started.
Automatic preheating
Lit: Aftertreatment devices regeneration in progress
•
Displays the operation state of preheating.
•
Indicates regeneration state of aftertreatment devices.
•
Indicates regeneration state of aftertreatment devices.
•
When manual stationary regeneration is necessary, KDPF soot accumulation monitor lights up.
•
Indicates the state of messages.
•
Indicates the state of messages.
•
Displays the operation of auto-deceleration function
•
Displays the working mode.
•
Displays the set mode of travel speed.
Not lit: Aftertreatment devices regeneration has been completed.
Aftertreatment devices regeneration disable
Lit: Aftertreatment devices regeneration is disabled
Message
Lit: There is an unread message
(Unread)
Not lit: No message
Not lit: Aftertreatment devices regeneration disable is canceled
Message (Not yet replied, already-read)
Remarks
Range and method for display
Lit: There is a read and unreplied message. Not lit: No message
Auto-deceler- Lit: ON ation Not lit: OFF P: Heavy-duty operation E: Low-fuel consumption operation Working mode
B: Breaker operation ATT/P: 2-way attachment operation ATT/E: 2-way attachment operation with low fuel consumption
Travel speed
PC45MR-5, PC55MR-5
Lo: Low-speed travel Hi: High-speed travel
10-37
Component Parts of Control System
10 Structure and Function
Operator Mode Function of Machine Monitor These items are normally displayed. The operator can display, set these items with switch operation. Some items may require special switch operation. Items available in the operator mode are as follows. Category
Item
Patterns for display (*2)
(*1) W
X
Y
Z
1
1
1
1
Display of password input
2
-
-
-
Display of service person identification state
3
-
-
-
Display of maintenance due time over
-
-
-
2
Display to check working mode and travel speed
4
2
2
3
Display of standard screen
5
3
3
4
Display of KOMATSU logo
A
Display of engine shutdown secondary switch screen Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Stop operation of alarm buzzer Operation to display clock and service meter B
Check of maintenance information Setting and display of user menu • Operation Record •
Machine Setting
•
Aftertreatment Devices Regeneration
•
Maintenance
•
Monitor Setting
•
Display of message (including KOMTRAX messages for user)
Caution lamp C
Display of KDPF regeneration Action level and failure code Checking function of LCD (Liquid Crystal Display)
D
Checking function of service meter Function of usage limitation setting and password change
*1: The operator mode items are classified as follows. A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to the standard screen, and display after starting switch is turned to “OFF” position B: Display when the machine monitor switch is operated C: Display when condition is satisfied D: Display that requires special switch operation.
10-38
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Control System
*2: The sequence of display from the time when the starting switch is turned to “ON” position to the time when the standard screen appears varies depending on the settings and conditions of the machine as follows: W: When the engine start lock is enabled. X: When the engine start lock is disabled. Y: When any abnormality is detected by the check before starting Z: When any item is detected as the maintenance due time is over REMARK • For how to operate the operator mode functions, see “Operation and Maintenance Manual”. • For the operating method of the engine start lock function, see“ Password setting and canceling manual”.
Service Mode Function of Machine Monitor These functions are not displayed normally. A technician can display and set them special operation of switches. These functions are used for special settings, testing, adjusting, or troubleshooting. Items available in the service mode are as follows: REMARK For operating method of the service mode functions, see TESTING AND ADJISTING, “SERVICE MODE”. Pre-defined Monitoring Self-define Monitoring Abnormality Record
Mechanical Sys Abnormality Record Electrical Sys Abnormality Record
Maintenance Record Maintenance Mode Setting Phone Number Entry Default
Key-on mode Unit With/Without Attachment Auto Idle Stop Time Fixing
Diagnostic Tests
Cylinder Cutout Mode Operation Active Regeneration for Service KDPF Memory Reset Rail Pressure Memory Reset
Adjustment
Pump Absorption Torque Attachment EPC 2 Adjustment Attachment EPC 3 Adjustment
Batt. Disconnect Set KOMTRAX Settings
Terminal Status GPS & Communication State Modem Information
Service Message
PC45MR-5, PC55MR-5
10-39
Component Parts of Control System
10 Structure and Function
KOMTRAX Terminal Structure of KOMTRAX Terminal General View Model: TC630/TC635
1: GPS antenna connection
4: Communication antenna connection
2: Machine harness connection (070-18P)
5: LED lamp display
3: Machine harness connection (070-12P)
Function of KOMTRAX Terminal •
This terminal uses the communication technology of cell phone.
•
This terminal is the wireless communication equipment which enables to transmit GPS locational information and various machine information which is received from network signal or input signal. It can transmit the information via communication antenna.
•
The condition of KOMTRAX terminal can be checked on the “KOMTRAX Setting” screen in the service mode of the machine monitor.
•
Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
•
The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its display section.
REMARK • When commencing the operation of the KOMTRAX system or changing the country in which the system is used, you must give notice to Komatsu Ltd. • When operating the system in Japan, it is required to install a terminal for exclusive use in Japan.
Input and Output Signals of KOMTRAX Terminal 070-18P“CK01” Pin No.
10-40
Signal name
Input and output signals
1
(*1)
-
2
(*1)
-
3
(*1)
-
4
(*1)
-
5
(*1)
-
6
(*1)
-
7
(*1)
-
8
(*1)
-
PC45MR-5, PC55MR-5
10 Structure and Function
Pin No.
Component Parts of Control System
Signal name
Input and output signals
9
(*1)
-
10
CAN (C)_H
Input and output
11
CAN (C)_L
Input and output
12
(*1)
-
13
(*1)
-
14
External starting signal
Input and output
15
System operating lamp
Output
16
(*1)
-
17
(*1)
-
18
(*1)
-
*1: Never connect these pins, otherwise it may cause malfunction or failures.
070-12P“CK02” Pin No.
Signal name
Input and output signals
1
GND
-
2
GND
-
3
Starting switch (ACC)
Input
4
Alternator (R)
Input
5
(*1)
6
Power supply
Input
7
Power supply
Input
8
(*1)
-
9
(*1)
-
10
(*1)
-
11
Starting switch (C)
12
(*1)
-
Input -
*1: Never connect these pins, otherwise it may cause malfunction or failures.
PC45MR-5, PC55MR-5
10-41
Component Parts of Control System
10 Structure and Function
Machine Controller Structure of Machine Controller
Input and Output Signals of Machine Controller AMP-81P“CN-CP01” Pin No.
10-42
Signal name
Input and output signals
1
Continuous power supply (12 V)
Input
2
Continuous power supply return
Input
3
(*1)
4
Continuous power supply (12 V)
Input
5
Continuous power supply return
Input
6
(*1)
7
CAN_H_0
8
Potentiometer power supply (5 V)
Output
9
Potentiometer power supply (5 V)
Output
10
(*1)
-
11
(*1)
-
12
(*1)
-
13
GND (analog signal)
Input
14
Terminating resistor
Input and output
15
Terminating resistor
Input and output
-
Input and output
PC45MR-5, PC55MR-5
10 Structure and Function
Pin No.
Component Parts of Control System
Signal name
Input and output 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
22
PPC lock lever cancel signal
Input
23
Starting switch C signal
Input
24
External starting signal
Input
25
(*1)
26
CAN_L_0
27
(*1)
-
28
(*1)
-
29
Travel PPC pressure sensor
Input
30
R.H. attachment lever sub
Input
31
(*1)
32
GND (analog signal)
Input
33
Terminating resistor
Input and output
34
Terminating resistor
Input and output
35
Service pressure sensor 1
Input
36
Breaker switch (main)
Input
37
(*1)
-
38
(*1)
-
39
(*1)
-
40
(*1)
-
41
PPC lock lever signal
Input
42
Working lamp switch
Input
43
(*1)
-
44
(*1)
-
45
CAN_H_1
46
GND (analog signal)
Input
47
GND (analog signal)
Input
48
Swing parking brake cancel PPC pressure
Input
49
(*1)
-
50
(*1)
-
51
GND (analog signal)
Input
52
GND (analog signal)
Input
53
(*1)
PC45MR-5, PC55MR-5
Input and output
-
Input and output
-
10-43
Component Parts of Control System
Pin No.
10 Structure and Function
Signal name
Input and output signals
54
(*1)
-
55
Breaker switch sub
Input
56
Engine controller operation signal
Input
57
Machine model selection switch 2
Input
58
(*1)
-
59
(*1)
-
60
PPC lock relay monitor signal
Input
61
Travel speed increase switch
Input
62
Starting switch ACC signal
Input
63
Machine model selection switch 1
Input
64
CAN_L_1
65
GND (analog signal)
Input
66
GND (analog signal)
Input
67
(*1)
68
R.H. attachment control lever (main)
Input
69
Fuel level sensor
Input
70
GND (analog signal)
Input
71
(*1)
-
72
(*1)
-
73
(*1)
-
74
(*1)
-
75
(*1)
-
76
(*1)
-
77
(*1)
-
78
Seat belt switch
Input
79
PPC lock solenoid valve emergency drive switch monitoring signal
Input
80
Air conditioner compressor signal
Input
81
(*1)
Input and output
-
-
*1: Never connect these pins. It may cause malfunction or failures.
AMP-40P “CN-CP02” Pin No.
10-44
Signal name
Input and output signals
82
(*1)
-
83
Alternator R signal
Input
84
Bucket DUMP stop solenoid
Input
85
(*1)
86
Travel alarm
Input
87
2nd attachment EPC
Input
-
PC45MR-5, PC55MR-5
10 Structure and Function
Pin No.
Component Parts of Control System
Signal name
Input and output signals
88
(*1)
-
89
(*1)
-
90
(*1)
-
91
(*1)
-
92
(*1)
-
93
(*1)
-
94
(*1)
-
95
(*1)
-
96
(*1)
-
97
(*1)
-
98
(*1)
-
99
System operating lamp
100
(*1)
101
Power supply (boom swing neutral sensor)
Input
102
PC-EPC valve
Input
103
1st attachment EPC
Input
104
(*1)
-
105
(*1)
-
106
(*1)
-
107
Travel speed increase solenoid
108
(*1)
109
PPC lock relay cancel
110
(*1)
111
1st attachment EPC
112
(*1)
-
113
(*1)
-
114
Solenoid return
Input
115
Solenoid return
Input
116
Battery relay secondary current
Input
117
Solenoid return
Input
118
Battery relay secondary current
Input
119
(*1)
120
Solenoid return
Input
121
Battery relay secondary current
Input
Input -
Input Input Input
-
*1: Never connect these pins. It may cause malfunction or failures.
PC45MR-5, PC55MR-5
10-45
Component Parts of Control System
10 Structure and Function
Fuel Control Dial Structure of Fuel Control Dial Fuel control dial is installed in the R.H. console box.
General View and Sectional View
1: Potentiometer
3: Knob
2: Spring
Function of Fuel Control Dial
When knob (3) is turned, the shaft of potentiometer (1) rotates. The resistance of variable resistor in potentiometer (1) varies according to this rotation, and throttle signals are sent to the controller.
10-46
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Control System
REMARK The hatched area in the following graph is the abnormality detection area. When the throttle voltage is in this area, the engine speed is set to high idle.
PC45MR-5, PC55MR-5
10-47
Layout Drawing of Hydraulic System
10 Structure and Function
Hydraulic System Layout Drawing of Hydraulic System Chassis Part
1: Hydraulic tank
7: Engine controller
2: Fuel supply pump
8: LS valve
3: Travel PPC pressure sensor
9: Servo valve
4: Work equipment PPC pressure switch
10: PC-EPC valve
5: Swing parking brake pressure sensor
11: PC valve
6: Control valve
12: Main pump
10-48
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Hydraulic System
Around Cab and Floor
1: Machine monitor
4: Machine controller
2: Fuel control dial
5: Pump secondary drive switch
3: Starting switch
PC45MR-5, PC55MR-5
10-49
CLSS
10 Structure and Function
CLSS CLSS Abbreviation for Closed-center Load Sensing System
Structure of CLSS Actuators
Control valve
PC valve
LS valve
Servo piston G0048454
Features of CLSS •
Fine controllability not influenced by load
•
Control performance that allows digging even under fine control operation condition
•
Easy combined operation ensured by the flow dividing performance that is determined by the opening areas of spools during combined operations
•
Energy saving by variable discharge pump control
Composition of CLSS •
CLSS consists of variable displacement piston pump, control valves, and respective actuators.
•
The main pump consists of a pump body, PC valve, and LS valve.
10-50
PC45MR-5, PC55MR-5
10 Structure and Function
CLSS
Function of CLSS Pump Swash Plate Angle Control CLSS controls the pump swash plate angle (pump discharged volume) so that LS differential pressure (∆PLS) will be constant, which is the differential pressure between pump discharged pressure (PP) and control valve outlet LS pressure (PLS) (actuator load pressure). “LS differential pressure (∆PLS) = Pump discharged pressure (PP) - LS pressure (PLS)” •
•
The pump swash plate shifts toward the maximum angle position when LS differential pressure (∆PLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high). The pump swash plate shifts toward the minimum angle position when LS differential pressure is higher than the set pressure (when the actuator load pressure is low).
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PC45MR-5, PC55MR-5
10-51
CLSS
10 Structure and Function
Pressure Compensation Control Load
Load
W
W
Actuator
Actuator
ΔP
ΔP S1
S2
Pressure compensation valve
Pressure compensation valve
Pump G0048455
•
A pressure compensation valve is installed to the inlet port side of the control valve in order to balance the load.
•
When actuators are operated in combined operations, the pressure difference (∆P) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve is kept the same regardless the size of the load (pressure).
•
The oil flow from the pump is divided (compensated) in proportion to the open areas (S1) and (S2) of each valve.
10-52
PC45MR-5, PC55MR-5
10 Structure and Function
Engine and Pump Combined Control System
Engine and Pump Combined Control System Engine and Pump Combined Control System Diagram
Input and output signals a: PC-EPC valve drive signal
f: Oil pressure switch signal
b: Solenoid valve GND
g: 1st throttle signal
c: CAN signal
h: Fuel supply pump control signal
d: CAN signal
i: Various sensor signals
e: Oil pressure sensor signal 1: Battery disconnect switch
12: Various sensors
2: Battery
13: Oil pressure sensor
3: Fusible link
14: Oil pressure switch
4: Fuse box
15: Main pump
5: Resistor for PC-EPC valve
15a: Servo
6: Machine controller
15b: LS valve
7: Engine controller
15c: PC valve
8: Machine monitor
16: Control valve
9: Pump secondary drive switch
16a: Merge-divider valve
10: Fuel control dial
17: PC-EPC valve
11: Fuel supply pump
18: Starting switch
PC45MR-5, PC55MR-5
10-53
Engine and Pump Combined Control System
10 Structure and Function
Function of Engine and Pump Combined Control System Working Mode Selection Function •
The operator can select one from five working modes of P, E, B, ATT/P, and ATT/E in the working mode on machine monitor.
•
Operator can select the most appropriate engine torque (T) and pump absorption torque according to the work.
•
When “Without Attachment” is selected in “With/Without Attachment” items of “Default” in Service mode, the selectable modes are 2 of P and E.
•
The machine controller obtains the pump absorption upper limit torque by calculating the engine speed being set with the working mode and the fuel control dial and the actual engine speed. It controls the pump so that the engine speed is kept around the matching point set in each mode even when the heavy load is applied.
•
When the engine speed decreases, it reduces the pump absorption torque to prevent engine from being stopped.
Control Method in Each Mode
10-54
Working mode
Matching point
P, ATT/P (during operation), B
28.2 kW/2375 min-1 {37.8 HP/2375 rpm}
E, ATT/E (during operation)
22.6 kW/1896 min-1 {30.3 HP/1896 rpm}
PC45MR-5, PC55MR-5
10 Structure and Function
•
In mode P, E, ATT/P, or ATT/E, B, the engine speed is kept around the matching point set in each mode.
•
As the load of the pump increases, and the pump discharged pressure increases, the engine speed decreases.
•
The machine controller raises the engine speed to near the matching point in order to reduce the discharged volume of the pump.
•
As the load of the pump decreases and the pump discharged pressure decreases, the pump discharged volume increases until the engine speed comes to near the matching point.
Engine and Pump Combined Control System
Control Function When the Pump Secondary Drive Switch is Turned On When the main pump does not operate normally, and machine does not work due to an abnormality occurring in the controller, etc., operate the pump drive secondary switch (1). With this operation, temporary work can be performed with absorption torque to mode E. At this time, only PC-EPC valve senses the oil pressure since a constant current flows from the battery to PCEPC valve. REMARK Pump drive secondary switch (1) is an alternative type. If the machine is operated with this switch at emergency (a) position while the machine is normal, action level L03 appears on the display. a: Emergency (when abnormal) b: Normal (when normal)
PC45MR-5, PC55MR-5
10-55
Component Parts of Hydraulic System
10 Structure and Function
Component Parts of Hydraulic System Hydraulic Tank Structure of Hydraulic Tank General View
1: Hydraulic tank
4: Sight gauge
2: Oil filler cap
5: Drain plug
3: Breather
10-56
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Sectional View
6: Filter
8: Cyclone assembly
7: Bypass valve
9: Strainer
Specifications of Hydraulic Tank Hydraulic tank capacity: 33 ℓ Hydraulic tank refill capacity: 20 ℓ Bypass valve set pressure: 0.25±0.05 MPa {2.5±0.5 kgf/cm2}
PC45MR-5, PC55MR-5
10-57
Component Parts of Hydraulic System
10 Structure and Function
Operation of Cyclone Assembly
1.
The hydraulic oil returning from each actuator flows through the filter to block (1) of the cyclone assembly.
2.
The hydraulic oil flows from block (1) into the cylindrical part of cyclone (2) increasing the speed, and the flow becomes swirls.
3.
A centrifugal force is generated as the hydraulic oil swirls, and bubbles with a lower specific gravity gather together to the center.
4.
The hydraulic oil and air are separated by discharging the collected bubbles into the hydraulic oil in the tank through the upper center of block (1) and outlet (a) on the side of cyclone (2).
5.
The hydraulic oil containing no bubble is discharged through outlet (b) at the bottom of cyclone (2), and then it flows through the strainer into the main pump again.
Hydraulic Tank Oil Filler Cap Structure of Hydraulic Tank Oil Filler Cap 1:Filter element 2:Bottom plate 3:Gasket 4:Seam valve 5:Spring
10-58
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Function of Hydraulic Tank Oil Filler Cap Prevention of Pressure Rise in Hydraulic Tank The pressure in the hydraulic tank increases as the oil level and the temperature in the hydraulic tank rise corresponding to the operation of the hydraulic cylinders while the hydraulic circuit is in operation. To prevent this from occurring, bottom plate (1) is pushed up to release the pressure in the tank and prevent pressure from rising when the pressure in the tank exceeds the set pressure. Pressure valve cracking pressure: 38±15 kPa {0.39±0.15 kgf/cm2}
Hydraulic Tank Breather Structure of Hydraulic Tank Breather Sectional View 1: Nut 2: Cover 3: Filter element 4: Case 5: Valve assembly 6: Body
Function of Hydraulic Tank Breather Prevention of Negative Pressure in Hydraulic Tank Negative pressure is generated if the oil level in the hydraulic tank lowers since it is pressurized and airtight. To prevent this from occurring, the valve assembly (5) is opened by the differential pressure from the barometric pressure, and the barometric pressure is taken in. (Set pressure of intake valve : 0.002±0.0003 MPa {0.02±0.003 kgf/cm2} ) (Set pressure of exhaust valve: 0.1±0.015 MPa {1.0±0.15 kgf/cm2} )
PC45MR-5, PC55MR-5
10-59
Component Parts of Hydraulic System
10 Structure and Function
Main Pump Structure of Main Pump General View
P1: Pump discharge port
P3: Swing and blade pump discharge port
P1L: Pump pressure input port (from control valve port PP)
P4: Pilot pressure output port
P1T: Travel deviation adjustment orifice
PLS: LS pressure input port (from control valve port LS)
P2: Pump discharge port
PS: Main pump suction port
P2T: Travel deviation adjustment orifice 10-60
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
1: Main pump
5: EPC valve
2: Servo valve
6: Bleeder
3: Swing and blade pump
7: Maximum delivery adjustment plug
4: Pilot pump
8: Minimum delivery adjustment plug
Sectional View
GH: Swing and blade pump Hi signal port
PE: Control piston pressure port
GL: Swing and blade pump Lo signal port
PEPC: EPC source pressure input port
PAVE: Pump average pressure port
PH: Pump shuttle pressure port
PDE: EPC drain port 1: Shaft
7: Cylinder block
2: Case
8: Valve plate
3: Cap
9: Servo piston
4: Rocker cam
10: Ball retainer
5: Shoe
11: Oil seal
6: Piston
PC45MR-5, PC55MR-5
10-61
Component Parts of Hydraulic System
10 Structure and Function
Structure
•
This pump consists of a variable capacity swash plate piston pump, Swing and blade pump pilot pump and servo valve.
•
Cylinder block (7) is supported on shaft (1) by spline (a).
•
Shaft (1) is supported by each bearing at the front and rear.
•
The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
•
Piston (6) and shoe (5) form a spherical bearing.
•
Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular pattern.
•
Rocker cam (4) is supported on ball retainer (10) installed to case (2).
•
Shoe (5) leads high-pressure oil to flat surface (A) of rocker cam (4) and form a static pressure bearing for its sliding.
•
Piston (6) reciprocates in the axial directions inside each cylinder of cylinder block (7).
•
Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil. The oil pressure is balanced properly on this surface.
•
The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through valve plate (8).
10-62
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
•
Cylinder block (7) is with even numbers of holes. Each one cocoon shape port out of every two ports on the surface contacting to valve plate (8) is connected to the long cocoon shape port of valve plate (8).
•
Two long cocoon shape ports on valve plates (8) correspond to two discharging ports which act as a double pump.
Function of Main Pump •
This pump converts the engine speed and torque transmitted to the shaft of the pump into hydraulic pressure, and discharges pressurized oil corresponding to the load.
•
The discharged volume changes as the swash plate angle changes.
•
There are 2 pump discharge ports, and each pump can supply pressurized oil separately.
•
It acts as a single pump after the pressurized oil merged at the control valve for the operation other than traveling.
•
Two discharging ports are connected to right travel and left travel respectively when traveling (divided mode).
•
The pressures of the left travel and right travel are basically the same and the function is the same as that of a single pump although it is divided mode when driving straight (with combined operation of traveling and the work equipment operation, it is merged mode).
•
The pump pressure of the outside track increases, and that of the inside decreases at steering operation during traveling. These two pressures are generated inside the pump (the pressure of the port with an even number is high, and that of the port with an uneven number is low in cylinder block).
•
The difference among the pressures is generated in divided mode only when operating steering during traveling. It is a special kind of state.
•
The average discharged pressure among the two pumps controls the PC valve.
Superiority of the Double Pump System •
It is the characteristic of the usual pump system that the motor pressure on the driven side become the same as the motor pressure on the driving side as the pressure compensation valve of control valve acts. That is, the pressure compensation valve on the driven side is throttled, and the pressure of the driven side circuit increases to be the same as that of the driving side circuit.
•
Normally, the motor pressure on the driving side (outside) increases, and that on the driven side (inside) decreases in the double pump system when operating steering during traveling. The motor pressure on the driven side remains low, and it prevents the flow rate of the motor on the driving side from being decreased.
Example of the Engine Output of the Single Pump System •
When driving straight The pressure on the right 9.80 MPa {100 kgf/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on the left (9.80 MPa {100 kgf/cm2} ) x the flow rate on the left (50.0 ℓ/min) = 8.1 kW {10.9 HP} + 8.1 kW {10.9 HP} = 16.2 kW {21.7 HP}
•
When operating steering The pressure on the right 19.6 MPa {200 kgf/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on the left (9.80 MPa {100 kgf/cm2} ) x the flow rate on the left (40.0 ℓ/min) = 16.2 kW {21.7 HP} + 6.6 kW {8.9 HP} = 22.8 kW {30.6 HP}
•
When engine stop is being prevented (when the horsepower inputted in the pump is larger than the engine horsepower, and the engine control is starting) The pressure on the right 19.6 MPa {200 kgf/cm2} ) x the flow rate on the right (30.0 ℓ/min) + the pressure on the left (19.6 MPa {200 kgf/cm2} ) x the flow rate on the left (20.0 ℓ/min) = 9.6 kW {12.9 HP} + 6.6 kW {8.9 HP} = 16.2 kW {21.7 HP}
The average of the right and left flow rate has dropped from 50.0 ℓ/min to 25.0 ℓ/min (it has been decreased by 50.0 %).
Example of the Engine Output of the Double Pump System •
When driving straight
PC45MR-5, PC55MR-5
10-63
Component Parts of Hydraulic System
10 Structure and Function
The pressure on the right 9.80 MPa {100 kgf/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on the left (9.80 MPa {100 kgf/cm2} ) x the flow rate on the left (50.0 ℓ/min) = 8.1 kW {10.9 HP} + 8.1 kW {10.9 HP} = 16.2 kW {21.8 HP} •
When operating steering The pressure on the right 19.6 MPa {200 kgf/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on the left (4.90 MPa {50 kgf/cm2} ) x the flow rate on the left (40.0 ℓ/min) = 16.2 kW {21.7 HP} + 2.9 kW {3.9 HP} = 19.1 kW {25.6 HP}
•
When engine stop is being prevented (when the horsepower inputted in the pump is larger than the engine horsepower, and the engine control is starting) The pressure on the right 19.6 MPa {200 kgf/cm2} ) x the flow rate on the right (43.0 ℓ/min) + the pressure on the left (4.9 MPa {50 kgf/cm2} ) x the flow rate on the left (33.0 ℓ/min) = 14.0 kW {18.8 HP} + 2.2 kW {3.0 HP} = 16.2 kW {21.8 HP}
The average of the right and left flow rate has dropped from 50.0 ℓ/min to 38.0 ℓ/min (it has been decreased by 24.0 %). The decrease of the flow rate when engine stop is being prevented is 24.0 % with the double pump system. It is lower than 50.0 % which would be obtained with the single pump system.
Operation of Main Pump Selection of Discharged Volume (Selection of Swash Plate Angle) 1.
Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on plane (A).
2.
The leaning (a) between the center line (X) of rocker cam (4) and cylinder block (7) changes as rocker cam (4) pivots on ball retainer (10), and leans.
3.
(a) is called the swash plate angle.
Suction and Discharge of Pressurized Oil 1.
While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), flat surface (A) works as a cam for shoe (5).
2.
Piston (6) reciprocates in cylinder block (7).
3.
Difference is made between volumes (E) and (F) in cylinder block (7) since cylinder block (7) moves rotationally along face (A) of the rocker cam.
4.
The oil in amount of (F) minus (E) per each piston (6) is suctioned in and discharged from.
5.
As cylinder block (7) rotates and the volume of chamber (E) decreases, pressurized oil is discharged on the process.
6.
As the volume of chamber (F) increases, pressurized oil is suctioned on the process.
10-64
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
No Pressurized Oil is Suctioned In or Discharged (Swash Plate Angle = 0) 1.
The difference between volumes (E) and (F) inside cylinder block (7) is zero when center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is zero).
2.
Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not performed. (Angle of swash plate never becomes zero actually)
3.
Pump discharged volume is in proportion to swash plate angle (a).
4.
There are an even number of holes (10 pieces) on cylinder block (7), and they match the two grooves of valve plate (8) alternately. The oil of quantity for five pistons is discharged respectively through each pump discharge port.
Control of Discharged Volume 1.
As swash plate angle (a) increases, the difference between volumes (E) and (F) increases, then discharged volume (Q) increases.
2.
Swash plate angle (a) is changed by servo piston (9).
3.
Servo piston (9) moves in a linear reciprocating motion corresponding to the signal pressure from the PC valve and LS valve.
4.
This linear motion is transmitted to rocker cam (4).
5.
Being supported by ball retainer (10) on case (2), rocker cam (4) moves rotationally.
PC45MR-5, PC55MR-5
10-65
Component Parts of Hydraulic System
10 Structure and Function
Main Pump Servo Valve Structure of Main Pump Servo Valve General View and Sectional View
GH: Swing and blade pump Hi signal port
PLS: LS pressure input port
GL: Swing and blade pump Lo signal port
PH: Pump shuttle pressure port
PAVE: Pump average pressure input port
PM: PC mode selector pressure input port
PDE: EPC drain port
P1L: Pump pressure input port
PE: Control piston pressure port
T: Drain port
PEPC: EPC source pressure input port 10-66
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
1: Lever
10: Lock nut
2: Spool
11: Spring (LS valve)
3: Plug
12: PC-EPC valve
4: Sheet
13: Spool
5: Piston
14: Ball
6: Sleeve
15: Plug
7: PC valve
16: PC mode selector power supply connector
8: LS valve
17: Spring (PC valve)
9: Plug
18: Retainer
Operation of Main Pump Servo Valve Operation of Spring 1.
The spring force of spring (2) in PC valve is determined by the position of the swash plate.
2.
If servo piston (6) moves to the right, spring (2) is compressed through lever (1), and the spring force changes. The spring has characteristics that the spring constant changes into 2 stages depending on the height of the spring.
Operation When Pump Pressure (PAVE) is Low (Load is Light)
PC45MR-5, PC55MR-5
10-67
Component Parts of Hydraulic System
10 Structure and Function
1.
The force of spool (4) decreases, and the position of the spool (3) is more to the right. The port (C) is connected to port (D) at this time, and the pressure entering LS valve becomes drain pressure (PT).
2.
The servo piston (6) moves to the left when port (F) is connected to port (G) of the LS valve, and the pressure in port (J) becomes drain pressure (PT).
3.
Pump discharged volume increases.
4.
As servo piston (6) moves, lever (1) moves to the left, spring (2) expands, and the spring force is decreased. Consequently, spool (3) moves to the left, port (C) is disconnected from port (D), and pump discharged pressure (B) and (C) are connected.
5.
Servo piston (6) stops moving to the left since the pressure in port (C) rises, and the piston pressure increases.
Operation When Pump Pressure (PAVE) is High (Load is Heavy)
1.
The force of spool (4) increases, and the position of the spool (3) is more to the left. Ports (B) and (C) are connected at this time and the pressure entering LS valve becomes pump pressure (PP).
2.
When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure (PP), and servo piston (6) moves to the right.
3.
The pump discharged volume is going to decrease.
10-68
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
4.
As servo piston (6) moves, lever (1) moves to the right and spring (2) is compressed and spring force is increased. Consequently, spool (3) moves to the right and port (C) is disconnected from port (B), and drain pressure port (D) and port (C) are connected.
5.
Servo piston (6) stops moving to the right since pressure in port (C) reduces, and the piston pressure decreases.
Operation When Servo Piston is Stopped at Balanced Position
The stop position (or the pump discharged volume) of servo piston (6) is determined by the position where the thrust caused by pump average pressure (PAVE) applied to spool (4) is balanced with the force of spring (2).
When Swing and Blade Pump Pressure Rises or Decreases The stopping position of servo piston (6) is determined in the same way as the pressure applied to spool (4) changes and pump average pressure (PAVE) increases or decreases.
When PC-EPC Valve is in Operation The stopping position of servo piston (6) is determined in the same way as the output pressure of PC-EPC valve is changed by the signal current from the controller and the pressure applied to spool (5) changes and pump average pressure (PAVE) increases or decreases.
PC45MR-5, PC55MR-5
10-69
Component Parts of Hydraulic System
10 Structure and Function
Main Pump LS Valve LS Abbreviation for Load Sensing
Function of Main Pump LS Valve •
The LS (Load Sensing) valve controls the pump discharged volume according to the travel of the control lever, or the flow demanded by the actuator.
•
LS valve detects the demand flow by the actuator from differential pressure (∆PLS) between inlet pressure (PPLS) and outlet pressure (PLS) of the control valve, and it controls pump discharged volume (Q). [(PPLS) is called LS pump pressure, (PLS) the LS pressure, and (∆PLS) the LS differential pressure]
•
In other words, it controls pump discharged volume (Q) so that pressure loss [= LS differential pressure (∆PLS)] which occurs when the oil flows through the passage in control valve spool will be constant, and the pump will be able to discharge the proper volume of oil as demanded by the actuator.
•
Pump discharged pressure (PP), LS pump pressure (PPLS), and LS pressure (PLS) are transmitted to LS valve. The relationship between LS differential pressure (∆PLS) and pump discharged volume (Q) changes as shown in the figure below.
•
The demanded flow of the actuator is always supplied in the range where the flow rate does not exceed the maximum flow rate during the operation with fine control, the pump discharged volume when the engine is running at low speed will be the same as that when the engine is running at high speed. When the engine is running at low speed, the setting of LS differential pressure automatically decreases, and the discharged volume decreases.
•
LS valve detects the pressure difference between before and after the fixed orifice (metering orifice) of discharging passage of swing and blade pump, and control the LS set pressure.
•
The discharged volume of swing and blade pump decreases when the engine is running at low speed, and the pressure difference between before and after the fixed orifice (metering differential pressure (GH) (GL)) will be almost equal and low. The discharged volume of swing and blade pump increases when the engine is running at high speed, and metering differential pressure (GH) - (GL) will be high.
•
When metering differential pressure is high (the engine speed is high), LS set pressure is set to higher value. When metering differential pressure (GH) - (GL) is low (the engine speed is low), LS set pressure is set to lower value.
•
The pump pressure (P1L), LS pressure (PLS), and the differential pressure before and after the swing and blade pump (metering differential pressure (GH) - (GL)) are sent.The relationship between LS differential pressure (∆PLS) and pump discharged volume (Q) varies as shown in the following figure.
10-70
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Main Pump PC Valve PC Abbreviation for Pressure Compensation
Function of Main Pump PC Valve •
PC valve controls the equal horse power so that the horsepower absorbed by the pump does not exceed the engine horsepower, and the oil flow does not exceed a certain level (depending on the discharged pressure) even if the travel of the control valve is increased extremely when pump discharged pressure (PP) is high.
•
When the pump discharged pressure increases due to increased load during operation, this valve decreases the pump discharged volume.
•
When the pump discharged pressure decreases, this valve increases the pump discharged volume.
•
This pump has 2 discharge ports, and it senses the average of respective discharged pressures (P1) and (P2)
•
The average of (P1) and (P2) is called (PAVE), and the relation between this average pressure pump discharged volume the pump discharged volume [total discharge of this average pressure pump discharged volume (P1) and (P2)] is as shown in the figure below.
PC45MR-5, PC55MR-5
10-71
Component Parts of Hydraulic System
10 Structure and Function
Control Valve Structure of Control Valve General View 9-spool valve REMARK • They can be added and removed one by one at any time since the service valves are single add-on type. • The service valve can be added between the upper cover and the valve under it.
10-72
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
A1: To L.H. travel motor
A5: To bucket cylinder head
A2: To R.H. travel motor
A6: To boom swing cylinder head
A3: To boom cylinder head
A7: To blade cylinder head
A4: To arm cylinder head
A8: To swing motor port (MA)
PC45MR-5, PC55MR-5
10-73
Component Parts of Hydraulic System
10 Structure and Function
A9: To stop valve
PA9: From attachment PPC valve
B1: To L.H. travel motor
PB1: From L.H. travel REVERSE PPC valve
B2: To R.H. travel motor
PB2: From R.H. travel REVERSE PPC valve
B3: To boom cylinder bottom
PB3: From boom RAISE PPC valve
B4: To arm cylinder bottom
PB4: From arm IN PPC valve
B5: To bucket cylinder bottom
PB5: From bucket CURL PPC valve
B6: To boom swing cylinder bottom
PB6: From boom swing LEFT PPC valve
B7: To blade cylinder bottom
PB7: From blade LOWER PPC valve
B8: To swing motor port (MB)
PB8: From swing LEFT PPC valve
B9: To stop valve
PB9: From attachment PPC valve
C: To hydraulic oil cooler
PP: To pump LS valve
LS: To pump LS valve
PP1: P1 pump pressure pickup port
P1: From main pump (variable pump)
PP2: P2 pump pressure pickup port
P2: From main pump (variable pump)
PP3: Pressure pickup port on work equipment side
P3: From main pump (Swing and blade pump)
PLS1: L.H. travel LS pressure pickup port
PA1: From L.H. travel forward PPC valve
PLS2: R.H. travel LS pressure pickup port
PA2: From R.H. travel forward PPC valve
PLS3: Work equipment LS pressure pickup port
PA3: From boom LOWER PPC valve
PTR: To auto-decelerator travel sensor port
PA4: From arm OUT PPC valve
PW: To auto-decelerator work equipment sensor port
PA5: From bucket DUMP PPC valve
PS: To swing motor B port
PA6: From boom swing RIGHT PPC valve
S: To swing motor S port
PA7: From blade RAISE PPC valve
T: To hydraulic tank
PA8: From swing RIGHT PPC valve
TS: To hydraulic tank
10-74
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Sectional Views (A-A, B-B)
1: Suction valve (left travel)
4: Suction valve (arm bottom)
2: Suction valve (right travel)
5: Suction valve (bucket bottom)
3: Suction valve (boom bottom)
6: Suction valve (blade bottom)
PC45MR-5, PC55MR-5
10-75
Component Parts of Hydraulic System
10 Structure and Function
7: Port relief valve
18: Spool (right travel)
8: Safety valve
19: Unload valve
9: Suction valve (blade head)
20: Spool (boom)
10: Suction valve (boom swing head)
21: Spool (arm)
11: Suction valve (bucket head)
22: Spool (bucket)
12: Suction valve (arm head)
23. Spool (boom swing)
13: Suction valve (boom head)
24: Spool (blade)
14: Main relief valve
25: Spool (swing)
15: Suction valve (right travel)
26: Spool (attachment)
16: Suction valve (left travel)
27: Unload valve
17: Spool (left travel)
10-76
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Sectional Views (C-C, D-D, E-E)
1: Lift check valve
8: Pressure compensation valve (*1) (boom swing)
2: Pressure compensation valve (*1) (left travel)
9: Pressure compensation valve (*1) (attachment)
3: Pressure compensation valve (*1) (right travel)
10: Pressure compensation valve (*2) (attachment)
4: Spool (merge-divider valve)
11: Swing and blade pump relief valve
5: Pressure compensation valve (*1) (boom)
12: Pressure compensation valve (*2) (boom swing)
6: Pressure compensation valve (*1) (arm)
13: Pressure compensation valve (*2) (bucket)
7: Pressure compensation valve (*1) (bucket)
14: Pressure compensation valve (*2) (arm)
PC45MR-5, PC55MR-5
10-77
Component Parts of Hydraulic System
10 Structure and Function
15: Pressure compensation valve (*2) (boom)
20: Pilot pressure check valve
16: LS bypass plug
21: Spool (left travel)
17: Pressure compensation valve (*2) (right travel)
22: Suction valve (left travel)
18: Pressure compensation valve (*2) (left travel)
23: Suction valve (right travel)
19: Hydraulic oil cooler bypass valve *1: Flow control valve *2: Pressure reducing valve
10-78
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Sectional Views (F-F, G-G, H-H, J-J, AK-AK, AN-AN)
R.H. Travel Valve 1: Pressure compensation valve (*2) (right travel) PC45MR-5, PC55MR-5
10-79
Component Parts of Hydraulic System
10 Structure and Function
2: Pressure compensation valve (*1) (right travel) 3: Spool (right travel) 4: Pilot pressure check valve 5: Suction valve 6: Suction valve
Unload Valve 7: Unload valve 8: Check valve 9: Main relief valve 10: Unload valve 11: LS bypass plug
Unload Valve and Merge-Divider Valve 12: Spool (merge-divider valve) 13: Unload valve 14: Check valve 15: Unload valve
Boom Valve 16: Pressure compensation valve (*1) (boom) 17: Spool (boom) 18: Pilot pressure check valve 19: Suction valve 20: Boom hydraulic drift prevention valve 21: Check valve 22: Check valve 23: Suction valve 24: Pressure compensation valve (*2) (boom) *1: Flow control valve *2: Pressure reducing valve
10-80
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Sectional Views (K-K, L-L, M-M, N-N, AA-AA, AB-AB)
Arm Valve 1: Pressure compensation valve (*1) (arm) PC45MR-5, PC55MR-5
10-81
Component Parts of Hydraulic System
10 Structure and Function
2: Spool (arm) 3: Pilot pressure check valve 4: Suction valve 5: Check valve 6: Suction valve 7: Pressure compensation valve (*2) (arm)
Bucket Valve 8: Pressure compensation valve (*1) (bucket) 9: Spool (bucket) 10: Pilot pressure check valve 11: Suction valve 12: Check valve 13: Suction valve 14: Pressure compensation valve (*2) (bucket)
Boom Swing Valve 15: Pressure compensation valve (*1) (boom swing) 16. Spool (boom swing) 17: Pilot pressure check valve 18: Check valve 19: Suction valve 20: Pressure compensation valve (*2) (boom swing)
Blade Valve 21: Spool (blade) 22: Pilot pressure shuttle valve 23: Suction valve 24: Check valve
Swing Valve 25: Spool (swing) 26: Swing and blade pump relief valve 27: Safety valve 28: Pressure relief plug *1: Flow control valve *2: Pressure reducing valve
General View 10-spool valve REMARK The shapes of parts of 10-spool valve, except cross section AC-AC, are the same as that of 9-spool valve.
10-82
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
A10: To angle selector valve.
PA10: From power angle PPC valve
B10: To angle selector valve.
PB10: From power angle PPC valve
1: Pressure compensation valve (*1) (power angle)
4: Suction valve
2: Pressure compensation valve (*2) (power angle)
5: Pilot pressure check valve
3: Spool (power angle) *1: Flow control valve *2: Pressure reducing valve
PC45MR-5, PC55MR-5
10-83
Component Parts of Hydraulic System
10 Structure and Function
Hydraulic Circuit Diagram of Control Valve and Names of Valves 9-Spool Valve
1: L.H. travel valve
10-84
2: R.H. travel valve
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
3: Merge-divider valve
22: Safety valve
4: Boom valve
Set pressure: 28.9 MPa {295 kgf/cm2}
5: Arm valve
23: Main relief valve
6: Bucket valve
Set pressure: 26.5 MPa {270 kgf/cm2}
7: Boom swing valve
24: Logic valve
8: Blade valve
25: Pressure compensation valve
9: Swing valve
26: Suction valve
10: Attachment valve
27: Check valve
11: L.H. travel valve spool
28: Pilot pressure check valve
12: R.H. travel valve spool
29: Pilot pressure shuttle valve
13: Merge-divider valve spool
30: Back pressure check valve
14: Boom valve spool
Set pressure: 0.37 MPa {3.8 kgf/cm2}
15: Arm valve spool
31: Hydraulic oil cooler bypass valve
16: Bucket valve spool
Set pressure: 0.75 MPa {7.6 kgf/cm2}
17: Boom swing valve spool
32: Swing and blade pump relief valve
18: Blade valve spool
Set pressure: 21.6 MPa {220 kgf/cm2}
19: Swing valve spool
33: Boom lock valve
20: Attachment valve spool
34: Port relief valve
21: Unload valve
Set pressure: 20.5 MPa {210 kgf/cm2}
Set pressure: LS pressure + 2.94 MPa {30 kgf/cm2}
10-Spool Valve REMARK The hydraulic circuit diagram of 10-spool valve shows only the portions different from the 9-pool valve are shown.
PC45MR-5, PC55MR-5
10-85
Component Parts of Hydraulic System
10 Structure and Function
1: Power angle valve
4: Pilot pressure check valve
2: Power angle valve spool
5: Port relief valve
3: Pressure compensation valve
Set pressure: 20.6 MPa {210 kgf/cm2}
Unload Valve of Control Valve Function of Unload Valve of Control Valve When the Work Equipment is Held
•
This valve releases discharged volume (Q) into the tank circuit corresponding to the swash plate at minimum angle when the work equipment is held (the control valve is in neutral).
•
Pump discharged pressures (P1) and (P2) are set by the reaction force of spring (2) in the valve.
•
The pressure in LS circuit (PLS) is 0 MPa {0 kgf/cm2} since the control valve is in neutral.
10-86
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
When Work Equipment is in Fine Control
•
Pump discharged pressures (P1) and (P2) are set to be equal to the sum of LS pressures (PLS1) and (PLS2) and the pressure caused by reaction forced of spring (2) when the actuator demand flow is less than the pump discharge at the minimum swash plate angle and the work equipment is operated with fine control.
•
The unload valve opens and LS differential pressure (∆PLS) becomes the set pressure of spring (2) when the differential pressure between pump discharged pressures (P1) and (P2) and LS pressures (PLS1) and (PLS2) reaches the set pressure of spring (2).
PC45MR-5, PC55MR-5
10-87
Component Parts of Hydraulic System
10 Structure and Function
When the Work Equipment is Operated
The unload valve blocks the oil flowing to tank circuit (T), and all of pump discharged volumes (Q1) and (Q2) are returned to the actuator circuit when the actuator demand flow exceeds the pump discharge volume at the minimum pump swash plate angle when the work equipment is operated.
10-88
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
When Only Traveling is Operated (L.H. and R.H.)
The pump swash plate angle becomes maximum, and the oil flow is controlled according to the opening of spool (1) when only traveling is operated (L.H. and R.H.).
PC45MR-5, PC55MR-5
10-89
Component Parts of Hydraulic System
10 Structure and Function
Operation of Unload Valve of Control Valve When the Work Equipment is Held
1.
Pump discharged pressures of (P1) and (P2) act on the left side of spool (1), and LS pressures of (PLS1) and (PLS2) act on the right side of the spool.
2.
LS pressure [(PLS1) and (PLS2)] is 0 when the work equipment is held (control valve is held), and only pump discharged pressures of (P1) and (P2) act. Pump discharged pressures of (P1) and (P2) are set only by the spring load of spring (2).
3.
The differential pressure between pump discharged pressure (P1) and LS pressure (PLS1) and the differential pressure between pump discharged pressure (P2) and LS pressure (PLS2) reach the set pressure of spring (2).
4.
Spool (1) moves to the right, and the pressurized oil flows from pump circuits (P1) and (P2) through notch (a) of spool (1) into tank circuit (T).
10-90
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
When Work Equipment is in Fine Control
1.
When operating the work equipment with fine control, LS pressures of (PLS1) and (PLS2) are generated and they act on the right side of spool (1).
2.
The differential pressure between LS pressures of (PLS1) and (PLS2) and pump discharged pressures of (P1) and (P2) is large since the open area of the control valve spool is small.
3.
The differential pressure between pump discharged pressures of (P1) and (P2) and LS pressures of (PLS1) and (PLS2) reaches the set pressure of spring (2).
4.
Spool (1) moves to the right, and pump circuits (P1) and (P2) are connected to tank circuit (T).
5.
Pump discharged pressures of (P1) and (P2) are set to the set pressure of spring (2) + LS pressures of (PLS1) and (PLS2).
6.
LS differential pressure (∆PLS) becomes the set pressure of spring (2).
PC45MR-5, PC55MR-5
10-91
Component Parts of Hydraulic System
10 Structure and Function
When the Work Equipment is Operated
1.
When the work equipment is largely operated, LS pressures of (PLS1) and (PLS2) are generated, and they act on the right side of spool (1).
2.
The differential pressure between LS pressures of (PLS1) and (PLS2) and pump discharged pressures of (P1) and (P2) is small since the open area of the control valve spool is large.
3.
The differential pressure between pump discharged pressures of (P1) and (P2) and LS pressures of (PLS1), (PLS2) does not reach the set pressure of spring (2).
4.
Spool (1) is pushed to the left by spring (2).
5.
Pump circuits (P1) and (P2) are disconnected from tank circuit (T), and all the pump discharged volumes (Q1) and (Q2) flow to the actuator circuit.
10-92
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
When Only Traveling is Operated (L.H. and R.H.)
1.
When only traveling is operated (L.H. and R.H.), the merge-divider valve divides the main pump discharged volume.
2.
Each unload valve of pump circuits (P1) and (P2) operates according to the open areas of each travel spool (1) on the right and left sides.
PC45MR-5, PC55MR-5
10-93
Component Parts of Hydraulic System
10 Structure and Function
Pressure Compensation Valve of Control Valve Function of Pressure Compensation Valve of Control Valve
When the load pressure becomes lower than another actuator and the flow is going to increase during a combined operation, this valve compensates the load pressure. (At this time, the load pressure of another actuator under combined operation (the right side) is higher than that of the actuator on this side (the left side).)
10-94
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Operation of Pressure Compensation Valve of Control Valve
1.
When the load pressure of the other actuator (right side) increases during combined operation, the flow to the actuator circuit (A) on this side (left side) is going to increase.
2.
In this case, LS pressure (PLS) of another actuator acts to spring chamber (PLS'), it pushes pressure reducing valve (1) and flow control valve (2) to the left.
3.
Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to generate a pressure loss between (PP) and (PPA).
4.
The flow control valve (2) and the pressure reducing valve (1) balance each other out at the place where the pressure difference between (PA) and (PLS) which applies to the both end surfaces of the pressure reducing valve (1) becomes the same as the pressure loss between (PP) and (PPA) around the flow control valve.
5.
The pressure difference between upstream pressure (PPA) and downstream pressure (PA) of both spools which is operating the combined operation becomes the same, and pump discharge is divided in proportion to the opening of each spool notch (a).
PC45MR-5, PC55MR-5
10-95
Component Parts of Hydraulic System
10 Structure and Function
Surface Area Ratio of Pressure Compensation Valve of Control Valve Function of Surface Area Ratio of Pressure Compensation Valve of Control Valve
Function The pressure compensation valve finely adjusts the surface area ratio (S1:S2) to determine the compensation characteristics according to the characteristics of each actuator. (S1) is the surface area on the left side of flow control valve (2), and (S2) is the surface area on the right side of pressure reducing valve (1).
Ratio of Pressures Applied on Areas (S1) and (S2) and Compensation Properties •
The flow rate from the pump is divided in proportion to the open area of notch (a) of spool (3) when the pressure loss between pump discharged pressure (PP) and upstream pressure of spool notch (PPA) is almost equal to the pressure difference between LS circuit pressure (PLS) and actuator circuit pressure (PA) (namely the pressure in port (A)) (the pressure ratio is 1.00).
•
The flow from the pump is less supplied to the compensated side when the pressure loss between pump discharged pressure (PP) and upstream pressure of spool notch (PPA) is larger than the pressure difference between LS circuit pressure (PLS) and actuator circuit pressure (PA) (namely the pressure in port (A)) (the pressure ratio is 1.00 or higher), the open area of the pressure compensation valve on the compensating side increases.
10-96
PC45MR-5, PC55MR-5
10 Structure and Function
•
Component Parts of Hydraulic System
The flow from the pump is more supplied to the compensated side when the pressure loss between pump discharged pressure (PP) and upstream pressure of spool notch (PPA) is smaller than the pressure difference between LS circuit pressure (PLS) and actuator circuit pressure (PA) (namely the pressure in port (A)) (the pressure ratio is 1.00 or lower), the open area of the pressure compensation valve on the compensating side decreases.
LS Introduction Throttle of Pressure Compensation Valve of Control Valve Function of LS Introduction Throttle of Pressure Compensation Valve of Control Valve
This function divides the pressurized oil from LS introduction throttle (b) of reducing valve (1) in order to supply more oil to the compensated side when another actuator is relieved during combined operations.
PC45MR-5, PC55MR-5
10-97
Component Parts of Hydraulic System
10 Structure and Function
Operation of LS Introduction Throttle of Pressure Compensation Valve of Control Valve
1.
If another actuator (right side) is relieved during combined operations, circuit pressures (PPA) and (PA) of another actuator will be the same as the pump circuit pressure [(PP) = relief pressure].
2.
The pressure of spring chamber (PLSA) of the other actuator will be the same as the pump circuit pressure (PP) by reducing valve (1) set in neutral.
3.
The pressure of spring chamber (PLSB) passes through LS introduction throttle (b) of reducing valve (1), and it becomes (PLS).
4.
The LS pressure (PLS) is connected to tank circuit (T) from LS bypass plug (4), and the pressure loss occurs at LS introduction throttle (b) ((PLS) < (PLSB)).
5.
Even when another actuator is relieved, a pressure difference is generated between (PP) and (PLS), so more oil flows from actuator circuit (A) on this side (left side).
Introduction of LS Pressure in Control Valve LS Abbreviation for Load Sensing
10-98
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Function of Introduction of LS Pressure in Control Valve
•
LS pressure is the actuator load pressure on the outlet side of the control valve.
•
Pump discharged pressure (PP3) is reduced to the same pressure as that of actuator circuit (A) at pressure reducing valve (3) of pressure compensation valve, and it is introduced to LS circuit (PLS).
PC45MR-5, PC55MR-5
10-99
Component Parts of Hydraulic System
10 Structure and Function
Operation of Introduction of LS Pressure in Control Valve
1.
Pump discharged pressure (PP3) flows through flow control valve (2), notch (a) in the spool, and bridge passage (b) to actuator circuit (A) when spool (1) is operated.
2.
Pressure reducing valve (3) moves to the right at this time, pump discharged pressure (PP3) is reduced by pressure loss at notch (c), and sent to LS circuit (PLS3). Then, it is sent to spring chamber (PLS').
3.
LS circuit (PLS) is connected from LS bypass plug (4) to tank circuit (T). (See “LS Bypass Plug of Control Valve”.)
4.
Actuator circuit pressure (A) acts on the left side of pressure reducing valve (3). The reduced pump discharged pressure (PP3) acts on the opposite side.
5.
Pressure reducing valve (3) is balanced out at a position where actuator circuit pressure (A) and the pressure of spring chamber (PLS') are the same. Pump discharged pressure (PP3) reduced at notch (a) becomes actuator circuit pressure (A), and is transmitted into LS circuit (PLS3).
LS Bypass Plug of Control Valve LS Abbreviation for Load Sensing
Function of LS Bypass Plug of Control Valve •
It releases the remaining pressure of LS pressure (PLS).
10-100
PC45MR-5, PC55MR-5
10 Structure and Function
•
Component Parts of Hydraulic System
While it moderates the increasing rate of LS pressure (PLS), this valve generates pressure loss in the throttle part of the spool and shuttle valve with this discarded throttle flow, decreasing the enabled LS differential pressure and improving stability.
Operation of LS Bypass Plug of Control Valve
The pressurized oil flows from LS circuit through filter (a) and orifice (b) to the tank circuit.
PC45MR-5, PC55MR-5
10-101
Component Parts of Hydraulic System
10 Structure and Function
Logic Valve of Control Valve Function of Logic Valve of Control Valve
The logic valve changes the pilot pressure in order to switch the merge-divider valve.
10-102
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Operation of Logic Valve of Control Valve
Operation in Dividing Mode 1.
Only travel PPC pressure acts on port (b).
2.
Travel PPC pressure acts on output port (c) of the merge-divider valve as it is.
3.
This pressure sets the merge-divider valve to the dividing mode.
Operation in Merging Mode 1.
Work equipment PPC pressure (excluding the swing pressure) acts on port (a).
2.
The pressure in output port (c) of the merge-divider valve is connected through spool (1) to spring chamber (d) and used as seal drain pressure.
3.
The merge-divider valve is not changed but kept in the merging mode.
REMARK Even if travel PPC pressure acts while work equipment PPC pressure (excluding the swing pressure) is acting, spool (1) is kept pressed and the merge-divider valve is kept in the merging mode.
PC45MR-5, PC55MR-5
10-103
Component Parts of Hydraulic System
10 Structure and Function
Merge-Divider Valve of Control Valve Function of Merge-Divider Valve of Control Valve When One Side Travel is Operated
The merge-divider valve spool separates pump discharged pressures (P1) and (P2) when traveling with only one side of tracks is operated.
10-104
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
When the Work Equipment is Operated, or When the Work Equipment is Operated While You Travel
When the work equipment is operated, or when the work equipment is operated during traveling, the mergedivider valve spool merges pump discharged pressures (P1) and (P2).
PC45MR-5, PC55MR-5
10-105
Component Parts of Hydraulic System
10 Structure and Function
Operation of Merge-Divider Valve of Control Valve Operation When You Travel with Only One Side of Tracks is Operated
1.
When traveling with only one side of tracks is operated, the travel PPC pressure acts on the right side of merge-divider valve spool (1) through the logic valve spool.
2.
When the travel PPC pressure is larger than the reaction force of spring (2), merge-divider valve (1) is pushed to the left.
3.
Pump pressures (P1), (P2), and (P3) are separated from LS pressures (PLS1), (PLS2), and (PLS3).
4.
The pump pressure is outputted to output pressure (PLS) which is applied to pump LS valve.
10-106
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Operation When the Work Equipment is Operated, or When the Work Equipment is Operated While You Travel
Operation When the Work Equipment is Operated 1.
When the work equipment is operated, the output from the logic valve spool is used as seal drain pressure.
2.
The pressure for switching the merge-divider valve is drained to the tank.
3.
Merge-divider valve spool (1) is pressed to the right by the force of spring (2).
4.
Pump pressures (P1), (P2), and (P3) are merged with LS pressures (PLS1), (PLS2), and (PLS3).
Operation When the Work Equipment is Operated While You Travel 1.
When the work equipment is operated during traveling, the logic valve spool is switched.
2.
The travel PPC pressure is not applied to the merge-divider valve.
3.
Since the pressure for switching the merge-divider valve is drained into the tank, they are merged.
4.
When the work equipment is in neutral, they are merged since the spring force of the merge-divider valve spool is larger than the pressure for shifting the travel PPC pressure.
PC45MR-5, PC55MR-5
10-107
Component Parts of Hydraulic System
10 Structure and Function
Travel Junction Valve of Control Valve Function of Travel Junction Valve of Control Valve When the Machine Travels Straight
•
The travel junction circuit is installed so that the flow difference between R.H. and L.H. travel circuits is corrected when the machine travels straight.
•
This function reduces travel deviation by making the flows to the right and left travel motors almost equal when the machine travels straight.
•
Damper (b) is installed to ease the transient characteristics of sudden opening and closing of the interconnection circuit when the travel control lever is operated quickly.
10-108
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Operation of Travel Junction Valve of Control Valve When the Machine Travels Straight
1.
Bridge circuits (PA) of the control valves of R.H. and L.H. travel circuits are connected to each other by junction circuit (L).
2.
This valve corrects the difference between the oil flow rates in R.H. and L.H. travel motors to reduce the travel deviation.
PC45MR-5, PC55MR-5
10-109
Component Parts of Hydraulic System
10 Structure and Function
When Machine Turns by Steering Operation
1.
When R.H. travel spool (right 1) is returned to neutral from the straight-travel state and the steering operation is performed, the load pressure difference “(left A) > (right A)” is made between R.H. and L.H. actuator circuits (PA).
2.
The discharged pressure of main pump is divided at this time.
3.
The flow rate of oil flowing into R.H. and L.H. travel motors changes corresponding to the opening area of the spool.
10-110
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Swing and Blade Valve of Control Valve Structure of Swing and Blade Valve of Control Valve
•
The swing and blade valves are the open center valves of the swing and blade pump. The blade valves are arranged in tandem after the swing valve.
•
Load check valve (2) is installed in each spool. These are corresponding to ports (A7), (B7), (A8), and (B8) of valves.
•
Relief valve(1) for the swing and blade pump is installed to the swing valve.
PC45MR-5, PC55MR-5
10-111
Component Parts of Hydraulic System
10 Structure and Function
Operation of Swing and Blade Valve of Control Valve
Swing Valve 1.
If pressure from PPC valve is applied to port (PA8), the spool moves to the left and oil flows into port (A8).
2.
If pressure from PPC valve is applied to port (PB8), the spool moves to the right and oil flows into port (B8).
Blade Valve 1.
If pressure from PPC valve is applied to port (PA7), the spool moves to the left and oil flows into port (A7).
2.
If pressure from PPC valve is applied to port (PB7), the spool moves to the right and oil flows into port (B7).
10-112
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Swing Parking Brake Release Circuit of Control Valve Operation of Swing Parking Brake Release Circuit of Control Valve
1.
The left and right swing PPC pressures and the arm IN PPC pressure pass through the check valve in the spring case, and the highest one of them is outputted from port (PS) to swing motor port (BR).
2.
The arm and swing control valves are connected by the pilot passage inside the control valve.
Work Equipment Pilot Pressure Detection Circuit of Control Valve Function of Work Equipment Pilot Pressure Detection Circuit of Control Valve This circuit collects the pilot pressures of the work equipment (excluding the swing operation), and outputs oil pressure signals through the auto-deceleration sensor port. PC45MR-5, PC55MR-5
10-113
Component Parts of Hydraulic System
10 Structure and Function
Operation of Work Equipment Pilot Pressure Detection Circuit of Control Valve
When the work equipment is operated, the pilot pressures of the boom, arm, bucket, boom swing, blade, and attachment are outputted to auto-deceleration sensor port (PW) through the check valves and shuttle valves in their respective spring cases.
Travel Pilot Pressure Detection Circuit of Control Valve Function of Travel Pilot Pressure Detection Circuit of Control Valve This circuits collects the pilot pressures for R.H. travel and L.H. travel, and outputs oil pressure signals through the auto-deceleration sensor port.
10-114
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Hydraulic System
Operation of Travel Pilot Pressure Detection Circuit of Control Valve
When the machine travels, R.H. and L.H. travel PPC pressures are outputted to auto-deceleration sensor port (PTR) through the check valves in their respective spring cases.
PC45MR-5, PC55MR-5
10-115
Layout Drawing of Work Equipment System
10 Structure and Function
Work Equipment System Layout Drawing of Work Equipment System Chassis Part
1: Arm cylinder
5: Multi-control valve (*1)
2: Boom cylinder
6: Bipartite solenoid valve
3: Boom swing cylinder
7: Blade cylinder
4: Pilot circuit accumulator
8: Bucket cylinder
*1: Optional device.
10-116
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Work Equipment System
9: Control valve
11: Work equipment PPC pressure switch
10: Swing parking brake pressure sensor
12: Travel PPC pressure sensor
PC45MR-5, PC55MR-5
10-117
Layout Drawing of Work Equipment System
10 Structure and Function
Around Cab and Floor
1: Blade PPC valve
7: Lock lever
2. R.H. work equipment PPC valve
8: Attachment PPC valve (*2)
3: Starting switch
9: Boom swing PPC valve
4: L.H. work equipment PPC valve
10: 1st-line attachment proportional switch (*3)
5: Machine controller
11: Breaker operating switch (*3)
6: PPC lock switch *2: Machine with attachment *3: Machine with proportional lever
10-118
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Work Equipment System
12: Lock lever automatic lock switch
PC45MR-5, PC55MR-5
10-119
Structure of Valve Control
10 Structure and Function
Structure of Valve Control
1: R.H. work equipment control lever (for operation of boom and bucket)
8: Attachment PPC valve (*1)
2. R.H. work equipment PPC valve
10: Travel PPC valve
3: L.H. work equipment control lever (for operation of arm and swing)
11: Travel pedal
4: L.H. work equipment PPC valve 5: Lock lever 6: Accumulator (for PPC circuit)
9: Bipartite solenoid valve
12: Boom swing PPC valve 13: R.H. travel lever 14: L.H. travel lever
7: Control valve *1: Machine with attachment
10-120
PC45MR-5, PC55MR-5
10 Structure and Function
15: Blade control lever
Structure of Valve Control
17: Boom swing control pedal
16: Blade PPC valve
PC45MR-5, PC55MR-5
10-121
PPC Lock System
10 Structure and Function
PPC Lock System PPC Abbreviation for Proportional Pressure Control
System Diagram of PPC Lock
Input and output signals a: PPC lock signal
g: Breaker operating switch signal
b: PPC lock signal
h: Oil pressure sensor signal
c: Lock lever automatic lock cancel switch signal
i: Oil pressure switch signal
d: Lock lever automatic lock relay drive signal
j: 1st-line attachment flow adjustment EPC valve signal
e: PPC lock solenoid valve drive signal f: Switch potentiometer signal 1: Battery disconnect switch
11: Breaker operating switch
2: Battery
12: PPC lock solenoid valve
3: Fusible link
13: Control valve
4: Fuse box
13a: Merge-divider valve
5: Starting switch
14: Main pump
6: Lock lever
15: Lock lever automatic lock cancel switch
7: PPC lock switch
16: 1st-line attachment flow adjustment EPC valve
8: Machine controller
17: Swing motor
9: PPC lock lever relay
17a: Swing parking brake
10: 1st-line attachment proportional switch
10-122
PC45MR-5, PC55MR-5
10 Structure and Function
PPC Lock System
Function of PPC Lock System •
PPC lock switch is interlocked with the lock lever. When the lock lever is set to LOCK position, PPC lock switch is turned “OFF”.
•
When PPC lock switch is turned OFF, the current flowing into PPC lock solenoid valve is cut out, and the work equipment and machine body do not move even if any control lever or pedal is operated.
PC45MR-5, PC55MR-5
10-123
Work Equipment and Travel Automatic Lock System
10 Structure and Function
Work Equipment and Travel Automatic Lock System Function of Work Equipment and Travel Automatic Lock System This function automatically sets the lock lever in the same state as when it is locked to prevent the work equipment or the machine continues its operation when the lock lever is unlocked while the work equipment control lever or the travel lever is operated.
Operation of Lock Lever Automatic Lock System This system recognizes an abnormality when either one or more of the oil pressure switches or sensors detect the pressure higher than specified pressure (D), or if the attachment drive signal is input in time period (C) after the lock lever is canceled (A). The machine controller outputs the lock lever automatic lock relay drive signal to shut off the current to PPC lock solenoid and set the machine to lock state (B). A: Lock lever is canceled B: Lock lever automatic lock is in operation C: Within 0.4 seconds D: 5 kPa E: 0.1 seconds REMARK The pressure may not increase within time (C) and the lock lever automatic lock control may not operate when the hydraulic oil temperature is low or high-viscosity hydraulic oil used.
Control When the Lock Lever Automatic Lock Cancel Switch is “ON” you can operate the machine by operating lock lever automatic lock cancel switch (1) if an abnormality occurs in the controller, etc., and the main pump does not operate normally, and machine does not work. At this time, the lock lever automatic lock control function does not work. a: Emergency (when abnormal) b: Normal (when normal) REMARK • Lock lever automatic lock cancel switch (1) is an alternate type switch. The lock lever automatic lock cancel pilot lamp lights up on the display if it is set to “EMERGENCY (a)” position when PPC lock lever is in the free state. • The following failure code is displayed when this switch is “ON”. Action level
Failure code
L00
DDNS0 Lock Lever Auto Lock Release SW On 0
10-124
Failure (displayed on screen)
PC45MR-5, PC55MR-5
10 Structure and Function
Attachment Oil Flow Adjuster System
Attachment Oil Flow Adjuster System (Machine with proportional lever)
Attachment Oil Flow Adjuster System Diagram
Input and output signals a: PC-EPC valve drive signal
g: 1st-line attachment proportional switch signal
b: Solenoid valve GND
h: Breaker control switch signal
c: CAN signal
i: 1st throttle signal
d: CAN signal
j: Fuel supply pump control signal
e: 1st-line attachment EPC drive signal
k: Various sensor signals
f: 1st-line attachment EPC drive signal 1: Battery disconnect switch
13: Various sensors
2: Battery
14: 1st-line attachment proportional switch
3: Fusible link
15: Breaker operating switch
4: Starting switch
16: Main pump
5: Fuse box
16a: Servo
6: Resistor for PC-EPC valve
16b: LS valve
7: Machine controller
16c: PC valve
8: Engine controller
17: Control valve
9: Machine monitor
17a: Merge-divider valve
10: Pump secondary drive switch
18: PPC lock solenoid valve
11: Fuel control dial
19: 1st-line attachment flow adjustment EPC valve
12: Fuel supply pump
20: 1st-line attachment flow adjustment EPC valve
PC45MR-5, PC55MR-5
10-125
Attachment Oil Flow Adjuster System
21: PC-EPC valve
10 Structure and Function
23: Attachment
22: Attachment circuit selector valve
Function of Attachment Oil Flow Adjuster System Operating the attachment proportional switch controls the flow rate to the attachment when mode ATT/P or ATT/E is selected and the attachment flow is set with the machine monitor.
10-126
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
Component Parts of Work Equipment System Work Equipment and Swing PPC Valve PPC Abbreviation for Proportional Pressure Control
Structure of Work Equipment and Swing PPC Valve General View
PC45MR-5, PC55MR-5
10-127
Component Parts of Work Equipment System
10 Structure and Function
L.H. work equipment control lever P: From pilot pump P1: To control valve (arm IN port) P2: To control valve (arm OUT port) P3: To control valve (swing RIGHT port) P4: To control valve (swing LEFT port) T: To hydraulic tank
R.H. work equipment control lever P: From pilot pump P1: To control valve (boom RAISE port) P2: To control valve (boom LOWER port) P3: To control valve (bucket DUMP port) P4: To control valve (bucket CURL port) T: To hydraulic tank
10-128
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
Sectional View
1: Spool
4: Nut (for connecting lever)
2: Piston
5: Joint
3: Disc
6: Plate
PC45MR-5, PC55MR-5
10-129
Component Parts of Work Equipment System
7: Retainer
10 Structure and Function
9: Filter
8: Body
Operation of Work Equipment and Swing PPC Valve At NEUTRAL Position Ports (A) and (B) of the control valve and ports (P1) and P2) of PPC valve are connected to drain chamber (D) through fine control hole (f) of spool (1).
D
f
T P
1 Solenoid valve
P1 A
Pump
P2 B
Control valve
G0048549
In Fine Control (When Fine Control is Started from Neutral State) 1.
When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed and moved down through metering spring (2).
2.
When fine control hole (f) is blocked from drain chamber (D), it is connected to pump pressure chamber (PP) almost at the same time.
3. 4.
The pilot pressure oil of the control pump flows to port (A) through fine control hole (f) and port (P1). When the pressure in port (P1) increases, spool (1) is pushed back. When fine control hole (f) is disconnected from pump pressure chamber (PP), it is connected to drain chamber (D) almost at the same time, and the pressure in port (P1) is released.
5.
Spool (1) moves up and down so that the force of metering spring (2) is balanced with the pressure in port (P1).
6.
The positional relation between spool (1) and body (10) (fine control hole (f) is at intermediate position between drain chamber (D) and pump pressure chamber (PP)) does not change until retainer (9) touches spool (1).
'
7
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6ROHQRLG YDOYH
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3
3XPS
$
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*
7.
Metering spring (2) is compressed in proportion to the travel of control lever.
8.
The pressure in port (P1) also increases in proportion to the travel of control lever.
9.
The control valve spool moves to a position where the pressure in port (A) (which is the same as the pressure in port (P1)) is balanced with the reaction force of the control valve spool return spring.
10-130
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
In Fine Control (When Control Lever is Gone Back) 1.
When disc (5) starts being returned, spool (1) is pushed up by the force of centering spring (3) and the pressure in port (P1).
2.
Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
3.
If the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
4.
When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure chamber (PP) almost at the same time.
5.
6.
I
The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to the lever position. When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into chamber (B) to replenish the port with pressurized oil.
'
7
I
3
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3 $
3XPS
33
3 %
&RQWURO YDOYH
*
When Control Lever is Fully Operated 1.
Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1).
2.
Fine control hole (f) is disconnected from drain chamber (D), and connected to pump pressure chamber (PP).
3.
The pilot pressure oil from the solenoid valve flows from port (P1) through fine control hole (f) to port (A), and pushes the control valve spool.
4.
The return oil from port (B) flows from port (P2) through fine control hole (f) to drain chamber (D).
' I
7 I
3
6ROHQRLG YDOYH
3XPS
3 $
33
3
&RQWURO YDOYH
%
*
PC45MR-5, PC55MR-5
10-131
Component Parts of Work Equipment System
10 Structure and Function
Attachment PPC Valve (Machines with attachment)
PPC Abbreviation for Proportional Pressure Control
Structure of Attachment PPC Valve General View and Sectional View
P: From pilot pump
P2: To control valve (attachment port)
P1: To control valve (attachment port)
T: To hydraulic tank
10-132
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
1: Spool
5: Retainer
2: Piston
6: Body
3: Lever
7: Filter
4: Plate REMARK For explanation of operation, see “Operation of Work Equipment and Swing PPC Valve”.
PC45MR-5, PC55MR-5
10-133
Component Parts of Work Equipment System
10 Structure and Function
Blade PPC Valve PPC Abbreviation for Proportional Pressure Control
Structure of Blade PPC Valve General View and Sectional View
P: From pilot pump
P2: To control valve (blade LOWER port)
P1: To control valve (blade RAISE port)
T: To hydraulic tank
1: Spool
2: Piston
10-134
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
3: Lever
6: Body
4: Plate
7: Filter
5: Retainer REMARK For explanation of operation, see “Operation of Work Equipment and Swing PPC Valve”.
PC45MR-5, PC55MR-5
10-135
Component Parts of Work Equipment System
10 Structure and Function
Boom Swing PPC Valve PPC Abbreviation for Proportional Pressure Control
Structure of Boom Swing PPC Valve General View and Sectional View
P: From pilot pump
P2: Control valve (to boom swing left port)
P1: Control valve (to boom swing right port)
T: To hydraulic tank
1: Spool
2: Piston
10-136
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
3: Lever
6: Body
4: Plate
7: Filter
5: Retainer REMARK For explanation of operation, see “Operation of Work Equipment and Swing PPC Valve”.
PC45MR-5, PC55MR-5
10-137
Component Parts of Work Equipment System
10 Structure and Function
Bipartite Solenoid Valve Structure of Bipartite Solenoid Valve General View and Sectional View
A: To PPC valve
P: From main pump
B: To 2nd travel speed selector solenoid valve
T: To hydraulic tank
1: PPC lock solenoid valve 2: 2nd travel speed selector solenoid valve 3: Control relief valve
Solenoid valve 4: Coil (ON/OFF) type 5: Push pin 6: Valve spool 7: Return spring 8: Valve body
Control relief valve 9: Adjustment screw 10: Lock nut 11: Plug 10-138
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
12: Return spring 13: Cover 14: Plunger
Operation of Solenoid Valve When Solenoid Valve is “De-energized” (Circuit is Cut Off) 1.
Coil (1) is de-energized when the signal current does not flow to coil (1).
2.
Spool (2) is pushed back to the left with the reaction force of spring (3).
3.
The circuit between port (P) and port (A) closes and pilot pressure does not flow from port (A) to the actuator. At the same time, port (T) opens and oil from the actuator is drained to the hydraulic tank.
When Solenoid Valve is “Energized” (Circuit is Connected) 1.
Coil (1) is energized when the signal current flows to coil (1).
2.
Accordinglys, spool (2) is pushed to the right by push pin (4).
3.
The circuit between port (P) and port (A) opens and pilot pressure flows from port (A) to the actuator. At the same time, port (T) closes and oil from the actuator does not flow to the hydraulic tank.
PC45MR-5, PC55MR-5
10-139
Component Parts of Work Equipment System
10 Structure and Function
Operation of Control Relief Valve 1.
As the oil pressure from the main pump increases, the oil in port (P) pushes plunger (1).
2.
The reaction force compresses spring (2) and moves plunger (1) up, and connect ports (P) and (T) to relieve the oil.
Set pressure: 3.14 MPa {32 kgf/cm2}
10-140
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Work Equipment System
Multi-Control Valve (Machine with multi-control valve)
Structure of Multi-Control Valve
Control Pattern Changeover Diagram (Port names refer to symbols in drawing)
PC45MR-5, PC55MR-5
10-141
Component Parts of Work Equipment System
10 Structure and Function
Pilot Circuit Accumulator Structure of Pilot Circuit Accumulator General View and Sectional View 1: Gas plug 2: Shell 3: Poppet 4: Holder 5: Bladder 6: Oil port
Specifications of Pilot Circuit Accumulator Gas used: Nitrogen gas Volume of gas: 300 cc Charged gas pressure: 1.18 MPa {12 kgf/cm2} (at 80 °C) Maximum using pressure: 6.87 MPa {70 kgf/cm2}
Function of Pilot Circuit Accumulator This accumulator (for pilot circuit) is installed between the main pump and solenoid valve. Even if the engine is stopped while the work equipment is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the compressed nitrogen gas in the accumulator. Accordingly, the work equipment can be lowered by its own weight by operating the spool.
10-142
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Swing System
Swing System Layout Drawing of Swing System Chassis Part
1. Swing circle
4: Control valve
2: Swing motor
5: Main pump
3. Swing machinery
PC45MR-5, PC55MR-5
10-143
Component Parts of Swing System
10 Structure and Function
Component Parts of Swing System Swing Motor Structure of Swing Motor General View
B: From control valve
MB: From control valve (swing RIGHT port)
S: From control valve
T: To hydraulic tank
MA: From control valve (swing LEFT port)
10-144
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Swing System
Sectional View
1: Output shaft
9: Cylinder block
2: Housing
10: Brake piston
3: Shoe
11: Swash plate
4: Piston
12: Brake spring
5: Center spring
13: Check valve
6: Valve plate
14: Swing modulating relief valve
7: Disc
15: Brake ring
8: Plate
16: Thrust plate
Specifications of Swing Motor Model: LMF16 Theoretical displacement: 16.1 cm3/rev Rated speed: 2100 min-1 {2100 rpm} PC45MR-5, PC55MR-5
10-145
Component Parts of Swing System
10 Structure and Function
Rated flow rate: 34 ℓ/min Suction valve cracking pressure: 0.04 MPa {0.45 kgf/cm2} Safety valve cracking pressure: 18.6 MPa {190 kgf/cm2}
Function of Swing Motor The swing motor converts the fluid energy of hydraulic oil into rotational mechanical energy and swings the upper structure.
Operation of Swing Motor 1.
The pressurized oil being sent from the pump flows through valve plate (7) into cylinder block (5). This oil flows to only one side of line Y-Y connecting the top dead center and bottom dead center during the stroke of piston (4).
2.
Pressurized oil which flows in either side of cylinder block (5) pushes pistons (4) (3 pieces or 4 pieces) and generates force F1 [F1 (N {kgf} ) = P (MPa {kgf/cm2} ) x πD2/4 cm2].
3.
This force acts on thrust plate (2) and is divided into components (F2) and (F3) since the thrust plate is fixed at angle (a) to output shaft (1).
4.
Radial component (F3) of these components generates torque (T = ∑(F3 x ri)] against (Y-Y) which is connecting the top dead center and bottom dead center.
5.
The combined force [T = ∑ (F3 x ri)] of these torques rotates cylinder block (5) through pistons (4) as the rotating torque.
6.
The output shaft rotates and transmits the torque since this cylinder block (5) is splined to the output shaft.
Brake Valve of Swing Motor Function of Brake Valve of Swing Motor •
The brake valve consists of the check valve and safety valve.
•
When the swing is stopped, the control valve shuts off the motor outlet circuit, but the motor rotation is continued by inertial force. Accordingly, the motor outlet pressure becomes abnormally high and can damage the motor.
•
Abnormal pressure of the motor outlet side is released (high-pressure side) to port (S) to prevent damage to the motor.
10-146
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Swing System
Operation of Brake Valve of Swing Motor Operation When Swing Operation is Started 1.
The pressurized oil from the pump flows through control valve (1) into port (MB) when the work equipment and swing control lever is operated for swinging to the left.
2.
The pressure in port (MB) increases, the starting torque is generated to start rotating the motor.
3.
The oil from the motor outlet returns to the tank via port (MA) and control valve (1).
Operation When Swing Operation is Stopped 1.
When the work equipment and swing control lever is returned to NEUTRAL position, the supply of the pressurized oil from the pump to port (MB) stops.
2.
The return circuit of the oil from the motor outlet to the tank is closed by control valve (1). As a result, the increased pressure in port (MA) generates the rotational resistance, and the brake operates.
3.
The pressure in port (MA) increases to the set pressure of the safety valve, and braking torque higher than the motor acts, and the motor stops.
4.
While the safety valve is in operation, the oil relieved from the safety valve and the oil from port (S) are supplied through check valve (CB) to prevent cavitation at port (MB).
PC45MR-5, PC55MR-5
10-147
Component Parts of Swing System
10 Structure and Function
Swing Parking Brake of Swing Motor Operation of Swing Parking Brake of Swing Motor Operation When Swing or Arm Control Lever are in Neutral 1.
Brake piston (1) is pushed up by brake spring (2) since PPC output pressure is 0 MPa {0 kgf/cm2} .
2.
Disc (3) and plate (4) are pressed, and the brake operates.
Operation When Swing or Arm Control Lever are Operated 1.
PPC output pressure flows through port (B) into brake chamber (a).
2.
The pressurized oil in chamber (a) presses down brake spring (2).
3.
Brake piston (1) moves downward and disc (3) and plate (4) are separated, and the brake is released.
10-148
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Swing System
Operation of Hydraulic Timer Hydraulic timer has the following function. •
Hydraulic timer quickly activates the swing parking brake when the swing motor stops so that motor parts do not get damaged.
•
Hydraulic timer delays the swing parking brake starting up so that the deceleration can be performed smoothly.
1.
PPC output pressure is applied to chamber (a) and the swing brake is released when PPC lever is operated.
2.
If PPC lever is set in neutral, no pressurized oil is supplied to port (B), and the pressurized oil in chamber (a) is pushed out by brake spring (2).
3.
The oil does not flow through on port (B) side but flows out to passage (c) since the check valve is installed in the control valve.
4.
The oil in chamber (a) flows out only slowly, and this delays the actuation of the swing brake for a certain time period since the oil passage is throttled by orifice (f) of brake piston (1).
PC45MR-5, PC55MR-5
10-149
Component Parts of Swing System
10 Structure and Function
Swing Modulating Valve of Swing Motor Function of Swing Modulating Valve of Swing Motor •
The swing motor relief valve has characteristics of preventing sudden increase of the relief pressure to reduce shocks generated when the machine stops and starts swinging.
Operation of Swing Modulating Relief Valve of Swing Motor When Circuit Pressure is (P0) 1.
The relief valve does not operate.
When Circuit Pressure Rises Suddenly 1.
When circuit pressure reaches (P1), pressure acts on the area difference between (D1) and (D3) [(D1 > (D3)], and oil presses spring (4), thus valve (3) starts opening.
2.
At this time, pressure acts on the area difference between (D1) and (D2) [(D2) > (D1)], thus seat (1) follows valve (3).
3.
The relief passage to port (S) for the oil in chamber (a) compressed by movement of seat (1) is narrowed by port (2), thus seat (1) moves slower than valve (3).
4.
Accordingly, the relief pressure increases gradually from (P1) to (P2) until seat (1) reaches sleeve (5).
10-150
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Swing System
Swing Machinery Structure of Swing Machinery General View and Sectional View
1: Swing motor
6: No. 2 sun gear (number of teeth: 21)
2: No. 1 sun gear (number of teeth: 21)
7: Swing pinion (number of teeth: 10)
3: No. 1 planetary gear (number of teeth: 33)
8: Taper roller bearing
4: Swing machinery case (number of teeth: 87)
9: No. 2 planetary carrier
5: No. 2 planetary gear (number of teeth: 33)
10: No. 1 planetary carrier
Specifications of Swing Machinery Reduction ratio: ((21 + 87) / 21 x (21 + 87) / 21) = 26.45 Swing reduction ratio: 26.45 x (92/9.0) = 238.04 Swing speed: 9.0 min-1 {9.0 rpm} Lubricating oil: SAE10W Amount of lubricating oil: 1.3 ℓ
PC45MR-5, PC55MR-5
10-151
Component Parts of Swing System
10 Structure and Function
Function of Swing Machinery The swing machinery reduces the swing motor speed, increases the swing force, and reduces the swing speed to proper speed.
10-152
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Swing System
Swing Circle Structure of Swing Circle General View and Sectional View
a: Position of inner race soft zone
b: Position of outer race soft zone
1: Greasing port of swing circle bearing
4: Inner race
2: Greasing port of swing circle pinion
5: Ball
3: Outer race
6: Seal
Specifications of Swing Circle Reduction ratio: 90/10 = 9.00 Grease: G2-LI
Function of Swing Circle The swing circle connects the upper structure and carrier unit.
PC45MR-5, PC55MR-5
10-153
Layout Drawing of Travel System
10 Structure and Function
Travel System Layout Drawing of Travel System Chassis Part
1: Travel alarm
6: Control valve
2: Engine controller
7: Main pump
3: 2nd travel speed selector solenoid valve
8: Travel PPC pressure sensor
4: Center swivel joint
9: Travel motor (L.H.)
5: Travel motor (R.H.)
10-154
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Travel System
Around Cab and Floor
1: Travel lever
3: Travel pedal
2: Machine controller
4: Travel PPC valve
PC45MR-5, PC55MR-5
10-155
System Diagram of Travel Control System
10 Structure and Function
System Diagram of Travel Control System
Input and output signals a: Oil pressure sensor signal
d: Travel alarm operation signal
b: 2nd travel speed selector solenoid valve drive signal
e: Travel speed selector switch signal
c: CAN signal 1: Machine controller
6: Main pump
2: Engine controller
7: Control valve
3: Machine monitor
8: Travel motor
4: Oil pressure sensor
9: 2nd travel speed selector solenoid valve
5: Travel alarm
10: Travel speed selector switch
Function of Travel Control System Travel Speed Selector Function Operating the travel speed selector switch of the blade lever changes the motor capacity, and travel speed. REMARK The travel speed is set to low speed (Lo) automatically if the load increases on a soft ground or on a slope even while the machine is traveling at high speed (Hi). The travel speed displayed on the machine monitor remains (Hi) at this time. Travel speed selector switch
Lo (Low speed)
Hi (High speed)
OFF
ON
Motor capacity
24.7 cc/rev
14.3 cc/rev
Travel speed
2.6 km/h
4.6 km/h
2nd travel speed selector solenoid valve
10-156
PC45MR-5, PC55MR-5
10 Structure and Function
Travel motor swash plate angle
System Diagram of Travel Control System
Maximum
Minimum
A: 21.6 MPa {221 kgf/cm2} B: 23.1 MPa {236 kgf/cm2}
PC45MR-5, PC55MR-5
10-157
Component Parts of Travel System
10 Structure and Function
Component Parts of Travel System Travel Motor Structure of Travel Motor General View
L.H. travel motor A: From control valve (left travel FORWARD port) B: From control valve (left travel REVERSE port) DR1: To hydraulic tank DR2: Plug PP: From 2nd travel speed solenoid valve
R.H. travel motor A: From control valve (right travel REVERSE port) B: From control valve (right travel FORWARD port) DR1: Plug DR2: To hydraulic tank PP: From 2nd travel speed solenoid valve
10-158
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Travel System
Sectional View
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 gear shift valve
PC45MR-5, PC55MR-5
10-159
Component Parts of Travel System
10 Structure and Function
Structure •
Swash plate (1) has 2 planes of x and y, and is supported on ball (2).
•
The travel speed is changed by setting the angle of swash plate (1) to the maximum or minimum with the pressurized oil from control chamber (a) which acts on control piston (3).
Specifications of Travel Motor Model: PHV-4B-60C-PT-9480Z3 Theoretical displacement (Lo): 24.7 cm3/rev Theoretical displacement (Hi): 14.3 cm3/rev Rated speed (Lo): 2227 min-1{ 2227 rpm} Rated speed (Hi): 3846 min-1{ 3846 rpm} Brake releasing pressure: 1.13 MPa {11.5 kgf/cm2} Travel speed selector pressure: 0.86 MPa {8.8 kgf/cm2} Automatic gear shift selecting pressure (Lo→Hi): 21.6 MPa {221 kgf/cm2} Automatic gear shift selecting pressure (Hi→Lo): 23.1 MPa {236 kgf/cm2} Reduction ratio: 63.80
Function of Travel Motor The travel motor converts the fluid energy of hydraulic oil into rotational mechanical energy, and travels the machine.
10-160
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Travel System
Motor Part of Travel Motor Operation of Motor Part of Travel Motor Operation at Low Speed (Motor Swash Plate Angle is at Maximum)
1.
The hydraulic oil from the pilot pump does not flow to port PP since 2nd travel speed selector solenoid valve (1) is de-energized.
2.
The circuit to control chamber (a) is shut off since automatic gear shift valve (2) pressed down by spring (3).
3.
Swash plate (6) is pressed to the right by the reaction force of center spring (7) since control chamber (a) is connected to the drain port.
4.
Swash plate (6) leans around ball (8) toward the maximum swash plate angle side, the motor capacity becomes maximum, and the travel speed decreases.
PC45MR-5, PC55MR-5
10-161
Component Parts of Travel System
10 Structure and Function
Operation at High Speed (Motor Swash Plate Angle is at Minimum)
1.
The pilot pressure from the pilot pump flows to port PP when 2nd travel speed selector solenoid valve (1) is energized.
2.
Automatic gear shift valve (2) compresses spring (3) and moves up, and the circuit to control chamber (a) is connected.
3.
The pressurized oil from the control valve flows from automatic gear shift valve (2) through check valve (4) to control chamber (a), and pushes control piston (5) to the left.
4.
Swash plate (6) leans around ball (8) toward the minimum swash plate angle side against center spring (7), the motor capacity becomes minimum, and the travel speed increases.
REMARK The automatic gear shift function works only while the travel speed selector switch is set in the high speed position. See “Operation of Automatic Gear Shift Valve of Travel Motor”.
10-162
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Travel System
Parking Brake of Travel Motor Operation of Parking Brake of Travel Motor Operation When Travel Lever is Operated 1.
When the travel lever is operated, the pressurized oil from the pump flows in chamber (a) of brake piston (1) and pushes brake piston (1) to the right.
2.
The pressing force of spring (4) against plate (2) and disc (3) is lost.
3.
Plate (2) and disc (3) are separated and the brake is released.
Operation When Travel Lever is in Neutral 1.
When the travel lever is set in NEUTRAL, the pressurized oil in chamber (a) of brake piston (1) is blocked.
2.
Piston (1) is pushed to the left by spring (4).
3.
Plate (2) and disc (3) are pressed, and the brake is applied.
Counterbalance Valve and Check Valve of Travel Motor Operation of Counterbalance Valve and Check Valve of Travel Motor Operation When the Pressurized Oil is Supplied 1.
When the travel lever is operated, the pressurized oil from the control valve is supplied to port (A).
2.
It pushes open check valve (1), and flows from motor inlet port (MA) to motor outlet port (MB).
3.
The pressurized oil flows through orifice (c) into chamber D, and pushes spool (3) to the right against spring (2).
4.
Ports (MB) and (B) are connected, the motor outlet side opens, and the motor starts rotation.
PC45MR-5, PC55MR-5
10-163
Component Parts of Travel System
10 Structure and Function
Operation When the Pressurized Oil is Blocked 1.
The pressurized oil from the control valve is blocked when the travel lever is returned to NEUTRAL.
2.
The reaction force of spring (2) pushes back spool (3) to the left.
3.
The pressurized oil in chamber (D) flows into port (A) through orifice (c). At this time, the back pressure is generated by the throttle effect of orifice (c), and it controls the speed of spool (3) returning to the left.
4.
Even after the pressurized oil in port (A) is blocked, the motor continues the rotation by inertial force.
5.
The motor stops smoothly by the returning oil being controlled with the changing speed and shape of the notch of spool (3).
Automatic Gear Shift Valve of Travel Motor Operation of Automatic Gear Shift Valve of Travel Motor Operation in Automatic Gear Shift from High Speed (Hi) to Low Speed (Lo)
1.
Motor drive pressure (Pc) is led into chambers (a) and (b) of automatic gear shift valve (1) while the machine is traveling at high speed with the travel speed selector switch in the high speed position.
2.
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) when motor drive pressure (Pc) increases.
3.
As a result, automatic gear shift valve (1) moves to the left and shuts off motor drive pressure (A) which is flowing into control chamber (c).
4.
Port DR opens and the oil in control chamber (c) is drained and control piston (3) moves to the left.
10-164
PC45MR-5, PC55MR-5
10 Structure and Function
5.
Component Parts of Travel System
The swash plate of motor (4) leans toward the maximum swash plate angle side and the travel speed decreases.
Operation in Automatic Gear Shift from Low Speed (Lo) to High Speed (Hi)
1.
While the machine is traveling at low speed with the travel speed selector switch in the high speed position, motor drive pressure (Pc) is led into chamber (a) of automatic gear shift valve (1). (Chamber “b” is connected to port DR)
2.
The total of force (F1) generated in chamber (a) by motor drive pressure (Pc) and reaction force (F2) of spring (2) becomes smaller than force (F3) generated by pilot pressure (PP) when motor drive pressure (Pc) decreases.
3.
Automatic gear shift valve (1) moves to the right and motor drive pressure (A) flows into control chamber (c).
4.
Port DR closes, oil flows into control chamber (c), and control piston (3) moves to the right.
5.
The swash plate of motor (4) leans toward the minimum swash plate angle side, and the machine travels with high speed.
PC45MR-5, PC55MR-5
10-165
Component Parts of Travel System
10 Structure and Function
Travel PPC Valve PPC Abbreviation for Proportional Pressure Control
Structure of Travel PPC Valve General View
P: From pilot pump
P3: To control valve (L.H. forward port)
P1: To control valve (R.H. forward port)
P4: To control valve (L.H. reverse port)
P2: To control valve (R.H. reverse port)
T: To hydraulic tank
10-166
PC45MR-5, PC55MR-5
10 Structure and Function
Component Parts of Travel System
Sectional View
1: Plate
4: Seal
2: Case
5: Spool
3: Piston
6: Damper
REMARK For explanation of operation, see “Operation of Work Equipment and Swing PPC Valve”.
PC45MR-5, PC55MR-5
10-167
Component Parts of Travel System
10 Structure and Function
Center Swivel Joint Structure of Center Swivel Joint General View and Sectional View
A1: From control valve (left travel REVERSE port)
E1: From 2nd travel speed selector solenoid valve
A2: To L.H. travel motor port B
E2: To 2nd travel speed selector valve
B1: From control valve (left travel FORWARD port)
F1: From control valve (blade RAISE port)
B2: To L.H. travel motor port A
F2: To blade cylinder head
C1: From control valve (right travel REVERSE port)
G1: From control valve (blade LOWER port)
C2: To R.H. travel motor port A
G2: To blade cylinder bottom
D1: From control valve (right travel FORWARD port)
T1: To hydraulic tank
D2: To L.H. travel motor port B
T2: From travel motor drain port
1: Cover
3: Slipper seal
2: Rotor
4: Shaft
Function of Center Swivel Joint The center swivel joint sends oil from the main pump installed to the top of the machine to the travel motor and blade installed to the bottom of the machine while turning. The center swivel joint is installed in order for the hoses and tubes not to be twisted, since the upper portion of the machine rotates against the lower portion of the machine.
10-168
PC45MR-5, PC55MR-5
10 Structure and Function
Layout Drawing of Undercarriage
Undercarriage and Frame Layout Drawing of Undercarriage
1: Idler
5: Travel motor
2: Track frame
6: Track roller
3: Carrier roller
7: Idler guard (*1)
4: Sprocket
8: Track shoe
*1: Machines with steel shoe
Specifications of Undercarriage Number of Carrier Rollers (One Side) 1 piece
Quantity of Track Rollers (One Side) 4 pieces
PC45MR-5, PC55MR-5
10-169
Idler Cushion
10 Structure and Function
Idler Cushion Structure of Idler Cushion Sectional View
1: Rod
4: Rear support
2: Cylinder
5: Nut
3: Recoil spring
6: Lubricator
Specifications of Idler Cushion Grease: G2-LI Quantity of grease: 120 cc
10-170
PC45MR-5, PC55MR-5
10 Structure and Function
Structure of Work Equipment
Work Equipment Structure of Work Equipment General View
1: Arm cylinder
7: Blade
2: Boom
8: Bucket
3: Boom cylinder
9: Bucket link
4: Boom swing cylinder
10: Bucket cylinder
5: Boom swing bracket
11: Arm
6: Blade cylinder
PC45MR-5, PC55MR-5
10-171
Function of Work Equipment
10 Structure and Function
Function of Work Equipment •
The boom is operated by the boom cylinder. The boom moves the whole work equipment upward and downward.
•
The arm is operated by the arm cylinder. The boom pulls in or pushes out the bucket.
•
The bucket is operated by the bucket cylinder and the bucket link.
•
The bucket link increases the moving range of the bucket.
•
The blade is operated by the blade cylinder.
•
The boom swing bracket can swing the boom swing direction to the right or left by the boom swing cylinder.
10-172
PC45MR-5, PC55MR-5
10 Structure and Function
Work Equipment Clearance Adjustment Shim
Work Equipment Clearance Adjustment Shim Function of Work Equipment Clearance Adjustment Shim There are 2 types of the work equipment clearance adjustment shims. The steel shim and plastic shim. The following is the explanation of the function of each type of clearance adjustment shim.
Steel Shims
The purpose of the steel shim is to reduce the clearance in the right and left direction. There may be some cases that shim is unnecessary to be inserted on one side if it is inserted in either on right or left side depending on the width of the clearance.
Plastic Shims
The purpose of the plastic shim is to reduce the clearance in the right and left direction of the work equipment, and to prevent a creak and scuffing caused by rubbing of the end faces of steel parts of a joint.
PC45MR-5, PC55MR-5
10-173
ROPS CAB
10 Structure and Function
CAB Related Parts ROPS CAB ROPS Abbreviation for Roll-Over Protective Structure
Structure of ROPS CAB REMARK The figure shows the cab specifications.
General View
1: Windshield wiper
5: Radio antenna
2: Front window
6: Door
3: Mirror
7: KOMTRAX communication antenna
4: Head lamp
8: KOMTRAX GPS antenna
Function of ROPS CAB ROPS cab protects the operator wearing seat belt from being crushed when the machine rolls over. 10-174
PC45MR-5, PC55MR-5
10 Structure and Function
Tilt Type Floor
Tilt Type Floor Structure of Tilt Type Floor General View
1: Gas spring
5: Tilt lock bracket
2: Wire
6: Cancel lever
3: Hinge pin
7: Floor assembly
4: Lock pin
Function of Tilt Type Floor The tilt type floor can be tilted open to facilitate the adjusting of the fan belt, replacement of the hydraulic hoses, etc. for better performance of inspection and maintenance. Tilt open angle: Approximately 35 °
PC45MR-5, PC55MR-5
10-175
20 Standard Value Table
PC45MR-5, PC55MR-5
20-1
Table of Contents
20 Standard Value Table
Table of Contents Abbreviation List ............................................................................................................................................ 20-3 Standard Value Table for Engine .................................................................................................................... 20-9 Standard Value Table for Engine: PC45MR-5.......................................................................................... 20-9 Standard Value Table for Engine: PC55MR-5.........................................................................................20-11 Standard Value Table for Machine................................................................................................................ 20-13 Standard Value Table for Machine: PC45MR-5 ..................................................................................... 20-13 Standard Value Table for Machine: PC55MR-5 ..................................................................................... 20-25 Machine Posture and Procedures to Measure Performance ................................................................. 20-37
20-2
PC45MR-5, PC55MR-5
20 Standard Value Table
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
20-3
Abbreviation List
Abbreviation
Actual word spelled out
20 Standard Value Table
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
20-4
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
20 Standard Value Table
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
20-5
Abbreviation List
20 Standard Value Table
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
20-6
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
20 Standard Value Table
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
20-7
Abbreviation List
20 Standard Value Table
Abbreviation S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
20-8
Actual word spelled out
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Engine: PC45MR-5
Standard Value Table for Engine Standard Value Table for Engine: PC45MR-5 Performance
Item
Engine speed at high idle
Engine speed at low idle
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
Unit
Maximum value during the swing operation or travelling
Standard value for new machine
Repair limit
2550±50 {2550±50}
2550±50 {2550±50}
2430±50 {2430±50}
2430±50 {2430±50}
1225±50 {1225±50}
1225±50 {1225±50}
min-1 {rpm} Each control lever: NEUTRAL position
•
Travel speed: Hi
•
Auto-deceleration switch: OFF
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Auto-deceleration switch: OFF
min-1 {rpm}
Air Intake and Exhaust System
Item
Exhaust gas color
Valve clearance
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Engine coolant temperature: 60 to 100 °C
•
After keeping it at normal condition for 5 seconds
•
Fuel control dial: MAX (High idle) position
•
Auto-deceleration switch: OFF
Engine coolant temperature: Normal temperature
PC45MR-5, PC55MR-5
Intake valve Exhaust valve
Unit
Standard value for new machine
Repair limit
Bosch index
Max. 0.5
Max. 1.5
0.20±0.05
0.20±0.05
0.20±0.05
0.20±0.05
mm
20-9
Standard Value Table for Engine: PC45MR-5
20 Standard Value Table
Main Body
Item
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
Compression pressure
Unit
Standard value for new machine
Repair limit
MPa
3.14 to 3.43
2.45 to 2.65
{32 to 35 }
{25 to 28 }
•
Engine coolant temperature: 40 to 60 °C
•
At cranking (engine speed): 250 min-1 {250 {kgf/cm2} rpm} (reference)
Lubrication System
Item
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
Engine oil pressure
•
Engine coolant temperature: 60 to 100 °C
•
Working mode: P (Power Mode)
•
Each control lever and control pedal in NEUTRAL Fuel control diposition
•
Engine oil EO10W30-LA
Unit
Fuel control dial: MAX (High idle) position
Standard value for new machine
Repair limit
0.32 to 0.47
Min. 0.05
{3.3 to 4.8 }
{Min. 0.51 }
Min. 0.06
Min. 0.05
{Min. 0.6 }
{Min. 0.51 }
Max. 120
Max. 120
MPa {kgf/cm2}
al: MIN (Low idle) position
EO15W40-LA EO30-DH Engine oil temWhole speed range (inside oil pan) perature
°C
Cooling System
Item
Tension of alternator belt
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
Deflection when pressed with finger approximately 98 N {approximately 10 kgf}(measure at any intermediate points described in the right column)
Unit
Between alternator and crankshaft pulley Between alternator and fan pulley
mm
Between crankshaft pulley and fan pulley Air conditioner compressor belt tension
20-10
•
Between compressor pulley and idler pulley
•
Deflection when pressed with finger at 58.8 N {6.0 kgf}
mm
Standard value for new machine
Repair limit
8 to 12
10 to 14
5 to 8
7 to 10
7 to 11
9 to 13
5 to 6
5 to 6
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Engine: PC55MR-5
Standard Value Table for Engine: PC55MR-5 Performance
Item
Engine speed at high idle
Engine speed at low idle
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
Unit
Maximum value during the swing operation or travelling
Standard value for new machine
Repair limit
2550±50 {2550±50}
2550±50 {2550±50}
2430±50 {2430±50}
2430±50 {2430±50}
1225±50 {1225±50}
1225±50 {1225±50}
min-1 {rpm} Each control lever: NEUTRAL position
•
Travel speed: Hi
•
Auto-deceleration switch: OFF
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Auto-deceleration switch: OFF
min-1 {rpm}
Air Intake and Exhaust System
Item
Exhaust gas color
Valve clearance
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Engine coolant temperature: 60 to 100 °C
•
After keeping it at normal condition for 5 seconds
•
Fuel control dial: MAX (High idle) position
•
Auto-deceleration switch: OFF
Engine coolant temperature: Normal temperature
Intake valve Exhaust valve
Unit
Standard value for new machine
Repair limit
Bosch index
Max. 0.5
Max. 1.5
0.20±0.05
0.20±0.05
0.20±0.05
0.20±0.05
mm
Main Body
Item Compression pressure
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
MPa
3.14 to 3.43
2.45 to 2.65
{32 to 35 }
{25 to 28 }
•
Engine coolant temperature: 40 to 60 °C
•
At cranking (engine speed): 250 min-1 {250 {kgf/cm2} rpm} (reference)
PC45MR-5, PC55MR-5
20-11
Standard Value Table for Engine: PC55MR-5
20 Standard Value Table
Lubrication System
Item
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
Engine oil pressure
•
Engine coolant temperature: 60 to 100 °C
•
Working mode: P (Power Mode)
•
Each control lever and control pedal in NEUTRAL Fuel control diposition
•
Engine oil EO10W30-LA
Unit
Fuel control dial: MAX (High idle) position
Standard value for new machine
Repair limit
0.32 to 0.47
Min. 0.05
{3.3 to 4.8 }
{Min. 0.51 }
MPa {kgf/cm2}
al: MIN (Low idle) position
Min. 0.06
Min. 0.05
{Min. 0.6 }
{Min. 0.51 }
Max. 120
Max. 120
EO15W40-LA EO30-DH Engine oil temWhole speed range (inside oil pan) perature
°C
Cooling System
Item
Tension of alternator belt
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
Deflection when pressed with finger approximately 98 N {approximately 10 kgf}(measure at any intermediate points described in the right column)
Unit
Between alternator and crankshaft pulley Between alternator and fan pulley
mm
Between crankshaft pulley and fan pulley Air conditioner compressor belt tension
20-12
•
Between compressor pulley and idler pulley
•
Deflection when pressed with finger at 58.8 N {6.0 kgf}
mm
Standard value for new machine
Repair limit
8 to 12
10 to 14
5 to 8
7 to 10
7 to 11
9 to 13
5 to 6
5 to 6
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Machine: PC45MR-5
Standard Value Table for Machine Standard Value Table for Machine: PC45MR-5 Engine Speed
Item
Engine speed at 1-pump relief
Engine speed at 2-pump relief
Engine speed when auto-deceleration is operated
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Arm CURL relief
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Arm CURL relief + Blade relief
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P (Power Mode)
•
Auto-deceleration switch: ON
•
Approximately 5 seconds after each control lever and control pedal are set in NEUTRAL
Unit
min-1 {rpm}
Standard value for new machine
Repair limit
Min. 2220 {Min. 2220}
Min. 2220 {Min. 2220}
Min. 2150 {Min. 2150}
Min. 2150 {Min. 2150}
1225±50 {1225±50}
1225±50 {1225±50}
Control Valve Spool Stroke
Item
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
ℓ = 30
ℓ = 30
a=6
a=6
b=6
b=6
Boom Arm Bucket Swing
•
Spool operation of control valve unit
Breaker
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 1”.
Boom swing
mm
Blade L.H. travel R.H. travel
PC45MR-5, PC55MR-5
20-13
Standard Value Table for Machine: PC45MR-5
20 Standard Value Table
Travel of Control Lever and Pedal Stroke
Item
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
Boom control lever
N → Boom RAISE, Boom LOWER
85±10
85±10
Arm control lever
N → Arm IN, Arm OUT
85±10
85±10
Bucket control lever
N → Bucket CURL, Bucket DUMP
85±10
85±10
Swing control lever
N → Swing LEFT, Swing RIGHT
85±10
85±10
25±5
25±5
50±5
50±5
N → Travel FORWARD, Travel REVERSE (RIGHT/LEFT)
100±10
100±10
Work equipment, Swing, Blade
Max. 5
Max. 5
Travel
Max. 5
Max. 5
Boom swing control pedal Blade control lever
Travel control lever
Play of control lever
20-14
•
Engine: Stopped
•
Center of lever knob
•
End of pedal
•
Read maximum value through travel end (excludN → RAISE, ing play at NEUTRAL). LOWER
N → Swing LEFT, Swing RIGHT
mm
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Machine: PC45MR-5
Operating Force of Control Lever and Pedal Machine model
PC45MR-5
Engine
4D88E-7 Standard value for new machine
Repair limit
Boom control lever
15.68±4.9 {1.6±0.5}
15.68±9.8 {1.6±1}
Arm control lever
15.68±4.9 {1.6±0.5}
15.68±9.8 {1.6±1}
15.68±4.9 {1.6±0.5}
15.68±9.8 {1.6±1}
15.68±4.9 {1.6±0.5}
15.68±9.8 {1.6±1}
78.4±19.6 {8.0±2.0}
78.4±29.4 {8.0±3.0}
Blade control lever
29.4±9.8 {3.0±1.0}
29.4±19.6 {3.0±2}
Travel control lever
22.5±4.9 {2.3±0.5}
22.5±9.8 {2.3±1}
Item
Measurement condition
Bucket control lever
•
Hydraulic oil temperature: 45 to 55 °C
Swing control lever
•
Fuel control dial: MAX (High idle) position
•
Boom swing control pedal
Hitch push-pull scale to center of lever grip or end of pedal to measure
•
Read maximum value through travel end
Unit
N {kgf}
Work Equipment, Swing, Boom Swing, and Travel Oil Pressures
Item
Unload pressure
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
MPa
2.94±0.49
2.94±0.49
•
Auto-deceleration switch: OFF
{kgf/cm2}
{30±5 }
{30±5 }
•
Each control lever and control pedal: NEUTRAL position 26.5±0.98
26.5±0.98
{270±10 }
{270±10 }
26.5±0.98
26.5±0.98
{270±10 }
{270±10 }
26.5±0.98
26.5±0.98
MPa
{270±10 }
{270±10 }
{kgf/cm2}
26.5±0.98
26.5±0.98
{270±10 }
{270±10 }
Boom relief pressure Arm relief pressure Bucket relief pressure
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
Boom swing relief pressure
Swing relief pressure
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
19.6±0.98
19.6±0.98
•
Working mode: P (Power Mode)
{200±10 }
{200±10 }
•
Auto-deceleration switch: OFF
PC45MR-5, PC55MR-5
20-15
Standard Value Table for Machine: PC45MR-5
Item
• •
Travel relief pressure
Control circuit oil pressure
LS differential pressure
PPC valve outlet pressure
Engine
4D88E-7
Hydraulic oil temperature: 45 to 55 °C Fuel control dial: MAX (High idle) position Working mode: P (Power Mode)
Standard value for new machine
Repair limit
21.6 (+0.98/-0.49)
21.6 (+0.98/-0.49)
MPa
{220 (+10/-5) }
{220 (+10/-5) }
{kgf/cm2}
21.6 (+0.98/-0.49)
21.6 (+0.98/-0.49)
{220 (+10/-5) }
{220 (+10/-5) }
MPa
26.5±0.98
26.5±0.98
{kgf/cm2}
{270±10 }
{270±10 }
Unit
RAISE
LOWER
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
MPa
•
Auto-deceleration switch: OFF
{kgf/cm2}
•
Each control lever and control pedal: NEUTRAL position
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
Each control lever and control pedal: NEUTRAL position
Each control lever: Bucket LS differential pressure = CURL operaPump discharged pressure tion (with no - LS pressure load)
3.14(+0.29/-0.30) 3.14(+0.29/-0.30) {32±5 }
{32±5 }
3.23±0.49
3.23±0.49
{33±5 }
{33±5 }
1.57±0.1
1.57±0.1
{16±1 }
{16±1 }
0
0
{0 }
{0 }
MPa {kgf/cm2}
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
For on/off conditions of the When solenoid {kgf/cm2} 2.94 (+0.49/-0.1) solenoid, see Testing and is ON (ener{30 (+5/-1) } Adjusting, “Examine Outlet gized) Pressure of Solenoid Valve”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
20-16
PC45MR-5
•
•
Solenoid valve outlet pressure
Machine model
Measurement condition •
Blade relief pressure
20 Standard Value Table
Working mode: P (Power Mode)
When solenoid is OFF (deenergized) MPa
Each control lever and control pedal: NEUTRAL Control lever and control pedal in tested circuit: Operate them to stroke end
2.94 (+0.49/-0.1) {30 (+5/-1) }
0
0
{0 }
{0 }
2.94 (+0.49/-0.1)
2.94 (+0.49/-0.1)
{30 (+5/-1) }
{30 (+5/-1) }
MPa {kgf/cm2}
PC45MR-5, PC55MR-5
20 Standard Value Table
Item
Swing parking brake cancel pressure
Standard Value Table for Machine: PC45MR-5
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition
• •
Hydraulic oil temperature: 45 to 55 °C Fuel control dial: MAX (High idle) position
Each control lever: Swing RIGHT, Swing LEFT
Unit
Standard value for new machine
Repair limit
MPa
2.94 (+0.49/-0.1)
2.94 (+0.49/-0.1)
{kgf/cm2}
{30 (+5/-1) }
{30 (+5/-1) }
Each control lever: Arm IN
Swing
Item
Overswing
Time required to start swinging
Time required to finish swinging
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Work equipment: No-load, maximum reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Overswing of swing circle after 1 swing
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 2”.
•
Value inside ( ): Overswing at outside of swing circle
•
Work equipment: No-load, Time required to pass 90 ° max. reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 2”.
•
Work equipment: No-load, max. reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to complete 5 swings after 1 swing
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 2”.
PC45MR-5, PC55MR-5
Unit
Standard value for new machine
Repair limit
Degrees
Max. 40
Max. 50
(mm)
(261)
(328)
2.3±0.3
Max. 2.9
-
-
33±3
Max. 38
point after starting swing
Time required to pass 180 ° point after starting swing
Sec.
Sec.
20-17
Standard Value Table for Machine: PC45MR-5
Item
Swing drift on a slope
20 Standard Value Table
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Work equipment: Maximum reach
•
Bucket with rated load or full of soil and sand (Rated load: 2254 N {230 kgf})
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Set machine on 15 ° slope, and set upper structure at 45 deg. upward.
•
Put matchmarks on the inner race and outer race of the circle.
•
Distance that matchmarks move apart after 15 minutes
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 3”.
Unit
Standard value for new machine
Repair limit
Degrees
0
0
(mm)
(0 )
(0 )
Travel
Item
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to travel 20 m after running up 10 m on a level ground
Travel speed
20-18
Machine model
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 4”.
•
Value inside ( ): Time required by machine with steel shoe specification
Unit Lo
Sec. Hi
Standard value for new machine
Repair limit
27.7±2
27.7±4
(30.0±2 )
(30.0±4 )
15.7±2
15.7±4
(16.7±2 )
(16.7±4 )
PC45MR-5, PC55MR-5
20 Standard Value Table
Item
Travel deviation
Machine drift on slope
Standard Value Table for Machine: PC45MR-5
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Travel deviation (X) in travel of 20 m after running up 10 m on a firm and level ground
Unit Lo
Hi
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 4” and “Fig. 5”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Place machine on slope of 30 ° with sprocket on uphill side.
•
Travel distance by machine drift on a slope for 5 minutes
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 6”.
PC45MR-5, PC55MR-5
mm
mm
Standard value for new machine
Repair limit
Max. 300
Max. 330
Max. 300
Max. 330
0
0
20-19
Standard Value Table for Machine: PC45MR-5
20 Standard Value Table
Hydraulic drift of work equipment
Item Whole work equipment (Hydraulic drift measured at tooth tip) Boom cylinder (Retraction amount of cylinder) Arm cylinder (Extension amount of cylinder) Bucket cylinder (Retraction amount of cylinder)
Boom swing cylinder (Retraction amount and extension amount of cylinder)
Blade (Hydraulic drift of blade edge)
20-20
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Level and flat ground
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Each control lever and control pedal: NEUTRAL position
•
Bucket: Rated load (Rated load: 2254 N {230 kgf})
•
Start the measurement of hydraulic drift of work equipment immediately after setting the machine in measuring posture
•
Measure hydraulic drift every 5 minutes and judge at 15 minutes.
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 7”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Bucket: Rated load (Rated load: 2254 N {230 kgf})
•
Set the upper structure sideways on 15 deg. slope. Measure retraction and extension amounts for 15 minutes.
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 7”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Measure hydraulic drift of blade edge from maximum raising position for 15 minutes.
Unit
Standard value for new machine
Repair limit
Max. 300
Max. 450
Max. 6
Max. 30
Max. 30
Max. 30
Max. 16
Max. 30
Max. 20
Max. 30
Max. 30
Max. 45
mm
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Machine: PC45MR-5
Work Equipment Speed
Item
Boom speed
Arm speed
Bucket speed
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to move bucket teeth from ground to RAISE stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 8”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required for operation between dump stroke end and arm IN stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 9”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required for operation between dump stroke end and arm IN stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 10”.
PC45MR-5, PC55MR-5
Unit RAISE
LOWER
Sec.
Arm IN
DUMP
Sec.
Bucket CURL
DUMP
Sec.
Standard value for new machine
Repair limit
2.8±0.3
Max. 3.4
2.8±0.3
Max. 3.4
3.0±0.3
Max. 3.6
2.5±0.3
Max. 3.0
2.9±0.3
Max. 3.5
2.0±0.3
Max. 2.4
20-21
Standard Value Table for Machine: PC45MR-5
Item
Blade speed
Swing speed
20 Standard Value Table
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to move blade between ground point and maximum RAISE
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 11”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to swing between right stroke end and left stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 12”.
Unit RAISE
LOWER
Sec.
Swing LEFT
Swing RIGHT
Sec.
Standard value for new machine
Repair limit
1.1±0.3
Max. 1.4
1.1±0.3
Max. 1.4
7.0±1.5
Max. 10
7.0±1.5
Max. 10
Operation Time Lag
Item
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Set arm and bucket to OUT/DUMP stroke end. Lower boom from RAISE stroke end and measure time required to raise machine after bucket reaches ground.
Boom time lag
•
20-22
Machine model
Unit
Standard value for new machine
Repair limit
Sec.
Max. 2
Max. 3.9
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 13”.
PC45MR-5, PC55MR-5
20 Standard Value Table
Item
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Set boom top face horizontally and set bucket to DUMP stroke end. Move arm IN from OUT stroke end, and measure length of time until arm starts moving IN again after stopping.
Arm time lag
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 14”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Set boom to face horizontally and set arm to OUT stroke end. Curl bucket from DUMP stroke end, and measure length of time until bucket starts curling again after stopping.
Bucket time lag
Blade time lag
Standard Value Table for Machine: PC45MR-5
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 15”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Lower blade from RAISE stroke end, and measure time until the machine starts rising after the blade reach ground.
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig 16”.
Unit
Standard value for new machine
Repair limit
Sec.
Max. 1
Max. 2
Sec.
Max. 1
Max. 2
Sec.
Max. 2
Max. 3.9
Oil Leakage Volume
Item
Leakage from each cylinder
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Amount of the oil leak for 1 minute while relieving the circuit for measuring
PC45MR-5, PC55MR-5
Unit
Standard value for new machine
Repair limit
cc/min
Max. 2
Max. 10
20-23
Standard Value Table for Machine: PC45MR-5
20 Standard Value Table
Pump Performance
Item
Piston pump discharged volume
Machine model
PC45MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Engine speed: 2400 min-1 {2400 rpm}
•
Gear pump: No load applied
•
Test pump discharged pressure (MPa {kgf/cm2} ): P1
•
Other pump discharged pressure (MPa {kgf/cm2} ): P2
•
Average pump discharged pressure (MPa {kgf/cm2} ): (P1+P2)/2
Unit
ℓ/min
Standard value for new machine
Repair limit
Q
Q
(See graph.)
(See graph.)
REMARK Avoid measuring near turning point of the graph because the error increases there.
20-24
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Machine: PC55MR-5
Standard Value Table for Machine: PC55MR-5 Engine Speed
Item
Engine speed at 1-pump relief
Engine speed at 2-pump relief
Engine speed when auto-deceleration is operated
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Arm CURL relief
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Arm CURL relief + Blade relief
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P (Power Mode)
•
Auto-deceleration switch: ON
•
Approximately 5 seconds after each control lever and control pedal are set in NEUTRAL
Unit
min-1 {rpm}
Standard value for new machine
Repair limit
Min. 2220 {Min. 2220}
Min. 2220 {Min. 2220}
Min. 2150 {Min. 2150}
Min. 2150 {Min. 2150}
1225±50 {1225±50}
1225±50 {1225±50}
Control Valve Spool Stroke
Item
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
ℓ = 30
ℓ = 30
a=6
a=6
b=6
b=6
Boom Arm Bucket Swing
•
Spool operation of control valve unit
Breaker
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 1”.
Boom swing
mm
Blade L.H. travel R.H. travel
PC45MR-5, PC55MR-5
20-25
Standard Value Table for Machine: PC55MR-5
20 Standard Value Table
Travel of Control Lever and Pedal Stroke
Item
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
Boom control lever
N → Boom RAISE, Boom LOWER
85±10
85±10
Arm control lever
N → Arm IN, Arm OUT
85±10
85±10
Bucket control lever
N → Bucket CURL, Bucket DUMP
85±10
85±10
Swing control lever
N → Swing LEFT, Swing RIGHT
85±10
85±10
25±5
25±5
50±5
50±5
N → Travel FORWARD, Travel REVERSE (RIGHT/LEFT)
100±10
100±10
Work equipment, Swing, Blade
Max. 5
Max. 5
Travel
Max. 5
Max. 5
Boom swing control pedal Blade control lever
Travel control lever
Play of control lever
20-26
•
Engine: Stopped
•
Center of lever knob
•
End of pedal
•
Read maximum value through travel end (excludN → RAISE, ing play at NEUTRAL). LOWER
N → Swing LEFT, Swing RIGHT
mm
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Machine: PC55MR-5
Operating Force of Control Lever and Pedal Machine model
PC55MR-5
Engine
4D88E-7 Standard value for new machine
Repair limit
Boom control lever
15.68±4.9 {1.6±0.5}
15.68±4.9 {1.6±0.5}
Arm control lever
15.68±4.9 {1.6±0.5}
15.68±4.9 {1.6±0.5}
15.68±4.9 {1.6±0.5}
15.68±4.9 {1.6±0.5}
15.68±4.9 {1.6±0.5}
15.68±4.9 {1.6±0.5}
78.4±19.6 {8.0±2.0}
78.4±19.6 {8.0±2.0}
Blade control lever
29.4±9.8 {3.0±1.0}
29.4±9.8 {3.0±1.0}
Travel control lever
22.5±4.9 {2.3±0.5}
22.5±4.9 {2.3±0.5}
Item
Measurement condition
Bucket control lever
•
Hydraulic oil temperature: 45 to 55 °C
Swing control lever
•
Fuel control dial: MAX (High idle) position
•
Boom swing control pedal
Hitch push-pull scale to center of lever grip or end of pedal to measure
•
Read maximum value through travel end
Unit
N {kgf}
Work Equipment, Swing, Boom Swing, and Travel Oil Pressures
Item
Unload pressure
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
Unit
Standard value for new machine
Repair limit
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
MPa
2.94±0.49
2.94±0.49
•
Auto-deceleration switch: OFF
{kgf/cm2}
{30±5 }
{30±5 }
•
Each control lever and control pedal: NEUTRAL position 26.5±0.98
26.5±0.98
{270±10 }
{270±10 }
26.5±0.98
26.5±0.98
{270±10 }
{270±10 }
26.5±0.98
26.5±0.98
MPa
{270±10 }
{270±10 }
{kgf/cm2}
26.5±0.98
26.5±0.98
{270±10 }
{270±10 }
Boom relief pressure Arm relief pressure Bucket relief pressure
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
Boom swing relief pressure
Swing relief pressure
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
19.6±0.98
19.6±0.98
•
Working mode: P (Power Mode)
{200±10 }
{200±10 }
•
Auto-deceleration switch: OFF
PC45MR-5, PC55MR-5
20-27
Standard Value Table for Machine: PC55MR-5
Item
• •
Travel relief pressure
Control circuit oil pressure
LS differential pressure
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Blade relief pressure
20 Standard Value Table
Hydraulic oil temperature: 45 to 55 °C
Repair limit
21.6 (+0.98/-0.49)
21.6 (+0.98/-0.49)
MPa
{220 (+10/-5) }
{220 (+10/-5) }
{kgf/cm2}
21.6 (+0.98/-0.49)
21.6 (+0.98/-0.49)
{220 (+10/-5) }
{220 (+10/-5) }
MPa
26.5±0.98
26.5±0.98
{kgf/cm2}
{270±10 }
{270±10 }
RAISE
Fuel control dial: MAX (High idle) position Working mode: P (Power Mode)
Standard value for new machine
Unit
LOWER
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
MPa
•
Auto-deceleration switch: OFF
{kgf/cm2}
•
Each control lever and control pedal: NEUTRAL position
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Each control lever and control pedal: NEUTRAL position
Each control LS differential pressure = lever: Bucket Pump discharged pressure CURL (with no load)
3.14(+0.29/-0.30) 3.14(+0.29/-0.30) {32±5 }
{32±5 }
3.23±0.49
3.23±0.49
{33±5 }
{33±5 }
1.57±0.1
1.57±0.1
{16±1 }
{16±1 }
0
0
{0 }
{0 }
MPa {kgf/cm2}
- LS pressure
Solenoid valve outlet pressure
PPC valve outlet pressure
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
For on/off conditions of the When solenoid {kgf/cm2} 2.94 (+0.49/-0.1) solenoid, see Testing and is ON (ener{30 (+5/-1) } Adjusting, “Examine Outlet gized) Pressure of Solenoid Valve”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
20-28
Working mode: P (Power Mode)
When solenoid is OFF (deenergized) MPa
Each control lever and control pedal: NEUTRAL Control lever and control pedal in tested circuit: Operate them to stroke end
2.94 (+0.49/-0.1) {30 (+5/-1) }
0
0
{0 }
{0 }
2.94 (+0.49/-0.1)
2.94 (+0.49/-0.1)
{30 (+5/-1) }
{30 (+5/-1) }
MPa {kgf/cm2}
PC45MR-5, PC55MR-5
20 Standard Value Table
Item
Swing parking brake cancel pressure
Standard Value Table for Machine: PC55MR-5
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition
• •
Hydraulic oil temperature: 45 to 55 °C Fuel control dial: MAX (High idle) position
Each control lever: Swing RIGHT, Swing LEFT
Unit
Standard value for new machine
Repair limit
MPa
2.94 (+0.49/-0.1)
2.94 (+0.49/-0.1)
{kgf/cm2}
{30 (+5/-1) }
{30 (+5/-1) }
Each control lever: Arm IN
Swing
Item
Overswing
Time required to start swinging
Time required to finish swinging
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Work equipment: No-load, maximum reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Overswing of swing circle after 1 swing
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 2”.
•
Value inside ( ): Overswing at outside of swing circle
•
Work equipment: No-load, max. reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 2”.
•
Work equipment: No-load, max. reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to complete 5 swings after 1 swing
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 2”.
PC45MR-5, PC55MR-5
Unit
Standard value for new machine
Repair limit
Degrees
Max. 40
Max. 50
(mm)
(261)
(328)
2.3±0.3
Max. 2.9
-
-
33±3
Max. 38
Time required to pass 90 ° point after starting swing
Time required to pass 180 ° point after starting swing
Sec.
Sec.
20-29
Standard Value Table for Machine: PC55MR-5
Item
Swing drift on a slope
20 Standard Value Table
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Work equipment: Maximum reach
•
Bucket with rated load or full of soil and sand (Rated load: 2450 N {250 kgf})
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Set machine on 15 ° slope, and set upper structure at 45 deg. upward.
•
Put matchmarks on the inner race and outer race of the circle.
•
Distance that matchmarks move apart after 15 minutes
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 3”.
Unit
Standard value for new machine
Repair limit
Degrees
0
0
(mm)
(0 )
(0 )
Travel
Item
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to travel 20 m after running up 10 m on a level ground
Travel speed
20-30
Machine model
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 4”.
•
Value inside ( ): Time required by machine with steel shoe specification
Unit Lo
Sec. Hi
Standard value for new machine
Repair limit
27.7±2
27.7±4
(30.0±2 )
(30.0±4 )
15.7±2
15.7±4
(16.7±2 )
(16.7±4 )
PC45MR-5, PC55MR-5
20 Standard Value Table
Item
Travel deviation
Machine drift on slope
Standard Value Table for Machine: PC55MR-5
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Travel deviation (X) in travel of 20 m after running up 10 m on a firm and level ground
Unit Lo
Hi
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 4” and “Fig. 5”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Place machine on slope of 30 ° with sprocket on uphill side.
•
Travel distance by machine drift on a slope for 5 minutes
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 6”.
PC45MR-5, PC55MR-5
mm
mm
Standard value for new machine
Repair limit
Max. 300
Max. 330
Max. 300
Max. 330
0
0
20-31
Standard Value Table for Machine: PC55MR-5
20 Standard Value Table
Hydraulic drift of work equipment
Item Whole work equipment (Hydraulic drift measured at tooth tip) Boom cylinder (Retraction amount of cylinder) Arm cylinder (Extension amount of cylinder) Bucket cylinder (Retraction amount of cylinder)
Boom swing cylinder (Retraction amount and extension amount of cylinder)
Blade (Hydraulic drift of blade edge)
20-32
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Level and flat ground
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Each control lever and control pedal: NEUTRAL position
•
Bucket: Rated load (Rated load: 2450 N {250 kgf})
•
Start the measurement of hydraulic drift of work equipment immediately after setting the machine in measuring posture
•
Measure hydraulic drift every 5 minutes and judge at 15 minutes.
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 7”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Bucket: Rated load (Rated load: 2450 N {250 kgf})
•
Set the upper structure sideways on 15 deg. slope. Measure retraction and extension amounts for 15 minutes.
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 7”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine: Stopped
•
Measure hydraulic drift of blade edge from maximum raising position for 15 minutes.
Unit
Standard value for new machine
Repair limit
Max. 300
Max. 450
Max. 6
Max. 30
Max. 30
Max. 30
Max. 16
Max. 30
Max. 20
Max. 30
Max. 30
Max. 45
mm
PC45MR-5, PC55MR-5
20 Standard Value Table
Standard Value Table for Machine: PC55MR-5
Work Equipment Speed
Item
Boom speed
Arm speed
Bucket speed
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to move bucket teeth from ground to RAISE stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 8”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required for operation between dump stroke end and arm IN stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 9”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required for operation between dump stroke end and arm IN stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 10”.
PC45MR-5, PC55MR-5
Unit RAISE
LOWER
Sec.
Arm IN
DUMP
Sec.
Bucket CURL
DUMP
Sec.
Standard value for new machine
Repair limit
2.8±0.3
Max. 3.4
2.9±0.3
Max. 3.5
3.1±0.3
Max. 3.7
2.5 (+0.4/-0.2)
Max. 3.0
2.8±0.3
Max. 3.4
2.0±0.3
Max. 2.4
20-33
Standard Value Table for Machine: PC55MR-5
Item
Blade speed
Swing speed
20 Standard Value Table
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to move blade between ground point and maximum RAISE
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 11”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to swing between right stroke end and left stroke end
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 12”.
Unit RAISE
LOWER
Sec.
Swing LEFT
Swing RIGHT
Sec.
Standard value for new machine
Repair limit
1.3±0.3
Max. 1.6
1.3±0.3
Max. 1.6
7.0±1.5
Max. 10
7.0 (+1.8/-1.2)
Max. 10
Operation Time Lag
Item
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Set arm and bucket to OUT/DUMP stroke end. Lower boom from RAISE stroke end and measure time required to raise machine after bucket reaches ground.
Boom time lag
•
20-34
Machine model
Unit
Standard value for new machine
Repair limit
Sec.
Max. 2
Max. 3.9
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 13”.
PC45MR-5, PC55MR-5
20 Standard Value Table
Item
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Set boom top face horizontally and set bucket to DUMP stroke end. Move arm IN from OUT stroke end, and measure length of time until arm starts moving IN again after stopping.
Arm time lag
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 14”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Set boom to face horizontally and set arm to OUT stroke end. Curl bucket from DUMP stroke end, and measure length of time until bucket starts curling again after stopping.
Bucket time lag
Blade time lag
Standard Value Table for Machine: PC55MR-5
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 15”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P (Power Mode)
•
Lower blade from RAISE stroke end, and measure time until the machine starts rising after the blade reach ground.
•
Measurement posture: See “Machine Posture and Procedures to Measure Performance”, “Fig 16”.
Unit
Standard value for new machine
Repair limit
Sec.
Max. 1
Max. 2
Sec.
Max. 1
Max. 2
Sec.
Max. 2
Max. 3.9
Oil Leakage Volume
Item
Leakage from each cylinder
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Amount of the oil leak for 1 minute while relieving the circuit for measuring
PC45MR-5, PC55MR-5
Unit
Standard value for new machine
Repair limit
cc/min
Max. 2
Max. 10
20-35
Standard Value Table for Machine: PC55MR-5
20 Standard Value Table
Pump Performance
Item
Piston pump discharged volume
Machine model
PC55MR-5
Engine
4D88E-7
Measurement condition •
Hydraulic oil temperature: 45 to 55 °C
•
Engine speed: 2400 min-1 {2400 rpm}
•
Gear pump: No load applied
•
Test pump discharged pressure (MPa {kgf/cm2} ): P1
•
Other pump discharged pressure (MPa {kgf/cm2} ): P2
•
Average pump discharged pressure (MPa {kgf/cm2} ): (P1+P2)/2
Unit
ℓ/min
Standard value for new machine
Repair limit
Q
Q
(See graph.)
(See graph.)
REMARK Avoid measuring near turning point of the graph because the error increases there.
20-36
PC45MR-5, PC55MR-5
20 Standard Value Table
Machine Posture and Procedures to Measure Performance
Machine Posture and Procedures to Measure Performance Fig. 1
Fig. 2
Fig. 3
Fig. 4
PC45MR-5, PC55MR-5
20-37
Machine Posture and Procedures to Measure Performance
20 Standard Value Table
Fig. 5
Fig. 6
Fig. 7
Fig. 8
20-38
PC45MR-5, PC55MR-5
20 Standard Value Table
Machine Posture and Procedures to Measure Performance
Fig. 9
Fig. 10
Fig. 11
Fig. 12
PC45MR-5, PC55MR-5
20-39
Machine Posture and Procedures to Measure Performance
20 Standard Value Table
Fig. 13
Fig. 14
Fig. 15
Fig. 16
20-40
PC45MR-5, PC55MR-5
30 Testing and Adjusting
PC45MR-5, PC55MR-5
30-1
Table of Contents
30 Testing and Adjusting
Table of Contents Abbreviation List ............................................................................................................................................ 30-5 Precautions Before Work ..............................................................................................................................30-11 Related Information on Testing and Adjusting .............................................................................................. 30-12 Tools for Testing and Adjusting.............................................................................................................. 30-12 Sketch of Tools for Testing and Adjusting .............................................................................................. 30-16 Engine and Cooling System ......................................................................................................................... 30-18 Examine Engine Speed......................................................................................................................... 30-18 How to Examine Engine Speed...................................................................................................... 30-18 Examine Exhaust Gas Color ................................................................................................................. 30-20 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................ 30-20 How to Examine Exhaust Gas Color with Smoke Meter ................................................................. 30-21 Examine and Adjust Valve Clearance.................................................................................................... 30-22 Check Valve Clearance .................................................................................................................. 30-22 Adjust Valve Clearance .................................................................................................................. 30-23 Examine Compression Pressure ........................................................................................................... 30-24 How to Examine Compression Pressure ........................................................................................ 30-24 Examine Engine Oil Pressure ............................................................................................................... 30-26 How to Examine Engine Oil Pressure ............................................................................................ 30-26 Bleed Air from Fuel System................................................................................................................... 30-28 How to Bleed Air from Fuel System................................................................................................ 30-28 Examine Fuel Circuit for Leakage ......................................................................................................... 30-30 How to Examine Fuel System for Leakage..................................................................................... 30-30 Handle Cylinder Cut-out Mode Operation.............................................................................................. 30-31 Examine and Adjust Alternator Belt Tension.......................................................................................... 30-32 How to Examine Alternator Belt Tension ........................................................................................ 30-32 Adjust Alternator Belt Tension ........................................................................................................ 30-32 Examine and Adjust Air Conditioner Compressor Belt Tension ............................................................. 30-33 How to Examine and Adjust Air Conditioner Compressor Belt Tension .......................................... 30-33 Power Train.................................................................................................................................................. 30-35 Examine Swing Circle Bearing Clearance ............................................................................................. 30-35 How to Examine Swing Circle Bearing Clearance .......................................................................... 30-35 Undercarriage and Frame ............................................................................................................................ 30-36 Examine and Adjust Track Tension ....................................................................................................... 30-36 How to Examine Track Tension ...................................................................................................... 30-36 How to Adjust Track Tension .......................................................................................................... 30-36 Hydraulic System ......................................................................................................................................... 30-38 Release Remained Pressure in Hydraulic Circuit .................................................................................. 30-38 How to Release Remained Pressure from Hydraulic Tank ............................................................. 30-38 How to Release Remained Pressure in PPC Accumulator Circuit .................................................. 30-38 How to Release Remained Pressure in Hydraulic Cylinder Circuit ................................................. 30-38 How to Release Remained Pressure from Swing Motor Circuit...................................................... 30-43 How to Release Remained Pressure from Travel Motor Circuit...................................................... 30-43 Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits ...................... 30-44 How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits..................... 30-44 Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits..................................... 30-54 Examine and Adjust Swing and Blade Circuit Oil Pressure ................................................................... 30-55 How to Examine Oil Pressure in Swing and Blade Circuits............................................................. 30-55 Adjust Oil Pressure in Swing and Blade Circuits ............................................................................ 30-60 Examine and Adjust Oil Pressure in Control Circuit............................................................................... 30-62 Examine Oil Pressure in Control Circuit ......................................................................................... 30-62 Adjust Oil Pressure in Control Circuit ............................................................................................. 30-64 Adjust Oil Pressure in Pump PC Control Circuit .................................................................................... 30-66 How to Adjust Oil Pressure in Pump PC Control Circuit ................................................................. 30-66 Examine and Adjust Oil Pressure in Pump LS Control Circuit ............................................................... 30-68 Examine LS Differential Pressure with Machine Monitor ................................................................ 30-68 Examine LS Differential Pressure by Testing Tool .......................................................................... 30-69 30-2
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Table of Contents
Adjust LS Valve .............................................................................................................................. 30-71 Examine Outlet Pressure of Solenoid Valve .......................................................................................... 30-72 How to Examine Outlet Pressure of Solenoid Valve by Machine Monitor ....................................... 30-72 How to Examine Outlet Pressure of Solenoid Valve by Testing Tool............................................... 30-73 Operating Condition of Solenoid Valve ........................................................................................... 30-74 Examine PPC Valve Outlet Pressure..................................................................................................... 30-75 How to Examine Outlet Pressure of PPC Valve with Machine Monitor ........................................... 30-75 How to Examine Outlet Pressure of PPC Valve by Testing Tool ..................................................... 30-78 Adjust Play of Work Equipment and Swing PPC Valves ........................................................................ 30-80 How to Adjust Play of Work Equipment and Swing PPC Valves ..................................................... 30-80 Examine Swing Parking Brake Release Pressure ................................................................................. 30-81 How to Examine Swing Parking Brake Release Pressure with Machine Monitor............................ 30-81 How to Examine Swing Parking Brake Release Pressure by Testing Tool...................................... 30-81 Examine and Adjust Travel Deviation.................................................................................................... 30-83 How to Examine Travel Deviation .................................................................................................. 30-83 How to Adjust Travel Deviation ...................................................................................................... 30-83 Examine Parts Which Cause Hydraulic Drift of Work Equipment........................................................... 30-86 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder .......... 30-86 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder ....................................... 30-86 How to Examine Parts that Cause Hydraulic Drift of PPC Valve..................................................... 30-87 Examine Oil Leakage ............................................................................................................................ 30-88 How to Examine Oil Leakage from Boom Cylinder ......................................................................... 30-88 How to Examine Oil Leakage from Arm Cylinder............................................................................ 30-88 How to Examine Oil Leakage from Bucket Cylinder ....................................................................... 30-89 How to Examine Oil Leakage from Blade Cylinder ......................................................................... 30-89 Bleed Air from Hydraulic System........................................................................................................... 30-91 How to Bleed Air from Hydraulic System........................................................................................ 30-92 Pressurize Hydraulic Tank..................................................................................................................... 30-94 How to Pressurize Hydraulic Tank.................................................................................................. 30-94 CAB Related Parts ....................................................................................................................................... 30-95 How to Open and Close Floor Unit........................................................................................................ 30-95 Procedure to Open Floor Unit ........................................................................................................ 30-96 Procedure to Close Floor Unit .......................................................................................................30-101 Electrical System ........................................................................................................................................30-105 Set and Operate Machine Monitor........................................................................................................30-105 Operator Mode..............................................................................................................................30-108 Examine Function by LCD (Liquid Crystal Display) .......................................................................30-108 Examine Function of Service Meter...............................................................................................30-108 Usage Limitation and Maintenance Password Change Function ...................................................30-108 Service Mode ................................................................................................................................ 30-111 How to Operate Service Mode ...................................................................................................... 30-111 How to See Pre-defined Monitoring Information ............................................................................30-112 How to Examine Self-Define Monitor Information ..........................................................................30-116 Abnormality Record Menu.............................................................................................................30-123 How to See Maintenance Record..................................................................................................30-126 Maintenance Mode Setting............................................................................................................30-127 Set Phone Number Entry ..............................................................................................................30-131 Default Menu.................................................................................................................................30-133 Diagnostic Tests Menu ..................................................................................................................30-138 Adjustment Menu ..........................................................................................................................30-146 How to Operate Battery Disconnect Switch Setting .......................................................................30-150 KOMTRAX Settings Menu.............................................................................................................30-152 Show Service Message.................................................................................................................30-154 How to Start Up KOMTRAX Terminal ...................................................................................................30-156 Handle Voltage Circuit of Engine Controller .........................................................................................30-160 Examine Diodes...................................................................................................................................30-161 Examine Diodes by Digital Tester..................................................................................................30-161 How to Examine Diodes by Analog Tester.....................................................................................30-161 PC45MR-5, PC55MR-5
30-3
Table of Contents
30 Testing and Adjusting
Pm Clinic.....................................................................................................................................................30-162 Pm Clinic Service .................................................................................................................................30-162 Pm Clinic Check Sheet: PC45MR-5 ..............................................................................................30-163 Pm Clinic Check Sheet: PC55MR-5 ..............................................................................................30-170
30-4
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
30-5
Abbreviation List
Abbreviation
Actual word spelled out
30 Testing and Adjusting
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
30-6
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
30-7
Abbreviation List
30 Testing and Adjusting
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
30-8
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
30-9
Abbreviation List
30 Testing and Adjusting
Abbreviation S/T STRG
Actual word spelled out Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
30-10
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Precautions Before Work
Precautions Before Work Before you start, read the “Safety Notice for Operation” of the “Index and Foreword” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a dan-
ger that you can get caught in the machine. •
Do not wear oversized clothes or accessories.
•
Be sure to tie the long hair that comes out from the helmet.
•
Decide on the work procedure.
•
Obey the specified signal during the work.
k When you work together with more than one person, do the preparation that follows.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange an
observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not to
let the machine move. •
Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
•
Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts, there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.
PC45MR-5, PC55MR-5
30-11
Tools for Testing and Adjusting
30 Testing and Adjusting
Related Information on Testing and Adjusting Tools for Testing and Adjusting Tools to Examine Exhaust Gas Color Symbol
Part No.
Part name
Q'ty
A
799-201-9002
Handy smoke checker
1
B
Commercially available
Smoke meter
1
Remarks Bosch index: 0 to 9
Tools to Examine and Adjust Valve Clearance Symbol
Part No.
Part name
Q'ty
Remarks
A
Commercially available
Mirror
1
B
Commercially available
Feeler gauge
1
C
Commercially available
Socket wrench
1
Width across flats: 22 mm
Q'ty
Remarks
Tools to Examine Compression Pressure Symbol
Part No.
Part name
A
795-502-1590
B
YM-129A00-92 Compression gauge adapter 950
1
C
795-101-1571
Joint
1
D
6275-11-3890
Gasket
1
Gauge assembly
1
Pressure range: 0 to 7 MPa
Tools to Examine Engine Oil Pressure Symbol
Part No.
Part name
Q'ty
-
799-101-5002
Hydraulic tester
1
1
799-101-5160
Nipple
1
B
790-261-1205
Digital hydraulic tester
1
C
799-401-2320
Gauge
1
A
Remarks
Size: R1/8
Pressure range: 1 MPa
Tools to Examine Leakage in Fuel System Symbol
Part No.
Part name
Q'ty
A
Commercially available
Developer for dye penetrant (color checker)
1
Remarks
Tools to Examine Swing Circle Bearing Clearance Symbol
Part No.
A
Commercially available
30-12
Part name Dial gauge
Q'ty
Remarks
1
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Tools for Testing and Adjusting
Tools to Examine Track Shoe Tension Symbol
Part No.
A
Commercially available
Part name Wooden block
Q'ty
Remarks
1
Tools to Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5120
Gauge
1
Pressure range: 40 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
2
Size: M10 x 1.25 mm
D
07002-11023
O-ring
2
E
Commercially available
Pin
1
A
F
799T-404–8500 Sensor adapter
1
•
Material: SS400
•
Diameter: 50 mm
•
Length: 100 mm
Pressure range: 50 MPa
Tools to Examine and Adjust Oil Pressure in Swing and Blade Circuits Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5120
Gauge
1
Pressure range: 40 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
1
Size: M10 x 1.25 mm
D
07002-11023
O-ring
1
E
799T-404–8500 Sensor adapter
A
1
Pressure range: 50 MPa
Q'ty
Remarks
Tools to Examine and Adjust Control Circuit Oil Pressure Symbol
Part No.
Part name
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
1
Size: M10 x 1.25 mm
D
07002-11023
O-ring
1
E
799T-404–8500 Sensor adapter
A
PC45MR-5, PC55MR-5
1
Pressure range: 50 MPa
30-13
Tools for Testing and Adjusting
30 Testing and Adjusting
Tools to Examine and Adjust Pump LS Control Circuit Oil Pressure Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5120
Gauge
2
Pressure range: 40 MPa
2
799-101-5160
Nipple
2
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799-401-3200
Adapter
1
Size: 03
E
799-401-2701
Differential pressure gauge
1
Pressure range: 50 MPa
F
799T-404-8500 Sensor adapter
1
Pressure range: 50 MPa
Q'ty
Remarks
A
Tools to Examine Solenoid Valve Outlet Pressure Symbol
Part No.
Part name
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
3
790-301-1530
Elbow
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799T-404–8500 Sensor adapter
1
Pressure range: 50 MPa
Q'ty
Remarks
A
Tools to Examine PPC Valve Outlet Pressure Symbol
Part No.
Part name
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799T-404–8500 Sensor adapter
1
Pressure range: 50 MPa
Q'ty
Remarks
A
Tools to Examine Release Pressure in Swing Parking Brake Symbol
Part No.
Part name
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
A
30-14
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Tools for Testing and Adjusting
Tools to Examine Oil Leakage Symbol
Part No.
Part name
Q'ty
A
Commercially available
Measuring cylinder
1
B
07376-70422
Plug
1
C
Commercially available
Block
1
Remarks
Size: 04
Tools to Bleed Air from Hydraulic Circuit Symbol
Part No.
A
Commercially available
Oil container
1
B
Commercially available
Vinyl hose
1
PC45MR-5, PC55MR-5
Part name
Q'ty
Remarks
30-15
Sketch of Tools for Testing and Adjusting
30 Testing and Adjusting
Sketch of Tools for Testing and Adjusting Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. Sensor Adapter
Wiring Harness
30-16
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Nipple
PC45MR-5, PC55MR-5
30-17
Examine Engine Speed
30 Testing and Adjusting
Engine and Cooling System Examine Engine Speed Test this item by using the Pre-defined Monitoring or monitoring function of the machine monitor. Check this item under the following conditions. •
Engine coolant temperature60 to 100 °C
•
Hydraulic oil temperature45 to 55 °C
For testing of engine speed to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Engine Speed Examine Engine High Idle Speed 1.
See “Set and Operate Machine Monitor” and display (01/14) “Pre-defined Mon”.
2.
Set all control levers and control pedals in NEUTRAL position, and set the lock lever in LOCK position.
3.
Set the working mode to P (“Power Mode”), turn off the auto-deceleration, and set the travel speed setting to “Hi”.
4.
Start the engine, and check the engine speed with fuel control dial at MAX (High idle) position.
5.
Set the lock lever to FREE position, and check the maximum engine speed of the time when the swing control lever or the travel lever is operated gradually. REMARK For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
Examine Engine Low Idle Speed 1.
See “Set and Operate Machine Monitor” and display (01/14) “Pre-defined Mon”.
2.
Set all control levers and control pedals in NEUTRAL position, and set the lock lever in LOCK position.
3.
Set working mode to P (“Power Mode”), turn off auto-deceleration.
4.
Start the engine, and check the engine speed with fuel control dial at MIN (Low idle) position. REMARK For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
30-18
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine Engine Speed
Engine Speed Test at 1-Pump Relief 1.
See “Set and Operate Machine Monitor” and display (01/14) “Pre-defined Mon”.
2.
Set all control levers and control pedals in NEUTRAL position, and set the lock lever in LOCK position.
3.
Set the working mode to P (“Power Mode”), turn off the auto-deceleration, and set the travel speed setting to “Hi”.
4.
Start the engine, and set the fuel control dial to MAX (High idle) position.
5.
Set the work equipment lock lever in FREE position, operate R.H. work equipment control lever, and measure the engine speed at arm CURL relief. REMARK For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
Examine the Engine Speed at 2-Pump Relief 1.
See “Set and Operate Machine Monitor” and display (01/14) “Pre-defined Mon”.
2.
Set all control levers and control pedals in NEUTRAL position, and set the lock lever in LOCK position.
3.
Set the working mode to P (“Power Mode”), turn off the auto-deceleration, and set the travel speed setting to “Hi”.
4.
Start the engine, and set the fuel control dial to MAX (High idle) position.
5.
Set the work equipment lock lever in FREE position, operate R.H. and L.H. work equipment control levers, and measure the engine speed under the following condition. Arm CURL relief and blade relief REMARK For standard values, see Standard Value Table, “Standard Value Table for Machine”.
Engine Speed Test at Auto-Deceleration 1.
See “Set and Operate Machine Monitor” and display (01/14) “Pre-defined Mon”.
2.
Set all control levers and control pedals in NEUTRAL position, and set the lock lever in LOCK position.
3.
Start the engine and set the fuel control dial to MAX (High idle) position. Set the working mode to P (“Power Mode”), and then turn ON auto-deceleration.
4.
Check the engine speed when auto-decelerator is operated after rechecking that all control levers and control pedals are in NEUTRAL position. REMARK Engine speed drops to the speed when auto deceleration is activated if each control lever and control pedal remain NEUTRAL for 5 seconds and longer. Check the engine speed at the time. (For detail, see Structure and Function, “Engine System”). For standard values, see Standard Value Table, “Standard Value Table for Machine”.
PC45MR-5, PC55MR-5
30-19
Examine Exhaust Gas Color
30 Testing and Adjusting
Examine Exhaust Gas Color Tools to Examine Exhaust Gas Color Symbol
Part No.
Part name
Q'ty
A
799-201-9002
Handy smoke checker
1
B
Commercially available
Smoke meter
1
Remarks Bosch index: 0 to 9
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work. Check this item under the following conditions. Engine coolant temperature: 60 to 100 °C If an air source and an electric power source are not available in the field, use handy smoke checker A. When recording official data, etc., use smoke meter B. For testing of exhaust gas color to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Exhaust Gas Color with the Handy Smoke Checker 1.
Start the engine and increase the coolant temperature into the specified range.
2.
Fit a sheet of filter paper to handy smoke checker A.
3.
Insert the exhaust gas intake pipe of handy smoke checker A into exhaust pipe (1).
4.
Run the engine with fuel control dial at MAX (High idle ) and put the auto-deceleration switch to OFF position for 5 seconds. Collect the exhaust gas to the filter paper by operating the handle of smoke checker A. REMARK Collecting time: 1.4±0.2 seconds
5.
Remove the filter paper and compare it with the attached scale for judgment. For standard values, see Standard Value Table, “Standard Value Table for Engine”.
After finishing the test, remove the testing tools and restore the machine.
30-20
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine Exhaust Gas Color
How to Examine Exhaust Gas Color with Smoke Meter 1.
Start the engine and increase the coolant temperature into the specified range.
2.
Connect the probe hose, receptacle of the accelerator switch and air hose to smoke meter B. REMARK Limit the supplied air pressure to 1.47 MPa {15 kgf/cm2} .
3.
Connect the power cable to the electric power supply receptacle. REMARK Check that the power switch of smoke meter B is in OFF position before connecting the power cable to the receptacle.
4.
Insert the probe of smoke meter B into the outlet of exhaust pipe (1), and fix it to the exhaust pipe with clip.
5.
Loosen the cap nut (2) of the suction pump and place the filter paper. REMARK Place the filter paper securely so that the exhaust gas does not leak.
6.
Turn ON the power switch of smoke meter B.
7.
Run the engine with fuel control dial at MAX (High idle) and put the auto-deceleration switch to OFF position. Depress the accelerator pedal of smoke meter B for 5 seconds to collect the exhaust gas on the filter paper.
8.
Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. For standard values, see Standard Value Table, “Standard Value Table for Engine”.
After finishing the test, remove the testing tools and restore the machine.
PC45MR-5, PC55MR-5
30-21
Examine and Adjust Valve Clearance
30 Testing and Adjusting
Examine and Adjust Valve Clearance Tools to Examine and Adjust Valve Clearance Symbol
Part No.
Part name
Q'ty
A
Commercially available
Mirror
1
B
Commercially available
Feeler gauge
1
C
Commercially available
Socket wrench
1
Remarks
Width across flats: 22 mm
k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work. Check and adjust this item under the following conditions. Engine coolant temperature: Normal temperature For testing of valve clearance to perform troubleshooting, refer to this section.
Check Valve Clearance 1.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
2.
Remove the cylinder head cover.
3.
Remove the undercover, and insert socket wrench C to the center bolt of the crankshaft pulley.
4.
Remove flywheel housing cap (1).
5.
Rotate the crankshaft in the normal direction while watching the movement of the rocker arm of No. 1 cylinder (flywheel side) and the timing scale on the flywheel. Align stamp line (a) on the flywheel housing with stamp line (b) of No.1/4TOP on the flywheel. REMARK • “1” and “4” are marked on both sides of stamp line (b). • The stamp lines can easily be aligned by using mirror A. • When the piston is at the compression top dead center, the rocker arms of both intake and exhaust valves can be moved by the valve clearance. If they do not move, rotate the crankshaft 1 more turn.
30-22
PC45MR-5, PC55MR-5
30 Testing and Adjusting
6.
Examine and Adjust Valve Clearance
Insert feeler gauge B between the rocker arm and valve cap to test the valve clearance.
%
For standard values, see Standard Value Table, “Standard Value Table for Engine”.
After finishing the test, remove the testing tools and restore the machine. 3 Cylinder head cover mounting nut: 78.4 to 98.0 Nm {8.0 to 10 kgfm}
Adjust Valve Clearance Adjust the valve clearance according to the following procedure, if necessary. 1. Loosen lock nut (2) with adjustment screw (3) fixed. 2. Insert feeler gauge B between the rocker arm and valve cap, and adjust the valve clearance with adjustment screw (3).
REMARK Turn adjustment screw (3) with feeler gauge B inserted, and adjust the valve clearance until the feeler gauge B can move lightly.
For standard value table, see Standard Value Table, “Standard Value Table for Engine”. 3.
With adjustment screw (3) fixed, tighten lock nut (2). 3 Lock nut (2): 25.48±2.94 Nm {2.6±0.3 kgfm}
REMARK • After tightening lock nut (2), check the valve clearance again. • Apply lubricating oil to the contact faces of adjustment screw (3) and push rod. After finishing the adjustment, restore the machine. 3 Cylinder head cover mounting nut: 78.4 to 98.0 Nm {8.0 to 10 kgfm}
PC45MR-5, PC55MR-5
30-23
Examine Compression Pressure
30 Testing and Adjusting
Examine Compression Pressure Tools to Examine Compression Pressure Symbol
Part No.
Part name
Q'ty
A
795-502-1590
B
YM-129A00-92 Compression gauge adapter 950
1
C
795-101-1571
Joint
1
D
6275-11-3890
Gasket
1
Gauge assembly
1
Remarks Pressure range: 0 to 7 MPa
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When testing the compression pressure, be careful not to burn yourself by touching the exhaust
pipe, or get caught in a rotating part. Check this item under the following conditions. •
Engine oil temperature:40 to 60 °C
•
At cranking (engine speed): 250 min-1 {250 rpm} (reference)
For testing of compression pressure to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Compression Pressure 1.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
2.
Set the cylinders to be checked to the compression top dead center. For details, see “Examine and Adjust Valve Clearance”. REMARK Check that both of the intake rocker arm and exhaust rocker arm are at the compression top dead center by moving them by hand as much as the valve clearance.
3.
Remove fuel high-pressure pipe (1) and holder (2), and remove injector (3).
4.
Install gasket D to the tip of compression gauge adapter B and insert them into the mounting part of injector (3).
5.
Fix compression gauge adapter B with injector mounting holder (2). 3 Holder mounting bolt: 25.5±2.9 Nm {2.6±0.3 kgfm}
REMARK Do not reuse the holder mounting bolt. 6.
Connect compression gauge A and joint C to compression gauge adapter B.
7.
Tilt close the floor frame. For details, see “How to Open and Close Floor Unit”.
30-24
PC45MR-5, PC55MR-5
30 Testing and Adjusting
8.
Examine Compression Pressure
Set all the cylinders in “Cylinder Cutout Mode” by referring to “Set and Operate Machine Monitor”. k It is dangerous if all the cylinders are not set in
“Cylinder Cutout Mode” because engine will start. Be sure to set all the cylinders in this mode.
k Make sure that all the cylinders are in the cylinder
cutout mode. 9.
Measure the compression pressure when the engine is cranked by the starting motor. NOTICE Do not crank the engine for 20 seconds or longer to protect the starting motor. REMARK Read the compression pressure when the pointer of gauge is stabilized. For standard values, see Standard Value Table, “Standard Value Table for Engine”.
After finishing the test, remove the testing tools and restore the machine. Install the injectors and fuel high-pressure pipes. Start the engine and check for a fuel leak. NOTICE • When installing the injectors and fuel high-pressure pipes, take care that foreign materials do not stick or enter. • Replace the fuel high-pressure pipes with new ones.
PC45MR-5, PC55MR-5
30-25
Examine Engine Oil Pressure
30 Testing and Adjusting
Examine Engine Oil Pressure Tools to Examine Engine Oil Pressure Symbol
Part No.
Part name
Q'ty
-
799-101-5002
Hydraulic tester
1
1
799-101-5160
Nipple
1
B
790-261-1205
Digital hydraulic tester
1
C
799-401-2320
Gauge
1
A
Remarks
Size: R1/8
Pressure range: 1 MPa
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work. Check this item under the following conditions. Engine coolant temperature: 60 to 100 °C For testing of engine oil pressure to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Engine Oil Pressure 1.
Open the engine rear cover.
2.
Disconnect the connector from engine oil pressure switch (1) of the cylinder block.
3.
Remove engine oil pressure switch (1).
4.
Install nipple A1 of hydraulic tester A and connect them to gauge C.
5.
Start the engine.
30-26
PC45MR-5, PC55MR-5
30 Testing and Adjusting
6.
Raise engine coolant temperature to the specified range.
7.
Set the working mode to P (“Power Mode”) and set each control lever and control pedal to NEUTRAL position.
8.
Measure the engine oil pressure when the fuel control dial is at MAX (High idle) and MIN (Low idle) positions.
Examine Engine Oil Pressure
For standard values, see Standard Value Table, “Standard Value Table for Engine”.
After finishing the test, remove the testing tools and restore the machine.
3 Engine oil pressure switch (1): 3.9 to 6.9 Nm {0.4 to 0.7 kgfm}
PC45MR-5, PC55MR-5
30-27
Bleed Air from Fuel System
30 Testing and Adjusting
Bleed Air from Fuel System
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work. Air bleeding route of fuel system fuel tank→ prefilter→ feed pump→ main filter→ fuel cooler→ fuel tank Fuel feed pump (mechanical)
Rail pressure sensor Rail
Relief valve
Main filter
Supply pump Intake metering valve
Fuel feed pump (electromagnetic) Fuel cooler
Pre-filter
Crank speed sensor
Injector
ECU Gear speed sensor
Fuel tank Flow of injection fuel
Accelerator sensor Flow of intake /return fuel
Flow of electrical signal
For bleeding air from fuel system to perform troubleshooting or periodic maintenance, refer to this section.
How to Bleed Air from Fuel System In the following cases, bleed air according to this procedure. •
When the fuel filter is replaced
• 1.
When fuel has run out
2.
Open the cover at the rear right of the machine.
3.
Set filter vale (1) as shown in the figure.
4.
Loosen air bleeding bolt (2) of the fuel prefilter by 2 to 3 turns.
5.
Tighten air bleeding bolt (2) when the fuel including no air bubbles comes out from air bleeding bolt (2).
Fill the fuel tank with fuel.
3 bleeder bolt (2): 2.5±0.5 Nm {0.25±0.05 kgfm}
6.
Turn the engine starting switch to ON position.
30-28
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Bleed Air from Fuel System
REMARK The air is bled automatically in 10 to 15 seconds after the engine starting switch is turned to ON position.
PC45MR-5, PC55MR-5
30-29
Examine Fuel Circuit for Leakage
30 Testing and Adjusting
Examine Fuel Circuit for Leakage Tools to Examine Leakage in Fuel System Symbol
Part No.
Part name
Q'ty
A
Commercially available
Developer for dye penetrant (color checker)
1
Remarks
k Fuel leakage may result in a dangerous fire due to high pressure generated in the high-pressure cir-
cuit of the fuel system during engine operation. When checking the fuel circuit or removing the component, check that no fuel leaks by performing the following procedure.
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine. Clean the engine and the parts around it, and degrease them in advance so that you can easily check if there is leakage. For testing of fuel system for leakage to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Fuel System for Leakage Examine Fuel Circuit for Leakage at Engine Stop 1.
Start the engine.
2.
Run the engine with fuel control dial at MIN (Low idle) position. Stop the engine after its speed is stabilized.
3.
Spray the color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4.
Check the fuel piping and component for fuel leakage. •
Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is sprayed.
•
If there is a fuel leakage, repair it and perform the testing from step 1 again.
Examine Fuel Circuit for Leakage at Engine Low Idle 1.
Start the engine.
2.
Run the engine with fuel control dial at MIN (Low idle) position. Stop the engine after its speed is stabilized.
3.
Spray the color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4.
Start the engine, and set the fuel control dial to MIN (Low idle).
5.
Stop the engine and check the fuel piping and component for fuel leakage. •
Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is sprayed.
•
If there is a fuel leakage, repair it and perform the testing from step 1 again.
How to Examine Fuel Circuit for Leakage at Engine High Idle 1.
Start the engine.
2.
Run the engine with fuel control dial at MIN (Low idle) position. Stop the engine after its speed is stabilized.
3.
Spray the color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4.
Start the engine, and set the fuel control dial to MAX (High idle) position.
5.
Stop the engine and check the fuel piping and component for fuel leakage. •
Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is sprayed.
•
If there is a fuel leakage, repair it and perform the testing from step 1 again.
30-30
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Handle Cylinder Cut-out Mode Operation
Handle Cylinder Cut-out Mode Operation The cylinder cutout mode operation means to run the engine with the fuel injectors of one or more cylinders disabled electrically to reduce the number of active cylinders. The purposes and effects of cylinder cutout mode operation are as follows. •
Cylinder cutout mode operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal).
•
If the engine speed and output do not change from the normal operation (all-cylinder operation) when a cylinder is cutout with the cylinder cutout mode operation, that cylinder has a failure. The possible failures are as follows.
•
•
Compression gas leakage from cylinder head gasket area
•
Defective injection
•
Defective piston, piston ring or cylinder liner
•
Defective valve mechanism (valve operating system)
•
Defective electrical system
Common rail fuel injection system individually controls the injector of each cylinder electronically , so the cylinder cutout test can be performed easily by the simple operations of the switches compared with the mechanical fuel injection system. So, the defective cylinder can be found out easily.
PC45MR-5, PC55MR-5
30-31
Examine and Adjust Alternator Belt Tension
30 Testing and Adjusting
Examine and Adjust Alternator Belt Tension
k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine. For testing and adjusting the alternator belt tension to perform troubleshooting, refer to this section.
How to Examine Alternator Belt Tension When measuring the belt tension at the position (a) and (b), see “How to Open and Close Floor Unit”. Measure belt deflection at any of the positions (a) to (c) while pressing the intermediate point of V-belt with a finger. Belt pressing force: Approximately 98 N {Approximately 10 kgf} For standard values, see Standard Value Table, “Standard Value Table for Engine”.
Adjust Alternator Belt Tension If the belt deflection is incorrect, adjust it according to the following procedure. 1. Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”. 2.
Loosen mounting bolts (1) and (2) and lock nut (3).
3.
Turn adjustment bolt (4) and adjust the tension. REMARK If you turn adjustment bolt (4) clockwise, the belt tension increases.
4.
After adjusting the belt tension, tighten the mounting bolts in the order of (2) and (1), and then tighten lock nut (3). REMARK Replace the V-belt if there is no clearance between the Vbelt and pulley groove bottom, or if the V-belt is scratched, is stained with lubricating oil, or cracked.
5.
After tightening adjustment bolt (4), check the belt tension again by referring to the preceding testing method. If the belt is replaced, run the engine at low idle for at least 5 minutes to fit the belt, then test and adjust again.
After finishing the adjustment, restore the machine.
30-32
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Air Conditioner Compressor Belt Tension
Examine and Adjust Air Conditioner Compressor Belt Tension
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine. For testing and adjusting the tension of air conditioner compressor belt to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine and Adjust Air Conditioner Compressor Belt Tension (Machine with cab specification) 1. Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
2.
Check the belt tension of air conditioner compressor
Press the belt with a finger at a point midway between idle pulley (3) and compressor (4). (approximately 58.8N {6.0kgf}) If deflection (a) is in the standard range (5 to 6mm), the air conditioner compressor belt tension is correct.
If deflection (a) is out of the standard range, adjust it according to the following procedure. 1) Loosen bolts (5) (M10, 4 pieces) and remove undercover (6).
PC45MR-5, PC55MR-5
30-33
Examine and Adjust Air Conditioner Compressor Belt Tension
2)
Loosen nut (7).
3)
Adjust with adjustment nut (8) of idle pulley (3).
4)
Tighten nut (7) to fix idle pulley (3).
5)
Check the belt tension of air conditioner compressor again.
30 Testing and Adjusting
If the tension is not correct, adjust it again. 6)
Check each pulley for breakage and wear of the Vgroove and check the V-belts for wear. In particular, check carefully that the V-belt is not in contact with the V-groove bottom. If the V-belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks of the belt, ask your Komatsu distributor to replace it. When the new V-belt is installed, readjust it after operating for 1 hour.
7) 3.
Install undercover (6) with bolts (5) (M10, 4 pieces).
Close engine rear cover (1).
30-34
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine Swing Circle Bearing Clearance
Power Train Examine Swing Circle Bearing Clearance Tools to Examine Swing Circle Bearing Clearance Symbol
Part No.
A
Commercially available
Part name Dial gauge
Q'ty
Remarks
1
k Do not put your hand or foot under the truck during the test.
For testing of swing circle bearing clearance to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Swing Circle Bearing Clearance
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine. 1.
Fix dial gauge A to outer race (1) or inner race (2) of the swing circle, and put the probe to the end surface of inner race (2) or outer race (1) on the opposite side. Set dial gauge A in the front or rear of the machine.
2.
Set the work equipment to the maximum reach posture, and set the bucket tip to the height of the underside of the revolving frame. The front side of the upper structure lowers and the rear side rises.
3.
Set dial gauge A to the zero point.
4.
Set the arm almost perpendicular to the ground and lower the boom until the front part of the tracks float by 150 to 200 mm. The front side of the upper structure rises and the rear side lowers.
5.
Read the value indicated by dial gauge A. The value indicated by dial gauge A is the clearance of the bearing.
6.
Return the machine to the state in step 2, and check that dial gauge A indicates 0 point again. If the dial gauge does not indicate 0 point, repeat step 3 through 5.
PC45MR-5, PC55MR-5
30-35
Examine and Adjust Track Tension
30 Testing and Adjusting
Undercarriage and Frame Examine and Adjust Track Tension Tools to Examine Track Shoe Tension Symbol
Part No.
A
Commercially available
Part name Wooden block
Q'ty
Remarks
1
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine. For testing and adjusting of track tension to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Track Tension 1.
Set the fuel control dial to MIN (Low idle), drive the machine forward by the length of track on ground, and then slowly stop it.
2.
Put a bar A on the track shoe between the idler and the first carrier roller. REMARK Use an L shape steel bar, etc. which has few deformation for bar A.
3.
Measure the maximum clearance (a) between bar A and track shoe. Standard max. clearance (a) •
Road liner, iron shoe specification:10 to 30 mm
•
Rubber shoe specification:1 to 3 mm
How to Adjust Track Tension If the track tension is abnormal, adjust it according to the following procedure.
How to Increase the Tension 1.
Pump in grease through grease fitting (1) by using a grease gun.
2.
To check if the tension is correct, run the engine with the fuel control dial at MIN (low idle) position, move the machine slowly forward by length of track on ground, then stop the machine.
3.
After finishing adjustment, recheck that the tension is correct according to the above procedure.
30-36
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Track Tension
How to Decrease the Tension 1.
Loosen valve (2), remove the grease, and tighten valve (5).
k Do not loosen the valve more than one turn, be-
cause the valve may fly out due to the high internal pressure of the grease. 2.
To check if the tension is correct, run the engine with the fuel control dial at MIN (low idle) position, move the machine slowly forward by length of track on ground, then stop the machine.
3.
After finishing adjustment, check that the tension is correct according to the above procedure.
PC45MR-5, PC55MR-5
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Release Remained Pressure in Hydraulic Circuit
30 Testing and Adjusting
Hydraulic System Release Remained Pressure in Hydraulic Circuit For releasing the remaining pressure from hydraulic system to perform troubleshooting periodic maintenance, refer to this section.
How to Release Remained Pressure from Hydraulic Tank Release remaining pressure from the hydraulic tank according to the following procedure since hydraulic tank is sealed and pressurized when removing a hose connected to the hydraulic tank. 1. Lower the work equipment to the ground so that it is stable, and stop the engine. 2.
Remove bracket (1), and loosen oil filler cap (2) of the hydraulic tank gradually to release the air in the tank.
How to Release Remained Pressure in PPC Accumulator Circuit 1.
Turn the starting switch to ON position.
2.
Set the lock lever to FREE position. Operate the R.H. and L.H. work equipment control levers to back and forth, left to right for several times to release the remaining pressure in PPC accumulator circuit.
How to Release Remained Pressure in Hydraulic Cylinder Circuit When disconnecting a pipe between a hydraulic cylinder and the control valve, release the remaining pressure from the circuit according to the following procedure.
How to Release Remaining Pressure from Machine Without Anti-Drop Valve 1.
Release the remaining pressure in the hydraulic tank. See “How to Release Remained Pressure from Hydraulic Tank”. REMARK Leave the oil filler cap of the hydraulic tank removed.
2.
Turn the starting switch to ON position.
3.
Set the lock lever to FREE position, and operate the right and left work equipment control levers forward, backward, rightward, and leftward. REMARK The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is lost by operating the work equipment 2 or 3 times.
4.
Set the lock lever in LOCK position.
5.
Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds to increase the pressure in PPC accumulator.
6.
Repeat steps 2 to 5 several times, and all remaining pressure is released from the hydraulic cylinder circuit completely.
30-38
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Release Remained Pressure in Hydraulic Circuit
How to Release Remaining Pressure from Machine with Anti-Drop Valve for Boom k Place the machine on a level ground.
k When disassembling the anti-drop valve, always release the remaining pressure in the cylinder cir-
cuit. 1.
Check the function of PPC accumulator. 1) Retract arm cylinder and bucket cylinder to the stroke ends (to set the machine in maximum reach posture), and hold the work equipment at height (a) above the ground. (a) : 1.5 m 2)
Keep the arm cylinder and bucket cylinder retracted to the stroke ends, turn the starting switch to OFF position, and stop the engine.
3)
Turn the starting switch to ON position.
4)
Set the lock lever to FREE position.
5)
Operate the work equipment control lever fully in LOWER direction and check that the work equipment is lowered to the ground. NOTICE • Pressure of PPC accumulator drops gradually after the engine stops. Be sure to perform steps 2) to 5) in 15 seconds. • If the work equipment is lowered or stops lowering the bucket halfway through the operation, pressure in PPC accumulator may be low, and pressure cannot be released with this procedure. REMARK • If the work equipment is lowered by its own weight to the ground, the function of PPC accumulator is normal. • PPC accumulator is a periodic inspection item and an important periodic replacement part.
2.
Start the engine.
PC45MR-5, PC55MR-5
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Release Remained Pressure in Hydraulic Circuit
3.
30 Testing and Adjusting
Extend the arm cylinder and bucket cylinder to the end (to the maximum CURL position) or retract them to the end (to the maximum DUMP position), and lower the work equipment to the ground. REMARK Since the anti-drop valve is attached to boom cylinder bottom side, hydraulic oil on bottom side of boom cylinder is drained when work equipment is lowered to the ground, and remaining pressure drops.
4.
Turn the starting switch to OFF position.
5.
Loosen the oil filler cap of the hydraulic tank gradually, and release the air in the tank. REMARK Leave the oil filler cap of the hydraulic tank removed.
6.
Release the remaining pressure in hydraulic cylinder circuit 1) Turn the starting switch to ON position. 2)
Set the lock lever to FREE position, and operate the right and left work equipment control levers forward, backward, rightward, and leftward. REMARK The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is lost by operating the work equipment control levers 2 or 3 times.
7.
3)
Set the lock lever in LOCK position.
4)
Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds to increase the pressure in PPC accumulator.
Repeat steps 1) and 4) 4 or 5 times to release the remaining pressure from the hydraulic cylinder circuit.
k When disassembling the anti-drop valve, loosen anti-drop valve mounting bolts gradually. Make
sure that hydraulic oil pressure is released, then disassemble.
How to Release Remaining Pressure from Machine with Anti-Drop Valve for Arm IN Maximum Arm IN Posture
k Place the machine on a level ground.
k When disassembling the anti-drop valve, always release the remaining pressure in the cylinder cir-
cuit. The following is the procedure for releasing the remaining pressure in the arm maximum IN posture. 1. Check the function of PPC accumulator 1)
Retract arm cylinder and bucket cylinder to the stroke ends (to set the machine in maximum reach posture), and hold the work equipment at height (a) above the ground. (a) : 1.5 m
2)
Keep the arm cylinder and bucket cylinder retracted to the stroke ends, turn the starting switch to OFF position, and stop the engine.
3)
Turn the starting switch to ON position.
4)
Set the lock lever to FREE position.
30-40
PC45MR-5, PC55MR-5
30 Testing and Adjusting
5)
Release Remained Pressure in Hydraulic Circuit
Operate the work equipment control levers fully in LOWER direction and check that the work equipment is lowered to the ground. NOTICE • Pressure of PPC accumulator drops gradually after the engine stops. Be sure to perform steps 2) to 5) in 15 seconds. • If the work equipment is lowered or stops lowering the bucket halfway through the operation, pressure in PPC accumulator may be low, and pressure cannot be released with this procedure. REMARK • If the work equipment is lowered by its own weight to the ground, the function of PPC accumulator is normal. • PPC accumulator is a periodic inspection item and an important periodic replacement part.
2.
Start the engine.
3.
Extend the arm cylinder to the end (to the maximum IN position), and lower the work equipment to the ground. REMARK • Since the anti-drop valve is attached to the arm cylinder head side, hydraulic oil on arm cylinder head side is drained in this posture when work equipment is lowered to the ground, and remaining pressure decreases. • The amount of oil on the head side decreases as well.
4.
Turn the starting switch to OFF position.
5.
Loosen the oil filler cap of the hydraulic tank gradually, and release the air in the tank. REMARK Leave the oil filler cap of the hydraulic tank removed.
6.
Release the remaining pressure in hydraulic cylinder circuit 1) Turn the starting switch to ON position. 2)
Set the lock lever to FREE position, and operate the right and left work equipment control levers forward, backward, rightward, and leftward. REMARK The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is lost by operating the work equipment control levers 2 or 3 times.
7.
3)
Set the lock lever in LOCK position.
4)
Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds to increase the pressure in PPC accumulator.
Repeat steps 1) and 4) 4 or 5 times to release the remaining pressure from the hydraulic cylinder circuit.
k When disassembling the anti-drop valve, loosen anti-drop valve mounting bolts gradually. Make
sure that hydraulic oil pressure is released, then disassemble.
PC45MR-5, PC55MR-5
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Release Remained Pressure in Hydraulic Circuit
30 Testing and Adjusting
How to Release Remaining Pressure from Machine with Anti-Drop Valve for Arm IN Maximum Arm Out Posture
k Place the machine on a level ground.
k When disassembling the anti-drop valve, always release the remaining pressure in the cylinder cir-
cuit. The following is the procedure for releasing the remaining pressure in the arm maximum OUT posture. 1. Check the function of PPC accumulator 1)
Retract arm cylinder and bucket cylinder to the stroke ends (to set the machine in maximum reach posture), and hold the work equipment at height (a) above the ground. (a) : 1.5 m
2)
Keep the arm cylinder and bucket cylinder retracted to the stroke ends, turn the starting switch to OFF position, and stop the engine.
3)
Turn the starting switch to ON position.
4)
Set the lock lever to FREE position.
5)
Operate the work equipment control levers fully in LOWER direction and check that the work equipment is lowered to the ground. NOTICE • Pressure of PPC accumulator drops gradually after the engine stops. Be sure to perform steps 2) to 5) in 15 seconds. • If the work equipment is lowered or stops lowering the bucket halfway through the operation, pressure in PPC accumulator may be low, and pressure cannot be released with this procedure. REMARK • If the work equipment is lowered by its own weight to the ground, the function of PPC accumulator is normal. • PPC accumulator is a periodic inspection item and an important periodic replacement part.
2.
Start the engine.
3.
Retract the arm cylinder to the end (to the maximum OUT position), and lower the work equipment to the ground.
k Since the anti-drop valve is attached to the arm cyl-
inder head side, hydraulic oil on arm cylinder head side remains in this posture, and remaining pressure increases. When releasing the remaining pressure in this posture, increase the number of releasing steps of releasing the remaining pressure. 4.
Turn the starting switch to OFF position.
5.
Loosen the oil filler cap of the hydraulic tank gradually, and release the air in the tank. REMARK Leave the oil filler cap of the hydraulic tank removed.
6.
Release the remaining pressure in hydraulic cylinder circuit 1) Turn the starting switch to ON position.
30-42
PC45MR-5, PC55MR-5
30 Testing and Adjusting
2)
Release Remained Pressure in Hydraulic Circuit
Set the lock lever to FREE position, and operate the right and left work equipment control levers forward, backward, rightward, and leftward. REMARK The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is lost by operating the work equipment control levers 2 or 3 times.
7.
3)
Set the lock lever in LOCK position.
4)
Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds to increase the pressure in PPC accumulator.
Repeat steps 1) and 4) 10 or 15 times to release the remaining pressure from the hydraulic cylinder circuit.
k When disassembling the anti-drop valve, loosen anti-drop valve mounting bolts gradually. Make
sure that hydraulic oil pressure is released, then disassemble.
How to Release Remained Pressure from Swing Motor Circuit When disconnecting a pipe between the swing motor and control valve, release the remaining pressure from the circuit according to the following procedure. 1. Release the remaining pressure in the hydraulic tank. For details, see “How to Release Remained Pressure from Hydraulic Tank”. REMARK Leave the oil filler cap of the hydraulic tank removed. 2.
Turn the starting switch to ON position.
3.
Set the lock lever to FREE position, and operate the right and left work equipment control levers forward, backward, rightward, and leftward. REMARK The pressure in PPC accumulator is lost by operating the work equipment control lever 2 or 3 times.
4.
Set the lock lever in LOCK position.
5.
Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds to increase the pressure in PPC accumulator.
6.
Repeat steps 2 to 5 several times, and all remaining pressure is released from the swing motor circuit completely.
How to Release Remained Pressure from Travel Motor Circuit •
When disconnecting a pipe between the travel motor and control valve, release the remaining pressure from the piping according to the following procedure.
•
The control valve spool of the travel motor circuit is an open circuit. Remaining pressure can be released by performing the same operation as that described in “RELEASE REMAINING PRESSURE IN HYDRAULIC TANK”.
1.
Lower the work equipment to the ground so that it is stable, and stop the engine.
2.
Remove bracket (1), and loosen oil filler cap (2) of the hydraulic tank gradually to release the air in the tank.
PC45MR-5, PC55MR-5
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Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits Tools to Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5120
Gauge
1
Pressure range: 40 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
2
Size: M10 x 1.25 mm
D
07002-11023
O-ring
2
E
Commercially available
A
F
Pin
799T-404–8500 Sensor adapter
1 1
•
Material: SS400
•
Diameter: 50 mm
•
Length: 100 mm
Pressure range: 50 MPa
k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the pressure in the tank. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing and adjusting of oil pressure in work equipment, travel, and boom swing circuits to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits How to Examine Unload Pressure on Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove the cover (1).
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
4.
Remove the plug of pump discharge pressure pickup port (P1) or (P2).
5.
Install nipple C to pump discharged pressure pickup port (P1) or (P2),and connect the coupling (2) or (3) of sensor adapter F. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7.
Connect the connector (P04) of the sensor adapter F to the service pressure connector (P04).
8.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9.
Start the engine.
10. Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2” 11. Adjust the hydraulic oil temperature within the specified range. 12. Set the working mode to P (“Power Mode”). 13. Turn off the auto-deceleration. 14. Start the engine to increase the hydraulic oil temperature to 45 to 55 °C. 15. Set all the control levers and control pedals to NEUTRAL position. 16. Check that each control lever and pedal are in NEUTRAL, turn the fuel control dial to MAX (High idle) position, and check the oil pressure. The unloaded pressure of the unload valve is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Unload Pressure by Testing Tool 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
PC45MR-5, PC55MR-5
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Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
2.
Remove the cover at the rear left of the machine.
3.
Remove cover (1).
4.
Install nipple C to pump discharged pressure pickup port (P1) or (P2), and connect gauge A1 of hydraulic tester A.
30 Testing and Adjusting
REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1. 5.
Set working mode to P (“Power Mode”), turn off auto-deceleration.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Set each control lever and control pedal to NEUTRAL position.
8.
Check that each control lever and pedal are in NEUTRAL, set the fuel control dial to MAX (High idle) position, and check the oil pressure. The unloaded pressure of the unload valve is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
How to Examine Work Equipment Relief Pressure on Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
30-46
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
3.
Remove the cover (1).
4.
Remove the plug of pump discharge pressure pickup port (P1) or (P2).
5.
Install nipple C to pump discharged pressure pickup port (P1) or (P2),and connect the coupling (2) or (3) of sensor adapter F. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7.
Connect the connector (P04) of the sensor adapter F to the service pressure connector (P04).
8.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9.
Start the engine.
10. Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2” 11. Adjust the hydraulic oil temperature within the specified range. 12. Set the working mode to P (“Power Mode”). 13. Operate the cylinder to check (boom, arm, or bucket) to the stroke end. 14. Turn the fuel control dial in MAX (High idle) position and measure the oil pressure when the work equipment circuit to be checked is relieved. PC45MR-5, PC55MR-5
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Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
30 Testing and Adjusting
Relieved pressure of the main relief valve for work equipment and travel circuits is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Work Equipment Relief Pressure by Testing Tool 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove cover (1).
4.
Install nipple C to pump discharged pressure pickup port (P1) or (P2), and connect gauge A1 of hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set the working mode to P (“Power Mode”) mode.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Operate the cylinder to check (boom, arm, or bucket) to the stroke end.
8.
Set the fuel control dial in MAX (High idle) position and measure the oil pressure when the work equipment circuit to be checked is relieved. Relieved pressure of the main relief valve for work equipment and travel circuits is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
How to Examine Travel Relief Pressure on Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
2.
Remove the cover at the rear left of the machine.
3.
Remove the cover (1).
4.
Remove the plug of pump discharge pressure pickup port (P1) or (P2).
5.
Install nipple C to pump discharged pressure pickup port (P1) or (P2),and connect the coupling (2) or (3) of sensor adapter F. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7.
Connect the connector (P04) of the sensor adapter F to the service pressure connector (P04).
8.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9.
Start the engine.
10. Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2” 11. Adjust the hydraulic oil temperature within the specified range. 12. Set the working mode to P (“Power Mode”).
PC45MR-5, PC55MR-5
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Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
30 Testing and Adjusting
13. Insert the pin E between the sprocket and the track frame to securely lock the track. 14. Turn the fuel control dial in MAX (High idle) position and measure the oil pressure at travel relief. k Before
operating the travel lever and the pedal, check the sprocket position locked with pin and locked direction of the travel again.
Relieved pressure of the main relief valve for work equipment and travel circuits is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Travel Relief Pressure by Testing Tool 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove cover (1).
30-50
PC45MR-5, PC55MR-5
30 Testing and Adjusting
4.
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
Install nipple C to pump discharged pressure pickup port (P1) or (P2), and connect gauge A1 of hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set the working mode to P (“Power Mode”) mode.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Insert pin E between the sprocket and the track frame to securely lock the track.
8.
Set the fuel control dial in MAX (High idle) position and measure the oil pressure at travel relief.
k Before operating the travel lever and pedal, check
the sprocket position locked with pin and locked direction of the travel again. Relieved pressure of the main relief valve for work equipment and travel circuits is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
How to Examine Boom Swing Relief Pressure by Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
PC45MR-5, PC55MR-5
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Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
3.
Remove the cover (1).
4.
Remove the plug of pump discharge pressure pickup port (P1) or (P2).
5.
Install nipple C to pump discharged pressure pickup port (P1) or (P2),and connect the coupling (2) or (3) of sensor adapter F.
30 Testing and Adjusting
REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7.
Connect the connector (P04) of the sensor adapter F to the service pressure connector (P04).
8.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9.
Start the engine.
10. Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2” 11. Adjust the hydraulic oil temperature within the specified range. 12. Set the working mode to P (“Power Mode”). 13. Depress the boom swing control pedal, and move the boom swing cylinder to the stroke end. 14. Turn the fuel control dial in MAX (High idle) position and check the oil pressure at swing relief. 30-52
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
Relieved pressure of the main relief valve for work equipment and travel circuits is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Boom Swing Relief Pressure by Testing Tools 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove cover (1).
4.
Install nipple C to pump discharged pressure pickup port (P1) or (P2), and connect gauge A1 of hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set the working mode to P (“Power Mode”) mode.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Depress the boom swing control pedal. Operate the boom swing cylinder to the stroke end.
8.
Set the fuel control dial in MAX (High idle) position and measure the oil pressure at swing relief. Relieved pressure of the main relief valve for work equipment and travel circuits is displayed. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
PC45MR-5, PC55MR-5
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Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits
30 Testing and Adjusting
Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits How to Examine Unload Pressure The unload valve (unload pressure) cannot be adjusted.
Adjust Work Equipment, Travel, and Boom Swing Relief Pressure If the work equipment, travel, and boom swing relief pressures are abnormal, adjust main relief valve (1) according to the following procedure. REMARK (a) in the figure is installed in only 9-spool valve specification.
1.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
2.
Loosen lock nut (2).
3.
Turn adjustment screw (3) to adjust oil pressure. REMARK • Turn adjustment screw (3) clockwise to raise the pressure. Turn the screw counterclockwise to lower the pressure. • Pressure adjustment for 1 turn of adjustment screw (3):Approximately 12.6 MPa {Approximately 128 kgf/cm2}
k Do not turn adjustment screw (3) counterclockwise
more than 1 turn because it may fly out. 4.
After adjusting pressure, tighten lock nut (2). 3 Locknut (2): 39 to 49 Nm {4 to 5 kgfm}
After the adjustment, recheck the oil pressure according to the testing procedure described above.
30-54
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Swing and Blade Circuit Oil Pressure
Examine and Adjust Swing and Blade Circuit Oil Pressure Tools to Examine and Adjust Oil Pressure in Swing and Blade Circuits Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5120
Gauge
1
Pressure range: 40 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
1
Size: M10 x 1.25 mm
D
07002-11023
O-ring
1
E
799T-404–8500 Sensor adapter
A
1
Pressure range: 50 MPa
k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the pressure in the tank. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing and adjusting of oil pressure in swing and blade circuits to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Oil Pressure in Swing and Blade Circuits How to Examine Swing Relief Pressure on Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove the cover (1).
PC45MR-5, PC55MR-5
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Examine and Adjust Swing and Blade Circuit Oil Pressure
4.
30 Testing and Adjusting
Install the nipple C to the gear pump discharge port (P3). Then, connect the coupling (2) or (3) of sensor adapter E. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
5.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
6.
Connect the connector (P04) of the sensor adapter E to the service pressure connector (P04).
7.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
8.
Start the engine.
9.
Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2”
10. Adjust the hydraulic oil temperature within the specified range. 11. Set the working mode to P (“Power Mode”). 12. Turn the fuel control dial in MAX (High idle) position, relieve the left and right swing circuit with the swing control lever, and test the oil pressure.
k When relieving the swing circuit with the swing control lever, securely lock the upper structure
by using the work equipment. The set pressure of the swing motor safety valve is lower than that of the main relief valve. If the swing circuit is relieved, the set pressure of the safety valve is the same as the set pressure of the safety valve. For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Swing Relief Pressure by Testing Tool 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
30-56
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Swing and Blade Circuit Oil Pressure
3.
Remove cover (1).
4.
Install nipple C to gear pump discharged port (P3), and connect gauge A1 of hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set working mode to P (“Power Mode”), turn off auto-deceleration.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Set the fuel control dial in MAX (High idle) position, perform right or left swing relief, and measure the oil pressure.
k When
performing swing relief by operating the swing control lever, lock the machine securely by using the work equipment.
Set pressure of swing motor safety valve is lower than the set pressure of main relief valve. Increase the set pressure by performing swing relief. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
How to Examine Blade Relief Pressure by Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
PC45MR-5, PC55MR-5
30-57
Examine and Adjust Swing and Blade Circuit Oil Pressure
3.
Remove the cover (1).
4.
Remove the plug of gear pump discharge pressure pickup port (P3).
5.
Install nipple C to gear pump discharge pressure pickup port (P3),and connect the coupling (2) or (3) of sensor adapter E.
30 Testing and Adjusting
REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7.
Connect the connector (P04) of the sensor adapter E to the service pressure connector (P04).
8.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9.
Start the engine.
10. Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2” 11. Adjust the hydraulic oil temperature within the specified range. 12. Set the working mode to P (“Power Mode”). 13. Operate the blade to the stroke end. 14. Turn the fuel control dial in MAX (High idle) position and check the oil pressure when the blade circuit is relived. 30-58
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Swing and Blade Circuit Oil Pressure
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Blade Relief Pressure by Testing Tool 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove cover (1).
4.
Install nipple C to gear pump discharged port (P3), and connect gauge A1 of hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set the working mode to P (“Power Mode”) mode.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Operate the blade to the stroke end.
8.
Set the fuel control dial in MAX (High idle) position, and measure the oil pressure when the blade circuit is relieved. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
PC45MR-5, PC55MR-5
30-59
Examine and Adjust Swing and Blade Circuit Oil Pressure
30 Testing and Adjusting
Adjust Oil Pressure in Swing and Blade Circuits How to Adjust Swing Relief Pressure If the swing relief pressure is abnormal, adjust safety valve (1) of the swing motor according to the following procedure.
1.
Check that the blade relief pressure is normal.
2.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
3.
Loosen lock nut (2) of safety valve (1) and turn end cap (adjustment screw) (3) to adjust the pressure.
k Do not turn end cap (adjustment screw) (3) counterclockwise more than 1 turn because it may fly
out. NOTICE • If end cap (adjustment screw) (3) is turned clockwise, the pressure increases. • If end cap (adjustment screw) (3) is turned counterclockwise, the pressure decreases. Quantity of adjustment per turn of end cap (adjustment nut) (3): 17.4 MPa {178 kgf/cm2} 4.
After adjusting, tighten lock nut (2) with end cap (adjustment screw) (3) fixed. 3 Locknut (2): 93.2 to 117.7 Nm {9.5 to 12 kgfm}
After the adjustment, recheck the oil pressure according to the testing procedure described above.
Adjust Blade Relief Pressure If the blade relief pressure is abnormal, adjust relief valve (4) according to the following procedure. REMARK If the blade relief pressure is below the set swing relief pressure, the swing relief pressure decreases as well.
30-60
PC45MR-5, PC55MR-5
30 Testing and Adjusting
1.
Examine and Adjust Swing and Blade Circuit Oil Pressure
Loosen lock nut (5) of main relief valve (4) and turn end cap (adjustment screw) (6) to adjust the pressure. k Do not turn end cap (adjustment screw) (6) counter-
clockwise more than 1 turn. If it is turned more, it may fly out. REMARK • If end cap (adjustment screw) (6) is turned clockwise, the pressure increases. • If end cap (adjustment screw) (6) is turned counterclockwise, the pressure decreases. Quantity of adjustment per turn of end cap (adjustment nut) (6): 19.6 MPa {200 kgf/cm2} 2.
After adjusting, tighten lock nut (5) with end cap (adjustment screw) (6) fixed.
3 Locknut (5): 39 to 49 Nm {4 to 5 kgfm}
After the adjustment, recheck the oil pressure according to the testing procedure described above.
PC45MR-5, PC55MR-5
30-61
Examine and Adjust Oil Pressure in Control Circuit
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Control Circuit Tools to Examine and Adjust Control Circuit Oil Pressure Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
1
Size: M10 x 1.25 mm
D
07002-11023
O-ring
1
E
799T-404–8500 Sensor adapter
A
1
Pressure range: 50 MPa
k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the pressure in the tank. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing and adjusting of control circuit pressure to perform troubleshooting or periodic maintenance, refer to this section.
Examine Oil Pressure in Control Circuit How to Examine Oil Pressure of Control Circuit by Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover on the rear L.H side of the machine.
3.
Remove the cover (1).
4.
Remove the plug of pilot pump pressure pickup port (1).
30-62
PC45MR-5, PC55MR-5
30 Testing and Adjusting
5.
Examine and Adjust Oil Pressure in Control Circuit
Install the nipple C, and connect the coupling (2) or (3) of sensor adapter E. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Open the floor. See “METHOD FOR OPENING AND CLOSING FLOOR”.
7.
Connect the connector (P04) of the sensor adapter E to the service pressure connector (P04).
8.
Start the engine.
9.
Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2”
10. Adjust the hydraulic oil temperature within the specified range. 11. Set the working mode to P (“Power Mode”). 12. Turn off the auto-deceleration. 13. Turn the fuel control dial to MAX (High idle) position and check the oil pressure when all the control levers and pedals are in NEUTRAL. For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Oil Pressure of Control Circuit by Testing Tools 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove cover (1).
PC45MR-5, PC55MR-5
30-63
Examine and Adjust Oil Pressure in Control Circuit
4.
30 Testing and Adjusting
Install nipple C to pilot pump pressure output port (1), and connect gauge A1 of hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set working mode to P (“Power Mode”), turn off auto-deceleration.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Set the fuel control dial to MAX (High idle) position and check the oil pressure when all the control levers and pedals are in NEUTRAL. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
Adjust Oil Pressure in Control Circuit If the oil pressure in the control circuits is abnormal, adjust control relief valve (2) according to the following procedure.
1.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
30-64
PC45MR-5, PC55MR-5
30 Testing and Adjusting
2.
Examine and Adjust Oil Pressure in Control Circuit
Loosen lock nut (3) of relief valve (2) and turn adjustment screw (4) to adjust. REMARK • If adjustment screw (4) is turned clockwise, the pressure increases. • If adjustment screw (4) is turned counterclockwise, the pressure decreases. Quantity of adjustment per turn of adjustment screw (4): 0.92 MPa {9.4 kgf/cm2}
3.
After adjusting, tighten lock nut (3) with adjustment screw (4) fixed. 3 Locknut (3): 9.8 Nm {1.0 kgfm}
4.
Tilt close the floor frame. For details, see “How to Open and Close Floor Unit”.
After the adjustment, recheck the oil pressure according to the testing procedure described above.
PC45MR-5, PC55MR-5
30-65
Adjust Oil Pressure in Pump PC Control Circuit
30 Testing and Adjusting
Adjust Oil Pressure in Pump PC Control Circuit NOTICE Before starting the adjustment, check the oil pressures of following circuits are normal (work equipment, travel, boom swing, and control). Perform this adjustment item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For adjusting of pump PC control circuit oil pressure to perform troubleshooting, refer to this section.
How to Adjust Oil Pressure in Pump PC Control Circuit When the phenomena shown below occur and PC valve (1) seems to be defective, adjust it according to the following procedure. •
When the working load increases, the engine speed drops largely.
•
The engine speed is normal but the work equipment speed is low.
NOTICE Do not turn the lock nuts and adjustment screws other than the lock nut for adjusting PC-valve (1), since they affect the hydraulic pump performance. REMARK The width across flats of lock nut (2) for PC valve (1) is 19 mm, and the width across flats (inside) of the adjustment screw (3) is 5 mm. 1. Put a matchmark on the end surface of adjustment screw (3) and valve body. REMARK Put matchmark (b) to indicate the position before adjustment so that you can return the adjustment screw to the original position if you turn it in the opposite direction. 2.
Loosen lock nut (2).
3.
Turn adjustment screw (3) to adjust oil pressure. NOTICE The turning direction changes depends on the position of punch mark (a) because of the eccentric cam adjustment screw (3). Structurally, adjustable range of adjustment screw (3) is within 180 ° however actual adjustable range of the screw is within 90 ° when turning the screw clockwise and counterclockwise. •
When the work equipment speed is low, turn adjustment screw (3) in the direction to increase the pump absorption torque.
•
When the engine speed is low, turn adjustment screw (3) in the direction to decrease the pump absorption torque. Adjustable Range of Adjustment Screw (3)
Mark (a) made before adjustment
Within range of (e) in figure
Within range of (f) in figure
Turn the screw counterclockwise within a range of 90 °.
Pump absorption torque decreases
Pump absorption torque increases
30-66
PC45MR-5, PC55MR-5
30 Testing and Adjusting
4.
Adjust Oil Pressure in Pump PC Control Circuit
Mark (a) made before adjustment
Within range of (e) in figure
Within range of (f) in figure
Turn the screw clockwise within a range of 90 °.
Pump absorption torque increases
Pump absorption torque decreases
With adjustment screw (3) fixed, tighten lock nut (2). 3 Locknut (2): 27.4 to 34.4 Nm {2.8 to 3.5 kgfm}
PC45MR-5, PC55MR-5
30-67
Examine and Adjust Oil Pressure in Pump LS Control Circuit
30 Testing and Adjusting
Examine and Adjust Oil Pressure in Pump LS Control Circuit Tools to Examine and Adjust Pump LS Control Circuit Oil Pressure Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5120
Gauge
2
Pressure range: 40 MPa
2
799-101-5160
Nipple
2
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799-401-3200
Adapter
1
Size: 03
E
799-401-2701
Differential pressure gauge
1
Pressure range: 50 MPa
F
799T-404–8500 Sensor adapter
1
Pressure range: 50 MPa
A
k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the pressure in the tank. NOTICE Before starting the test, check that the oil pressures in the work equipment, travel, boom swing, and control circuits are normal. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing and adjusting of oil pressure in pump LS control circuit to perform troubleshooting or periodic maintenance, refer to this section.
Examine LS Differential Pressure with Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Remove the cover at the rear left of the machine.
3.
Remove the cover (1).
4.
Disconnect the hose (2) (pump discharge pressure side) and the hose (3) (LS pressure side).
5.
Connect the adapter C to the pump discharge pressure side, and the adapter D to the LS pressure side.
30-68
PC45MR-5, PC55MR-5
30 Testing and Adjusting
6.
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Install the nipple A2 to the adapter C, and D. Then, connect the coupling (4) or (5) of sensor adapter F. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
7.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
8.
Connect the connector (P04) of the sensor adapter F to the service pressure connector (P04).
9.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
10. Start the engine.
11. Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2” 12. Adjust the hydraulic oil temperature within the specified range. 13. Set all the control levers and the control pedals in NEUTRAL position, and set the lock lever in OFF position. 14. Operate the work equipment and move the cylinders as follows. •
Boom cylinder: Fully extended
•
Arm cylinder: Fully retracted
•
Bucket cylinder: Fully retracted
15. Turn the fuel control dial in MAX (High idle) position, and measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously when each control lever and control pedal are in NEUTRAL position or bucket CURL control lever is moved to full stroke position. REMARK Calculating LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
Examine LS Differential Pressure by Testing Tool To obtain the LS differential pressure, measure the pump discharged pressure and LS pressure (actuator load pressure) simultaneously, and calculate the difference. 1. Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”. 2.
Remove the cover at the rear left of the machine.
PC45MR-5, PC55MR-5
30-69
Examine and Adjust Oil Pressure in Pump LS Control Circuit
3.
Remove cover (1).
4.
Disconnect hoses (2) (pump discharged pressure side) and (3) (LS pressure side).
5.
Connect adapter C to the pump discharged pressure side, and connect adapter D to LS pressure side.
6.
Install nipples A2 to adapters C and D. Connect differential pressure gauge E or gauge A1 of hydraulic tester A. •
30 Testing and Adjusting
When using differential pressure gauge E, connect the high-pressure side (rear side) to the pump discharged pressure and the low-pressure side (bottom side) to LS pressure. REMARK Since the differential pressure gauge needs 12 V DC power, connect it to 1 battery.
•
When using gauge A1, measure the pressure while replacing the same gauge since the differential pressure goes up to approximately 2.9 MPa {approximately 30 kgf/cm2} at maximum. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
7.
Set all control levers and control pedals in NEUTRAL position, and set the lock lever in OFF position.
8.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
30-70
PC45MR-5, PC55MR-5
30 Testing and Adjusting
9.
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Set each cylinder in the following state by operating the work equipment. •
Boom cylinder: Fully extended
•
Arm cylinder: Fully retracted
•
Bucket cylinder: Fully retracted
10. Set the fuel control dial in MAX (High idle) position, and measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously when each control lever and control pedal are in NEUTRAL position or bucket CURL control lever is moved to full stroke position. REMARK Calculating LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
Adjust LS Valve If the LS differential pressure is abnormal, adjust LS valve (1) according to the following procedure.
1.
Put a matchmark on the end surfaces of adjustment screw (2) and lock nut (3). REMARK Put a matchmark on the end face of adjustment plug (2) and lock nut (3) to indicate the original position of the adjustment screw (so that you can return the adjustment screw to the original position if you turn it in the opposite direction).
2.
While fixing adjustment plug (2), loosen lock nut (3).
3.
Turn adjustment plug (2) and adjust differential pressure. REMARK If adjustment plug (2) is • Turned clockwise, differential pressure increases. • Turned counterclockwise, differential pressure decreases. (Reference) Adjustable range of adjustment plug (2) is as follows: • Counterclockwise: Within 180 ° •
4.
Clockwise: Within 180 °
While fixing adjustment plug (2), tighten lock nut (3).
3 Locknut (3): 27.4 to 34.3 Nm {2.8 to 3.5 kgfm}
After finishing adjustment, check that LS differential pressure is normal. For details, see above described “METHOD FOR TESTING LS DIFFERENTIAL PRESSURE”.
PC45MR-5, PC55MR-5
30-71
Examine Outlet Pressure of Solenoid Valve
30 Testing and Adjusting
Examine Outlet Pressure of Solenoid Valve Tools to Examine Solenoid Valve Outlet Pressure Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
3
790-301-1530
Elbow
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799T-404–8500 Sensor adapter
1
Pressure range: 50MPa
A
k Lower the work equipment to the ground in a stable posture, and stop the engine. Operate the con-
trol levers several times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the pressure in the tank. Before the test, check the control circuit oil pressure is normal. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing of solenoid valve outlet pressure to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Outlet Pressure of Solenoid Valve by Machine Monitor 1.
Release the remaining pressure by referring to “Release Remained Pressure in Hydraulic Circuit”.
2.
Open the floor. see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
3.
Disconnect the outlet hose (1) or (2) of the solenoid valves to be tested. (1): PPC lock solenoid valve (2): 2nd travel speed selector solenoid valve
4.
Connect the adapter C and connect the disconnected hose again.
30-72
PC45MR-5, PC55MR-5
30 Testing and Adjusting
5.
Examine Outlet Pressure of Solenoid Valve
Install the elbow A3, and the nipple C to the adapter C. Then, connect the coupling (3) or (4) of sensor adapter D. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Connect the connector (P04) of the sensor adapter D to the service pressure connector (P04).
7.
Start the engine.
8.
Select and display (12/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2”
9.
Adjust the hydraulic oil temperature within the specified range.
10. Set the working mode to P (“Power Mode”). 11. Turn off the auto-deceleration. 12. Turn the fuel control dial to MAX (High idle) position. Check the outlet pressure by operating each control levers and switches to turn ON or OFF the solenoid valve. REMARK For the conditions for turning the solenoid valve ON/OFF, see “Operating Condition of Solenoid Valve”. For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
How to Examine Outlet Pressure of Solenoid Valve by Testing Tool 1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
3.
Disconnect outlet hose (1) or (2) of the tested solenoid valve. (1): PPC lock solenoid valve (2): 2nd travel speed selector solenoid valve
PC45MR-5, PC55MR-5
30-73
Examine Outlet Pressure of Solenoid Valve
30 Testing and Adjusting
4.
Connect adapter C, and connect the disconnected hose again.
5.
Install elbow A3 and nipple A2 to adapter C, and connect them to gauge A1. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
6.
Tilt close the floor frame. For details, see “How to Open and Close Floor Unit”.
7.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
8.
Set the fuel control dial to MAX (High idle) position and operate each control levers and switches. Measure the outlet pressure when the solenoid valve is turned ON or OFF. REMARK For the conditions for turning the solenoid valve ON/OFF, see “Operating Condition of Solenoid Valve”. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
Operating Condition of Solenoid Valve (1) PPC Lock Solenoid Valve Operation Table Operating condition of solenoid valve
Operating state of solenoid valve
LOCK position (Lock)
OFF (De-energized)
FREE position (Free)
ON (Energized)
Lock lever
(2) Operation Table of 2nd Travel Speed Selector Solenoid Valve Operating condition of solenoid valve
Travel speed selector switch
30-74
Operating state of solenoid valve
OFF (Travel mode: Lo)
OFF (De-energized)
ON (Travel mode: Hi)
ON (Energized)
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine PPC Valve Outlet Pressure
Examine PPC Valve Outlet Pressure Tools to Examine PPC Valve Outlet Pressure Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799T-404–8500 Sensor adapter
1
Pressure range: 50 MPa
A
Before the test, check the control circuit oil pressure is normal. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing of PPC valve outlet pressure to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Outlet Pressure of PPC Valve with Machine Monitor Circuit diagram of PPC valve and control valve
1: Control valve
5: Boom swing PPC valve
2: Travel PPC valve
6: Blade PPC valve
3. R.H. PPC valve
7: Junction block
4. L.H. PPC valve
PC45MR-5, PC55MR-5
30-75
Examine PPC Valve Outlet Pressure
30 Testing and Adjusting
PPC Valve Piping Connection Table Circuit testing and operation
Port names on control valve side
Band color
L.H. travel (forward)
PA1
Brown/Yellow
L.H. travel (reverse)
PB1
Orange/Yellow
R.H. travel (forward)
PA2
Black/Yellow
R.H. travel (reverse)
PB2
Green/Yellow
Boom LOWER
PA3
Black
Boom RAISE
PB3
Yellow
Arm OUT
PA4
Orange
Arm IN
PB4
Green
Bucket DUMP
PA5
Red
Bucket CURL
PB5
Blue
Boom swing RIGHT
PA6
White/Blue
Boom swing LEFT
PB6
White/Red
Blade RAISE
PA7
Red/Yellow
Blade LOWER
PB7
Blue/Yellow
Turn LEFT
PA8
White
Turn RIGHT
PB8
Brown
The travel PPC valve outlet pressure can be monitored on the machine monitor. Select and display (14/14) “Predefined Mon” or monitoring code: 07101 “Travel PPC Pressure” in “SET AND OPERATE MACHINE MONITOR”, and perform testing. REMARK PPC valve outlet pressures other than the travel PPC valve outlet pressure can be monitored by using the sensor adapter D. For the method of using sensor adapter D, see the following procedure.
1.
Release the remaining pressure in the hydraulic cylinder circuit. See “Release Remained Pressure in Hydraulic Circuit”.
2.
Open the floor. See “METHOD FOR OPENING AND CLOSING FLOOR”.
3.
Disconnect the hoses of PPC circuit to be tested on PCC valve side or control valve side.
4.
Connect the adapter C and connect the disconnected hose again.
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
5.
Examine PPC Valve Outlet Pressure
Install the nipple A2 of hydraulic tester A, and connect the coupling (7) or (8) of sensor adapter D. REMARK • Connector (P11) side is displayed by monitoring code: 01141 “Service Press. Sens1”. • Connector (P12) side is displayed by monitoring code: 01142 “Service Press. Sens2”.
6.
Connect the connector (P04) of sensor adapter D to service pressure connector (P04).
7.
Start the engine.
8.
Select and display (14/14) “Predefined Mon” or following monitoring item on “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 01141“ Service Press. Sens1” Monitoring code: 01142“ Service Press. Sens2”
9.
Adjust the hydraulic oil temperature within the specified range.
10. Set the working mode to P (“Power Mode”). 11. Turn the fuel control dial in MAX (High idle) position, and measure the oil pressure under the following conditions. •
Each control lever and control pedal are in NEUTRAL
•
Control levers and control pedals of circuit to be tested are operated to stroke end For standard values, see Standard Value Table, “Standard Value Table for Machine”. REMARK The band colors identifies the installed hoses.
After finishing the test, remove the testing tools and restore the machine.
PC45MR-5, PC55MR-5
30-77
Examine PPC Valve Outlet Pressure
30 Testing and Adjusting
How to Examine Outlet Pressure of PPC Valve by Testing Tool Circuit diagram of PPC valve and control valve
1: Control valve
5: Boom swing PPC valve
2: Travel PPC valve
6: Blade PPC valve
3: R.H. PPC valve
7: Junction block
4: L.H. PPC valve PPC Valve Piping Connection Table Circuit for testing, Operation
Port name on control valve side
Band color
L.H. travel (FORWARD)
PA1
Brown/Yellow
L.H. travel (REVERSE)
PB1
Orange/Yellow
R.H. travel (FORWARD)
PA2
Black/Yellow
R.H. travel (REVERSE)
PB2
Green/Yellow
Boom LOWER
PA3
Black
Boom RAISE
PB3
Yellow
Arm OUT
PA4
Orange
Arm IN
PB4
Green
Bucket DUMP
PA5
Red
Bucket CURL
PB5
Blue
Boom swing RIGHT
PA6
White/Blue
Boom swing LEFT
PB6
White/Red
Blade RAISE
PA7
Red/Yellow
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine PPC Valve Outlet Pressure
Circuit for testing, Operation
Port name on control valve side
Band color
Blade LOWER
PB7
Blue/Yellow
Turn LEFT
PA8
White
Turn RIGHT
PB8
Brown
“Travel PPC Pressure” can be checked with the machine monitor. For the machine monitor operating method, see the section of “SET AND OPERATE MACHINE MONITOR”.
1.
Release the remaining pressure. For details, see “Release Remained Pressure in Hydraulic Circuit”.
2.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
3.
Disconnect the hose of tested PPC circuit from PPC valve or control valve.
4.
Install adapter C, install nipple A2 of hydraulic tester A, and connect gauge A1. REMARK Gauge in digital hydraulic tester B can also be used in place of gauge A1.
5.
Set the working mode to P (“Power Mode”) mode.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Set the fuel control dial in MAX (high idle) position, and measure the oil pressure under the following condition. •
When each control lever and control pedal is in neutral
•
When control lever and control pedal in tested circuit are operated to stroke end REMARK The band colors are used to distinguish the hoses.
For standard values, see Standard Value Table, “Standard Value Table for Machine”. After finishing the test, remove the testing tools and restore the machine.
PC45MR-5, PC55MR-5
30-79
Adjust Play of Work Equipment and Swing PPC Valves
30 Testing and Adjusting
Adjust Play of Work Equipment and Swing PPC Valves If the right and left work equipment levers have large play, adjust them according to the following procedure. For adjusting the play of work equipment PPC valve and swing PPC valve to perform troubleshooting, refer to this section.
How to Adjust Play of Work Equipment and Swing PPC Valves 1.
Remove the boot (1).
2.
Loosen the locknut (2) and tighten it until disc (3) touches the heads of pistons (4) (4 pieces). REMARK Do not move the piston when tightening.
3.
Fix the position of disc (3) and tighten lock nut (2) to the specified torque. 3 Lock nut (2): 68 to 88 Nm {7 to 9 kgfm}
4.
Apply gear oil and grease to the rocking portion of the joint. 2 Rocking portion of joint: Grease (G2-LI)
REMARK • Apply 7 to10 mℓ of grease to all periphery (a) of the pin. • Apply 0.2 to 0.4 mℓ of gear oil to sliding portions (b) of joint and pin (4 places). 5.
Install the boot (1).
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine Swing Parking Brake Release Pressure
Examine Swing Parking Brake Release Pressure Tools to Examine Release Pressure in Swing Parking Brake Symbol
Part No.
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70MPa
C
799-401-3100
Adapter
1
Size: 02
A
k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the pressure in the tank. Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing of swing parking brake release pressure to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Swing Parking Brake Release Pressure with Machine Monitor For the machine monitor operating method, see the section of “SET AND OPERATE MACHINE MONITOR”. 1. Select and display “Swing PPC Pressure” on “Monitoring Selection Menu”. For details, see “Set and Operate Machine Monitor”. Monitoring code: 09000 “Swing PPC Pressure” 2.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
3.
Set the fuel control dial in MAX (high idle) position, and measure the oil pressure under the following condition. •
When the control lever is operated to swing RIGHT or swing LEFT
•
When the control lever is operated to move the arm IN
For standard values, see Standard Value Table, “Standard Value Table for Machine”.
How to Examine Swing Parking Brake Release Pressure by Testing Tool 1.
Release the remaining pressure. For details, see RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Tilt open the floor frame. For details, see “How to Open and Close Floor Unit”.
3.
Disconnect swing motor inlet hose (1).
PC45MR-5, PC55MR-5
30-81
Examine Swing Parking Brake Release Pressure
4.
Connect adapter C, install nipple A2, and connect gauge A1 of hydraulic tester A.
5.
Tilt close the floor frame. For details, see “How to Open and Close Floor Unit”.
6.
Start the engine to increase the hydraulic oil temperature to 45 to 55 °C.
7.
Set the fuel control dial in MAX (high idle) position, and measure the oil pressure under the following condition. •
When the control lever is operated to swing RIGHT or swing LEFT
•
When the control lever is operated to move the arm IN
30 Testing and Adjusting
For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Travel Deviation
Examine and Adjust Travel Deviation Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing and adjusting of travel deviation, refer to this section.
How to Examine Travel Deviation 1.
Run the engine and keep the hydraulic oil temperature to the testing condition range.
2.
Fully extend the bucket cylinder, arm cylinder, and blade cylinder, and keep the boom angle at 45 °.
3.
Set the working mode to P (“Power Mode”).
4.
Set the travel mode to Lo.
5.
Turn the fuel control dial to MAX (High idle) position.
6.
Run up 10 m with the engine speed at high idle and then travel 20 m continuously, and measure deviation (a). REMARK Check that the discharged pressures of main pumps P1 and P2 are even. See “Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits”.
How to Adjust Travel Deviation
k If the adjustment plug is loosened more than the adjustment limit, high-pressure oil can be splashed.
Do this operation carefully.
k Lower the work equipment to the ground, stop the engine, and operate the control lever several
times to release the remaining pressure in the piping. And then, loosen the oil filter cap of the hydraulic tank slowly to release the pressure in the tank.
PC45MR-5, PC55MR-5
30-83
Examine and Adjust Travel Deviation
30 Testing and Adjusting
REMARK • If the travel deviation occurs, drain part of the larger pump discharged volume to the tank circuit with the travel deviation adjustment plug. The travel deviation can be adjusted. • Be careful during this adjustment. The travel speed, work equipment speed during the combined operations, and relief pressure can be decreased because of decrease in the pump discharged volume. • With this adjustment, you can adjust the travel deviation in the same direction for the forward and reverse travel. (If the direction of travel deviation is different for forward travel and reverse travel, it is possible that the trouble occurred in devices other than the hydraulic pump. See “40 Troubleshooting”, “MACHINE DOES NOT TRAVEL STRAIGHT” to do the troubleshooting.) • The travel deviation can be adjusted with this procedure only when the deviation amount is 200 mm or below. 1. Remove the triangle cover on the rear left of the machine. 2.
Remove the cover (1).
3.
Check the direction of the travel deviation and the position of the travel deviation adjustment plug (2) or (3). (2): Right deviation adjustment plug (P1 pressure side) (3): Left deviation adjustment plug (P2 pressure side) REMARK Adjust the deviation only with the plug at one side. Do not loosen the plug at the opposite side.
4.
Before you loosen the lock nut (4), put a matchmark on the lock nut (4) and the pump case.
5.
While the adjustment plug (2) or (3) is fixed with the hexagonal wrench (width across flats: 4 mm), loosen the lock nut (4). REMARK • Insert the hexagonal wrench into the adjustment plug securely. • When the lock nut is sealed with the vinyl seal, remove the vinyl seal before the work. Loosening angle of lock nut (4): Approx. 90 to 180 °
6.
Loosen the adjustment plug (2) or (3) to adjust the travel deviation. Adjustment quantity of travel deviation for each turn of adjustment plug (2), (3): 150 mm (Reference) NOTICE Be sure not to turn the adjustment plug (2) or (3) more than the adjustment limit (2 turns).
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine and Adjust Travel Deviation
REMARK • The adjustment plug (2) or (3) is already loosened in some cases, for adjustment of the travel deviation at shipment. Before the adjustment, tighten the adjustment plug (2) or (3) to the torque value that follows. • If the plug rotates together while you loosen the lock nut, tighten the adjustment plug (2) or (3) fully, and then adjust it. 3 Adjustment plug (2) or (3): 2.94 to 4.9 Nm {0.3 to 0.5 kgfm} • The adjustment plug (2) or (3) can be loosened (turn counterclockwise) by 2 turns from the fully tightened state. 7.
While the adjustment plug (2) or (3) is fixed, tighten the lock nut (4).
3 Lock nut (4): 11.8 to 14.7 Nm {1.2 to 1.5 kgfm}
REMARK • Hexagonal wrench: Width across flats 4 mm • Tighten the lock nut (4), and then seal the hole of the lock nut (4) with the vinyl seal. 8.
After the adjustment is completed, check the travel deviation again. For details, see “How to Examine Travel Deviation”.
PC45MR-5, PC55MR-5
30-85
Examine Parts Which Cause Hydraulic Drift of Work Equipment
30 Testing and Adjusting
Examine Parts Which Cause Hydraulic Drift of Work Equipment If the cause of hydraulic drift is defective cylinder packing, lowering speed may increase during the test because of the reasons as follows. •
Oil leaks from the bottom side to the head side when the machine is set in the measuring posture for hydraulic drift (where the holding pressure is applied to the bottom side). Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side.
•
As pressure in the bottom side (varies depending on the leakage amount) increases, the pressure in the head side increases and pressures are balanced on both side, and then lowering speed decreases. At this time, operate the lever to the direction that head side oil in tested cylinder is drained to tank circuit, and head side oil flows to drain circuit (bottom side is blocked by check valve), and pressure balance between head side and bottom side is lost, and then lowering speed increases.
For testing of the isolating of the part causing hydraulic drift in work equipment to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 1.
Set the work equipment in the same posture as the time when measuring hydraulic drift, and stop the engine.
2.
Apply rated load to the bucket. Rated load
3.
•
PC45MR-5: 2254 N {230 kgf}
•
PC55MR-5: 2450 N {250 kgf}
When testing the boom cylinder, set the boom control lever to RAISE position. When testing the bucket cylinder, set the bucket control lever to CURL position. Judging method •
When the lowering speed is increased at this time: The cylinder packing is defective.
•
No change: The control valve is defective.
REMARK If the accumulator pressure is reduced, run the engine for approximately 5 seconds to accumulate the pressure.
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 1.
Move the arm cylinder, stop it at approximately 100 mm before IN stroke end, and stop the engine.
2.
Turn the starting switch to ON position.
3.
Operate the arm control lever to IN to test. Identifying causes •
When the lowering speed is increased at this time: The cylinder packing is defective.
•
When no change occurs: The control valve is defective.
REMARK If the accumulator pressure decreases, run the engine for approximately 10 seconds to accumulate the pressure.
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine Parts Which Cause Hydraulic Drift of Work Equipment
How to Examine Parts that Cause Hydraulic Drift of PPC Valve Measure the hydraulic drift of the work equipment when the lock lever is in LOCK and FREE positions with the accumulator charged fully. In case there is a difference of hydraulic drift between LOCK and FREE positions, the PPC valve is defective (internal defect). NOTICE Operate the lock lever when the starting switch is turned to ON position. REMARK If the accumulator pressure decreases, run the engine for approximately 10 seconds to accumulate the pressure.
PC45MR-5, PC55MR-5
30-87
Examine Oil Leakage
30 Testing and Adjusting
Examine Oil Leakage Tools to Examine Oil Leakage Symbol
Part No.
Part name
Q'ty
A
Commercially available
Measuring cylinder
1
B
07376-70422
Plug
1
C
Commercially available
Block
1
Remarks
Size: 04
Check this item under the following conditions. Hydraulic oil temperature: 45 to 55 °C For testing of oil leakage to perform troubleshooting or periodic maintenance, refer to this section.
How to Examine Oil Leakage from Boom Cylinder 1.
Set the boom cylinder at RAISE stroke end, and stop the engine.
2.
Release the remaining pressure from the piping on the boom cylinder head side. For details, see “Release Remained Pressure in Hydraulic Circuit”. REMARK Operate the lever in the boom RAISE direction only to release the remaining pressure.
3.
Disconnect hose (1) on the cylinder head side, and block the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side. 4.
Start the engine, and perform boom RAISE relief with the fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Boom LOW-
ER” side. 5.
30 seconds after relief starts, measure the leakage from the cylinder head side for 1 minute by using measuring cylinder A. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, remove the testing tools and restore the machine.
How to Examine Oil Leakage from Arm Cylinder 1.
Set the arm cylinder at IN stroke end, and stop the engine.
2.
Release the remaining pressure from the piping on the arm cylinder head side. For details, see “Release Remained Pressure in Hydraulic Circuit”. REMARK Operate the lever in the arm IN direction only to release the remaining pressure.
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
3.
Examine Oil Leakage
Disconnect hose (2) on the cylinder head side and block the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side. 4.
Start the engine, and perform arm IN relief with the fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Arm OUT”
side. 5.
30 seconds after relief starts, measure the leakage from the cylinder head side for 1 minute by using measuring cylinder A. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, restore the machine.
How to Examine Oil Leakage from Bucket Cylinder 1.
Set the bucket cylinder at CURL stroke end, and stop the engine.
2.
Release the remaining pressure from the piping on the bucket cylinder head side. For details, see “Release Remained Pressure in Hydraulic Circuit”. REMARK Operate the lever in the bucket CURL direction only to release the remaining pressure.
3.
Disconnect hose (3) on the cylinder head side and block the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side. 4.
Start the engine, and perform bucket CURL relief with the fuel control dial at MAX (High idle) position. k Be
careful not to operate the lever to “Bucket DUMP” side.
5.
30 seconds after relief starts, measure the leakage from the cylinder head side for 1 minute by using measuring cylinder A. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, restore the machine.
How to Examine Oil Leakage from Blade Cylinder 1.
Start engine and drive the machine so that the idler sides of tracks get onto the wooden blocks, etc. to raise the front side of machine.
k Raise the front side of machine until blade does not touch the ground even when the blade lift
cylinder is extended to its LOWER stroke end.
k Set work equipment lock lever to LOCK position and put blocks C, etc. as chocks under the rear
of tracks. 2.
Fully extend the blade cylinder to its LOWER stroke end and stop the engine.
3.
Release the remaining pressure from the piping on the blade cylinder head side. For details, see “Release Remained Pressure in Hydraulic Circuit”. REMARK Bleed air only by lowering the blade.
PC45MR-5, PC55MR-5
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Examine Oil Leakage
4.
30 Testing and Adjusting
Disconnect hose (4) on the cylinder head side and block the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side. 5.
Start the engine, and perform blade LOWER relief with the fuel control dial at MAX (High idle) position. k Be
careful not to operate the lever to “Blade RAISE” side.
6.
30 seconds after relief starts, measure the leakage from the cylinder head side for 1 minute by using measuring cylinder A. For standard values, see Standard Value Table, “Standard Value Table for Machine”.
After finishing the test, restore the machine.
30-90
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Bleed Air from Hydraulic System
Bleed Air from Hydraulic System Tools to Bleed Air from Hydraulic Circuit Symbol
Part No.
Part name
Q'ty
A
Commercially available
Oil container
1
B
Commercially available
Air bleeding hose
1
Remarks
k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work. For releasing the air from hydraulic systems to perform troubleshooting, refer to this section.
●: Execution of work →: Go to next procedure Air bleeding procedure and items 1 Details of work
•
Hydraulic oil change
•
Strainer cleaning
•
Replacement of return filter element
•
Replacement and repair of main pump
•
Removal of suction piping
•
Replacement and repair of control valve
•
Removal of control valve piping
•
Replacement and repair of cylinder
•
Removal of cylinder piping
•
Replacement and repair of swing motor
•
Removal of swing motor piping
•
Replacement and repair of travel motor
•
Removal of travel motor piping
2
3
4
5
6
7
Bleeding air from main pump
Start the engine.
Bleed air from cylinder
Bleeding air from swing motor
Bleeding air from travel motor
PRESSURIZE HYDRAULIC TANK
Check of oil level and operation
●
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(*1)
(*1)
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→
→
→
●
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●
→
→
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→
→
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*1: Bleed air from the swing motor and travel motor only when the oil in the motor case is drained. PC45MR-5, PC55MR-5
30-91
Bleed Air from Hydraulic System
30 Testing and Adjusting
How to Bleed Air from Hydraulic System How to Bleed Air from the Main Pump NOTICE • If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be generated and this may cause a premature damage to the pump. Accordingly, bleed air securely. REMARK • Perform it when any hydraulic component or oil is replaced. • Keep the oil filler cap of the hydraulic tank loosened during air bleeding work of the main pump. 1. Remove the triangular cover at the rear left of the machine. 2. Remove cover (1).
3.
Loosen air bleeder (2) of the main pump, install vinyl hose B, and put its end in oil container A.
4.
Add oil to the hydraulic tank, and start the engine with fuel control dial set in MIN position (Low idle).
5.
When oil without air starts to flow out, tighten air bleeder (2). 3 Air bleeder (2): 8.8±1 Nm {0.9±0.1 kgfm}
6.
Pressurize the hydraulic tank. For details, see “How to Pressurize Hydraulic Tank”.
When starting the engine after bleeding air from main pump, run the engine for 10 minutes with the fuel control dial at MIN (Low idle) position.
How to Bleed Air from the Cylinder 1.
Start and run the engine for approximately 5 minutes with the fuel control dial at MIN (Low idle) position.
2.
Open oil cap of the hydraulic tank.
3.
Repeat raising and lowering the boom 4 to 5 times while running the engine with the fuel control dial at MIN (Low idle) position. REMARK Stop the piston rod at approximately 100 to 200 mm before each stroke end to avoid relieving.
4.
Repeat raising and lowering the boom 4 to 5 times while running the engine with the fuel control dial at MAX (High idle) position. REMARK Stop the piston rod at approximately 100 to 200 mm before each stroke end to avoid relieving.
5.
Move the piston rod to the stroke end to relieve the circuit while running the engine with the fuel control dial at MIN (Low idle) position.
6.
Bleed air from the arm cylinder, bucket cylinder, blade cylinder and boom swing cylinder according to step 2 to 4.
30-92
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Bleed Air from Hydraulic System
How to Bleed Air from Swing Motor NOTICE If the air is not bled from the swing motor and the machine is operated, the swing motor bearings may be damaged. REMARK Perform this only when the oil inside the swing motor case is drained. 1. Start the engine and run it with the fuel control dial at MIN (Low idle) position. 2.
Open oil cap of the hydraulic tank.
3.
With the fuel control dial at MIN (Low idle) position, swing to the right and left 3 times.
How to Bleed Air from Travel Motor 1.
Start the engine, and set the fuel control dial to MIN (Low idle) position.
2.
Open oil cap of the hydraulic tank.
3.
Raise L.H. track off the ground by using the work equipment.
4.
With the fuel control dial at MIN (Low idle) position, run L.H. track idle for approximately 30 seconds. REMARK Work on R.H. track in the same way.
Examine Oil Level 1.
Start the engine, retract the arm cylinder and bucket cylinder fully, lower the work equipment to the ground, and stop the engine.
2.
Check the oil level by sight gauge (4) at the rear of the hydraulic tank. REMARK • If the hydraulic oil level is between “H” and “L”, it is normal. • If the oil level is insufficient, add oil.
PC45MR-5, PC55MR-5
30-93
Pressurize Hydraulic Tank
30 Testing and Adjusting
Pressurize Hydraulic Tank
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
k When the hydraulic tank oil filler cap was removed, be sure to pressurize the hydraulic tank.
NOTICE The pump may suction the air if the pressurization is not performed for the hydraulic tank, and it may have harmful effect to the devices. When the hydraulic tank needs to be pressurized to perform troubleshooting, refer to this section.
How to Pressurize Hydraulic Tank 1.
Open the oil filler cap.
2.
Start the engine, and set the fuel control dial to MIN (Low idle) position.
3.
Set the lock lever to FREE position.
4.
Operate the cylinder rod of boom, bucket, arm and boom swing to the stroke end. NOTICE When operating each control lever, do not relieve the cylinder.
5.
Set the lock lever to LOCK position and stop the engine.
6.
Tighten the oil filler cap securely. By doing so, the hydraulic tank is pressurized.
After finishing the work, restore the machine.
30-94
PC45MR-5, PC55MR-5
30 Testing and Adjusting
How to Open and Close Floor Unit
CAB Related Parts How to Open and Close Floor Unit
k When opening and closing the floor, observe the follow-
ing warning and precautions for the work. k Wrong operation may cause serious personal injury or death.
k Do not open or close the floor when the machine is on
a slope.
k Do not open and close the floor in strong winds.
k Immediately after the engine is stopped, its parts and
oil are still very hot and may cause burn injury. Check that the temperature inside of engine compartment has been dropped before performing the opening or closing of floor.
k Do not stand on the floor or enter into the cab while
floor is open.
k While opening or closing the floor, do not enter under
the floor.
k Do not start the engine while floor is open.
k If any damage or problem is found at the floor opening
lock part, stop the work, close the floor, and then ask your Komatsu distributor for repair.
k Do not remove the floor mounting bolts (A).
The floor may jump up unexpectedly and it is dangerous. Set the machine to the following conditions before opening the floor. 1. Set the machine in the posture shown in the figure. 1)
Start the engine, and run it at low speed.
2)
Set the lock lever to FREE position (F). Be sure to operate the lock lever by the operating portion on the top.
3)
Push the blade control lever forward to lower the blade to the ground.
4)
Operate the work equipment control levers to extend bucket cylinder and arm cylinder to their stroke end, and then lower the boom gently. Lower the bucket link to the ground.
PC45MR-5, PC55MR-5
30-95
How to Open and Close Floor Unit
5)
30 Testing and Adjusting
Set the lock lever to LOCK position (L). Be sure to operate the lock lever by the operating portion on the top.
2.
Put the wooden blocks on the front and rear sides of the tracks so that the machine does not move.
9 J A0 5 4 6 6
Procedure to Open Floor Unit Procedure to Open Floor Unit: Canopy Spec 1.
Remove the triangle cover fixing bolts (1) (M10, 3 pieces), and remove the triangle cover (2).
2.
Remove the cover fixing bolts (3) (M8, 4 pieces), and remove the cover (4).
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PC45MR-5, PC55MR-5
30 Testing and Adjusting
3.
Remove the floor tilt fixing bolts (5) (M14, 2 pieces).
4.
Pull the engine rear cover (6) backward to open it.
How to Open and Close Floor Unit
Open the engine rear cover (6) fully and it is secured by rod (7).
5.
Remove the floor tilt fixing bolt (8) (M14, 1 piece).
6.
Close the engine rear cover (6).
7.
Open the inspection window (9).
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How to Open and Close Floor Unit
8.
While pulling the floor lock release lever (10) to FREE position (F) with your left hand, hold the handle (11) with your right hand and push it up to the direction of arrow (approximately 45 °) to release the floor lock.
9.
Hold the handle (11) and push it up to the direction of arrow (approximately 45 °) to raise the floor.
30 Testing and Adjusting
REMARK • If the floor does not rise, the release lever is not in RELEASE position. Pull back the handle with your right hand, and repeat the preceding procedure again. • Since the gas spring assists the opening of floor, the force to push up the floor decreases in the following cases. Take care. •
When the outside air temperature is low
•
When the force of gas spring decreases due to the long-term operation
10. Once the floor rises, push it up until the lock pin (12) reaches to the locking notch (14) of lock plate (13). When the lock pin (12) moves into the locking notch (14), the first lock is fixed.
11. Insert the second lock pin (15) into the locking hole (16) securely from inside. 12. Turn the lock pin (15) until its upper part (hook to prevent from coming off) catches the pin (17) of inserting part securely. NOTICE Check that the lock pin securely catches the pin and the pin does not come off. The second lock is fixed, and the floor opening work is completed.
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30 Testing and Adjusting
How to Open and Close Floor Unit
Procedure to Open Floor Unit: CAB Spec 1.
Remove the triangle cover fixing bolts (1) (M10, 3 pieces), and remove the triangle cover (2).
2.
Remove the floor tilt fixing bolts (3) (M14, 2 pieces).
3.
Pull the engine rear cover (4) backward to open it. Open the engine rear cover (4) fully and it is secured by rod (5).
4.
Remove the floor tilt fixing bolts (6) (M14, 4 pieces). REMARK If the floor tilt fixing bolts (6) are hard to be removed, remove the bolts (A) of air cleaner mounting bracket to move the air cleaner downward.
5.
Close the engine rear cover (4).
6.
Open the inspection window (7).
PC45MR-5, PC55MR-5
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How to Open and Close Floor Unit
7.
While pulling the floor lock release lever (8) to FREE position (F) with your left hand, hold the handle (9) with your right hand and push it up to the direction of arrow (approximately 45 °) to release the floor lock.
8.
Hold the handle (9) and push it up to the direction of arrow (approximately 45 °) to raise the floor.
30 Testing and Adjusting
REMARK • If the floor does not rise, the release lever is not in RELEASE position. Pull back the handle with your right hand, and repeat the preceding procedure again. • Since the gas spring assists the opening of floor, the force to push up the floor decreases in the following cases. Take care.
9.
•
When outside air temperature is low
•
When the force of gas spring decreases due to the long-term operation
Once the floor rises, push it up until the lock pin (10) reaches to the locking notch (12) of lock plate (11). When the lock pin (10) moves into the locking notch (12), the first lock is fixed.
10. Insert the second lock pin (13) into the locking hole (14) securely from inside. 11. Turn the lock pin (13) until its upper part (hook to prevent from coming off) catches the pin (15) of inserting part securely. NOTICE Check that the lock pin securely catches the pin and does not come off. The second lock is fixed, and the floor opening work is completed.
30-100
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30 Testing and Adjusting
How to Open and Close Floor Unit
Procedure to Close Floor Unit NOTICE Before closing the floor, check the wiring harness, piping, and seat inside floor and in the revolving frame for damage or problem. If any damage or problem is found, ask your Komatsu distributor for repair.
Procedure to Close Floor Unit: Canopy Spec 1.
Remove the lock pin (15) of second lock, and insert it into holder hole (18). If it is hard to remove the lock pin (15), hold the handle (11) and while pulling it up, remove the lock pin (15).
2.
While pulling the floor lock release lever (10) to FREE position (F) with your left hand, hold the handle (11) with your right hand and push it down slowly to the direction of arrow (approximately 45°) to release the first lock.
3.
Hold the handle (11) with your right hand and lower the floor slowly to the direction of arrow (approximately 45°). NOTICE Check that there is no pinched or damaged wiring harness and piping.
4.
Close the inspection window (9).
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How to Open and Close Floor Unit
5.
30 Testing and Adjusting
Open the engine rear cover (6). Open the engine rear cover (6) toward you fully and it is secured by the rod (7).
6.
Tighten the floor tilt fixing bolt (8) (M14, 1 piece).
3 Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgfm}
REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. 7.
Close the engine rear cover (6).
8.
Tighten the floor tilt fixing bolts (5) (M14, 2 pieces).
3 Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgfm}
REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size.
9.
Install the cover (4) with the cover fixing bolts (3) (M8, 4 pieces).
10. Install the triangle cover (2) with the triangle cover fixing bolts (1) (M10, 3 pieces).
Floor closing work is completed.
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30 Testing and Adjusting
How to Open and Close Floor Unit
Procedure to Close Floor Unit: CAB Spec 1.
Remove the lock pin (13) of the second lock, and insert it into holder hole (16). If it is hard to remove the lock pin (13), hold the handle (9) and while pulling it up, remove the lock pin (13).
2.
While pulling the floor lock release lever (8) to FREE position (F) with your left hand, hold the handle (9) with your right hand and push it down slowly to the direction of arrow (approximately 45°) to release the first lock.
3.
Hold the handle (9) with your right hand and lower the floor slowly to the direction of arrow (approximately 45°). NOTICE Check that there is no pinched or damaged wiring harness and piping.
4.
Close the inspection window (7).
5.
Open the engine rear cover (4). Open the engine rear cover (4) toward you fully and it is secured by the rod (5).
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How to Open and Close Floor Unit
6.
30 Testing and Adjusting
Tighten the floor tilt fixing bolts (6) (M14, 4 pieces). 3 Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgfm}
REMARK • If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size. • When the air cleaner has been moved downward, restore it to the original position, and install the air cleaner mounting bracket with bolts (A). 7.
Close the engine rear cover (4).
8.
Tighten the floor tilt fixing bolts (3) (M14, 2 pieces). 3 Tightening torque: 156.8 to 196.0 Nm {16.0 to 20.0 kgfm}
REMARK If any of the floor tilt fixing bolts is damaged, replace it with a Komatsu genuine part of the same size.
9.
Install the triangle cover (2) with the triangle cover fixing bolts (1) (M10, 3 pieces).
Floor closing work is completed.
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30 Testing and Adjusting
Set and Operate Machine Monitor
Electrical System Set and Operate Machine Monitor
Machine Monitor (Monitor Panel Section) (a): Multi-information display Depending on ambient temperature and condition of battery, battery voltage may drop suddenly and machine monitor display disappears when engine is started. But this phenomenon does not mean that machine monitor is defective.
Machine Monitor (Switch Section) 1: Function switches F1: F1 Function switch F2: F2 Function switch F3: F3 Function switch F4: F4 Function switch F5: F5 Function switch F6: F6 Function switch F7: F7 Function switch F8: F8 Function switch The function of each function switch is indicated by the icon which is displayed just above function switches F1 to F4 or on the left side of F5 to F8 on the multi-information display panel (a). If the icon for a function switch is not displayed, that function switch is not working.
PC45MR-5, PC55MR-5
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Set and Operate Machine Monitor
30 Testing and Adjusting
Operator Mode and Service Mode of Machine Monitor Machine monitor has operator mode and service mode. Various information is displayed on multi-information display (a). Some items are displayed automatically according to the configuration of the machine monitor whereas the other items can be displayed only when the machine monitor is operated with switches. •
Operator mode The information items in this mode are ordinarily displayed. The operator can display and set them by the operation with switches. (Display and setting of some items need special operation of switches.) For details, see Operation and Maintenance Manual. Operator mode
DISPLAY OF PASSWORD INPUT MAINTENANCE TIME CAUTION LAMP BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NORMAL SITUATION BASIC OPERATION OF MACHINE MONITOR WHEN ENGINE IS STOPPED IN NORMAL SITUATION BASIC OPERATION OF MACHINE MONITOR WHEN ENGINE IS STARTED WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON AUTO-DECELERATION FUNCTION HOW TO USE WORKING MODE SELECTING FUNCTION TRAVEL SPEED SELECTOR SWITCH BUZZER CANCEL FUNCTION SERVICE METER / CLOCK MAINTENANCE SCREEN SETTING USER MENU BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE AFTERTREATMENT DEVICES REGENERATION ACTION LEVEL DISPLAY Following functions become operational by performing special operations. CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) CHECKING FUNCTION OF SERVICE METER METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD
•
Service Mode The information items in this mode are not ordinarily displayed. Technicians can change display and settings by operating the switches specially. This mode is used for testing, adjusting, or troubleshooting. Service Mode
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS) METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS) METHOD FOR CONFIRMING MAINTENANCE RECORD METHOD FOR OPERATING MAINTENANCE MODE SETTING METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING
30-106
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30 Testing and Adjusting
Set and Operate Machine Monitor
Service Mode METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE) METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT) METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT ATTACHMENT) METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIMER FIXING) METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION) METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE) METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET) METHOD FOR OPERATING TESTING MENU (RAIL PRESSURE MEMORY RESET) METHOD FOR ADJUSTING WITH ADJUSTING MENU (PUMP ABSORPTION TORQUE) METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 2 ADJUSTMENT) METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 3 ADJUSTMENT) METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS) METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS) METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS) METHOD FOR DISPLAYING SERVICE MESSAGE
PC45MR-5, PC55MR-5
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30 Testing and Adjusting
Operator Mode The following are items which needs specific switch operation in operator mode. For details of contents and operations of each function and display, see Structure and Function, “Machine Monitor”or the “OPERATION AND MAINTENANCE MANUAL”.
Examine Function by LCD (Liquid Crystal Display) If the following operation is performed with the function switches while the standard screen is displayed, LCD screen turns completely white. Switch operations (While pressing F8): F8 + F6 •
When finishing the operation of the switches, release F6 first.
•
If there is a display error in the LCD, only that part is indicated in black.
•
An LCD panel sometimes shows black spots (spots that remain unlit) and bright spots (spots that remain lit) as one of the characteristics. If the number of the bright points and black points does not exceed 10, the LCD panel is not faulty or defective.
•
To return to the former screen, press any one of the function switches.
Examine Function of Service Meter When checking the service meter with the starting switch in OFF position, operate the function switches as follows to display only the service meter. Switch operations (While pressing F2): F2 + F3 REMARK • There is some time lag in start of the LCD, so hold down the switches until the service meter is displayed. • If you release one of the switches, the monitor goes off.
Usage Limitation and Maintenance Password Change Function On the machine monitor, a password can be set as a user limitation setting. If the password has been set, a password enter screen is displayed for resetting of maintenance items. Perform the Usage Limitation Setting and Change Password functions according to the following procedure. 1. While displaying the standard screen, operate the function switches as follows. Switch operation (While pressing F8, press other switches in order): F8 + F5 → F5 → F5 REMARK This operation of the switches is not accepted until 10 minutes elapsed after the starting switch is turned to ON position.
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30 Testing and Adjusting
2.
Set and Operate Machine Monitor
When “Usage Limitation Password” screen is displayed, input the current password with the function switches. F1: Decreases the number by 1 F2: Increases the number by 1 F3: Returns the screen to standard screen F4: Enters the input password F6: Moves the input position leftward F7: Moves the input position rightward F8: Clears all the input digits REMARK • Default password: 000000 • When the inputted password is correct, the screen changes to the next screen. • When the inputted password is incorrect, a message to request inputting the password again is displayed. • The password for usage limitation and the engine start lock password are not identical.
3.
On “Usage Limitation Setting” screen, select a setting with the function switch. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and returns to the previous screen F4: Enters the selection
4.
On “Usage Limitation ON/OFF” screen, select a setting with the function switch. “OFF”: The password input screen is not displayed “ON”: The password input screen appears for the setting of the breaker and attachment, or the reset operation of maintenance items. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and returns to the previous screen F4: Enters the selection
5.
Display “Usage Limitation Setting” and select “Change Password”. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and returns to the previous screen F4: Enters the selection
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Set and Operate Machine Monitor
6.
30 Testing and Adjusting
When “Usage Limitation New Password Input” screen is displayed, input new password with the function switches. F1: Decreases the number by 1 F2: Increases the number by 1 F3: Returns to “Usage Limitation Setting” menu F4: Enters new password F6: Moves the input position leftward F7: Moves the input position rightward F8: Clears all the input digits REMARK • Default password: 000000 • When the inputted password is correct, the screen changes to the next screen. • When the inputted password is incorrect, a message to request inputting the password again is displayed. • Set a new password of 4 to 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted).
7.
When “Usage Limitation New Password Input” screen is displayed again, input a new password again with the function switches. F1: Decreases the number by 1 F2: Increases the number by 1 F3: Returns to “Usage Limitation Setting” menu F4: Enters new password F6: Moves the input position leftward F7: Moves the input position rightward F8: Clears all the input digits REMARK If the password is different from the previous one, the monitor displays a message prompting reinput of the password. If the standard screen is displayed after the screen to notify completion of setting is displayed, the password is changed successfully.
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30 Testing and Adjusting
Set and Operate Machine Monitor
Service Mode How to Operate Service Mode To change the mode of the machine monitor to the service mode from the operator mode, perform the following operation. This operation is always required when you use the service mode. 1. While displaying the standard screen, press the function switch F8 to select following switches (F8 + F1 → F2 → F3). REMARK Switch operations which use SERVICE MODE are accepted only while the standard screen is displayed.
2.
When “Service Menu” screen is displayed, the service mode is selected. Select a service menu you use. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Returns the screen to the “standard” screen (operator mode) F4: Enters the selection F8: Changes the screen to Code Input screen. REMARK • If you press the function switch and input the code on Input Code screen, the menu is selected directly. F1: Decreases the number by 1 F2: Increases the number by 1 F3: Cancels the input and returns the screen to “Service Menu” screen F4: Enters the input code F6: Moves the input position leftward F7: Moves the input position rightward • Items with 2-digit codes are the menus displayed on “Service Menu” screen. The items on the right are the menus on the next hierarchy. The following shows the items selectable with “Service Menu” (including some items which need special switching operations). Selectable Items on “Service Menu” Code
Item
01
Pre-defined Monitoring
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION
02
Self-define Monitoring
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION
PC45MR-5, PC55MR-5
Reference page
30-111
Set and Operate Machine Monitor
Code
03
30 Testing and Adjusting
Item
Reference page
Mechanical Sys Abnormali- METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS) Abnormality ty Record Record Electrical Sys Abnormality METHOD FOR CONFIRMING ABNORMALITY RECORD Record
(ELECTRICAL SYSTEMS)
04
Maintenance Record
METHOD FOR CONFIRMING MAINTENANCE RECORD
05
Maintenance Mode Setting
METHOD FOR OPERATING MAINTENANCE MODE SETTING
06
Phone Number Entry
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING
07
08
09
10
11
12
Key-on mode
METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE)
Unit
METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT)
With/Without Attachment
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT ATTACHMENT)
Auto Idle Stop Timer Setting
METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIMER FIXING)
Cylinder Cutout Mode Operation
METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)
Active Regeneration for Service
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)
KDPF Memory Reset
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)
Rail Pressure Memory Reset
METHOD FOR OPERATING TESTING MENU (RAIL PRESSURE MEMORY RESET)
Pump Absorption Torque
METHOD FOR ADJUSTING WITH ADJUSTING MENU (PUMP ABSORPTION TORQUE)
Attachment EPC 2 Adjustment
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 2 ADJUSTMENT)
Attachment EPC 3 Adjustment
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 3 ADJUSTMENT)
Default
Diagnostic Tests
Adjustment
Batt. Disconnect Set
KOMTRAX Settings
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING
Terminal Status
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)
GPS & Communication State
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)
Modem Information
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)
Service Message
METHOD FOR DISPLAYING SERVICE MESSAGE
How to See Pre-defined Monitoring Information The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to various parts of the machine and the information from the controllers which is controlling them. In Pre-define Monitoring, frequently used monitoring items are already selected beforehand.
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30 Testing and Adjusting
Set and Operate Machine Monitor
1.
Select “Pre-defined Mon” on “Service Menu” screen.
2.
On “Pre-defined Mon” screen, displayed items can be checked with the function switch. F1: Selects Display of Non-display of auto-deceleration pilot lamp F2: Selects HOLD or releasing HOLD (If HOLD is selected, HOLD part is hatched) F3: Returns the screen to “Service Menu” screen F5: Changes the working mode (upper right of screen) F6: Moves to the next page F7: Returns to the previous page REMARK For the items not displayed in “Pre-defined Mon”, you can freely select and check from “Pre-defined Monitoring” items.
Table of Pre-defined Monitoring Items Pre-defined Monitoring (01/14) Machine Basics (1) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
18400
Intake Manf. Temp.
°C
°C
℉
ENG
4
03203
Battery Power supply
V
V
V
ENG
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (02/14) Machine Basics (2) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
37502
Ambient Air Temp.
°C
°C
℉
ENG
3
14200
Fuel Temperature
°C
°C
℉
ENG
4
63400
Exh.manif.Gas Temp.
°C
°C
℉
ENG
No.
ID
1
01002
2
Item name
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30 Testing and Adjusting
Pre-defined Monitoring (03/14) Fuel Injection System Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
36400
Rail Pressure
MPa
kgf/cm2
psi
ENG
3
14200
Fuel Temperature
°C
°C
℉
ENG
4
63400
Exh.manif.Gas Temp.
°C
°C
℉
ENG
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (04/14) EGR Actuator Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
62900
EGR V. Target Posn.
STEP
STEP
STEP
ENG
4
18100
EGR V. Actual Posn.
STEP
STEP
STEP
ENG
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (05/14) Intake Air Actuator Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
62701
Eng. Throt. Command
%
%
%
ENG
4
62700
IntakeThrot.Position
%
%
%
ENG
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (06/14) Engine Temperature Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
18400
Intake Manf. Temp.
°C
°C
℉
ENG
4
48500
EGR Temperature
°C
°C
℉
ENG
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (07/14) Intake and Exhaust Pressure No.
ID
1
01002
Item name Engine Speed
Unit SI
Metric
Imperial
Applicable component
r/min
rpm
rpm
ENG
psi
ENG
2
37400
Ambient Pressure
kPa
kgf/cm2
3
64000
Air Inlet Pressure
kPa
kgf/cm2
psi
ENG
4
48300
Act.Exh.Manf.Press.
kPa
kgf/cm2
psi
ENG
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30 Testing and Adjusting
Set and Operate Machine Monitor
Pre-defined Monitoring (08/14) Aftertreatment System (1) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
47100
KDPF Differential Pressure
kPa
kgf/cm2
psi
KDPF
4
63700
KDPF Inlet Pressure
kPa
kgf/cm2
psi
KDPF
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (09/14) Aftertreatment System (2) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
47400
KDPF Intmdt.GasTemp.
°C
°C
℉
KDPF
4
47300
KDPF Intake GasTemp.
°C
°C
℉
KDPF
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (10/14) Aftertreatment System (3) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
3
18100
EGR V. Actual Posn.
STEP
STEP
STEP
ENG
4
62700
IntakeThrot.Position
%
%
%
ENG
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (11/14) Pump Basics Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
01300
PC-EPC solenoid current
mA
mA
mA
MCN
3
01141
Service Press. Sens1
MPa
kgf/cm2
psi
MCN
4
01142
Service Press. Sens2
MPa
kgf/cm2
psi
MCN
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (12/14) PPC Pressure (1) Unit SI
Metric
Imperial
Applicable component
r/min
rpm
rpm
ENG
ON/OFF
ON/OFF
ON/OFF
MCN
Service Press. Sens1
MPa
kgf/cm2
psi
MCN
Service Press. Sens2
MPa
kgf/cm2
psi
MCN
No.
ID
Item name
1
01002
Engine Speed
2
65400
Pressure Switch, Work Equipment
3
01141
4
01142
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30 Testing and Adjusting
Pre-defined Monitoring (13/14) PPC Pressure (2) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
09000
Swing PPC Pressure
MPa
kgf/cm2
psi
MCN
3
01141
Service Press. Sens1
MPa
kgf/cm2
psi
MCN
4
01142
Service Press. Sens2
MPa
kgf/cm2
psi
MCN
No.
ID
1
01002
2
Item name
Pre-defined Monitoring (14/14) PPC Pressure (3) Unit SI
Metric
Imperial
Applicable component
Engine Speed
r/min
rpm
rpm
ENG
07101
Travel PPC pressure
MPa
kgf/cm2
psi
MCN
3
01141
Service Press. Sens1
MPa
kgf/cm2
psi
MCN
4
01142
Service Press. Sens2
MPa
kgf/cm2
psi
MCN
No.
ID
1
01002
2
Item name
How to Examine Self-Define Monitor Information The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to various parts of the machine and the information from the controllers which is controlling them. “Self-define Monitoring” is used to select a desired monitoring item. 1. Select “Self-define Monitoring” on “Service Menu” screen.
2.
When “Monitoring Selection Menu” screen is displayed, use the function switch to select items to be monitored. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Returns the screen to “Service Menu” screen F4: Enters the selection F6: Moves the selection leftward F7: Moves the selection rightward F8: Changes the screen to “ID Input” screen. •
Setting of the monitoring changes to “ENG”→“KDPF”→“MCN”→“MON”→“ENG” in this order when function switch F7 is pressed. (When F6 is pressed, it happens in the reverse order.)
•
Selection with function switches: Select an applicable equipment by using F6 or F7, select an item by using F1 or F2, and then enter it by using F4.
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•
Set and Operate Machine Monitor
If you press function switch F8 and input ID on Selfdefine Monitoring screen, the monitoring item is selected directly. F1: Decreases the number by 1 F2: Increases the number by 1 F3: Cancels the input and returns to “Self-define Monitoring” screen F4: Enters the input value F6: Moves the selection leftward F7: Moves the selection rightward
3.
•
If the color of the selected box changes from yellow to red, the selection of the item of that box is entered.
•
4 monitoring items at maximum can be selected at the same time. However, it may not be possible to set up to 4 items depending on the display pattern of the selected items.
After selecting monitoring items, use the function switch to execute the monitoring. •
Execution with function switch: Double click or keep pressing F4 for approximately 2 seconds.
•
When performing monitoring by inputting ID, input ID first, then input “99999” with the function switch, and enter with F4. F1: Decreases the number by 1 F2: Increases the number by 1 F3: Cancels the input and returns to “Self-define Monitoring” screen F4: Enters the input value F6: Moves the selection leftward F7: Moves the selection rightward
•
If monitoring items are selected up to the limit number, monitoring is executed automatically.
REMARK When performing monitoring of only two items, select each item, and confirm them with F4. If F4 is pressed once again, monitoring is executed. 4.
On “Monitoring” screen, perform the necessary operation of the machine and check the monitoring information. REMARK • Monitoring information is indicated by value, ON/OFF, or special display. • The unit of display can be selected in “SI” unit, “Metric” unit, or “Imperial” unit with “Default” function in service mode.
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5.
30 Testing and Adjusting
You can hold and release holding of the monitoring information by using the function switches. F1: Selects Display of Non-display of auto-deceleration pilot lamp F2: Selects HOLD or releasing HOLD (If HOLD is selected, HOLD part is hatched) F3: Return the screen to Self-define Monitoring screen F5: Changes the working mode (upper right of screen) F7: Saves the currently displayed monitoring item
6.
To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the corresponding mode is selected. REMARK If the setting is changed during monitoring, the new setting is held even after the screen returns to the normal screen after monitoring is finished.
7.
Selected monitoring item can be saved and deleted with function switches. F6: Clears the monitoring item F7: Saves the monitoring item •
If any item is saved, “Display the memorized items?” appears as a confirmation screen when “Self-define Monitoring” is selected in “Service Menu”. Press F4, the screen changes to “Monitoring” screen for the saved monitor item.
•
When an item is saved, it can be displayed as many times as required unless it is cleared.
•
If another item is saved while having the previous item saved, the previously saved item is overwritten by the latest one.
•
If saved monitoring items need to be deleted, press F6 and then press F4 to confirm operation.
Table of Self-Define Monitor Items Code No.
Unit Monitoring item (display on the screen)
SI
Metric
Imperial
Applicable component
01009
Eng's Dsrd.Opr.Spd.
r/min
rpm
rpm
ENG
62100
Target Engine Speed
r/min
rpm
rpm
ENG
01002
Engine Speed
r/min
rpm
rpm
ENG
04107
Coolant Temperature
°C
°C
℉
ENG
03203
Battery Power supply
V
V
V
ENG
30-118
Remarks
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Code No.
Set and Operate Machine Monitor
Unit Monitoring item (display on the screen)
SI
Metric
Imperial
62400
Oil Pressure SW
36400
Rail Pressure
MPa
kgf/cm2
psi
ENG
37400
Ambient Pressure
kPa
kgf/cm2
psi
ENG
37502
Ambient Air Temp.
°C
°C
℉
ENG
18400
Intake Manf. Temp.
°C
°C
℉
ENG
64000
Air Inlet Pressure
kPa
kgf/cm2
psi
ENG
63400
Exh.manif.Gas Temp.
°C
°C
℉
ENG
48500
EGR Temperature
°C
°C
℉
ENG
48300
Act.Exh.Manf.Press.
kPa
kgf/cm2
psi
ENG
62300
EGR Diff. Pressure
kPa
kgf/cm2
psi
ENG
62900
EGR V. Target Posn.
STEP
STEP
STEP
ENG
18100
EGR V. Actual Posn.
STEP
STEP
STEP
ENG
14200
Fuel Temperature
°C
°C
℉
ENG
31701
Accelerator Position
%
%
%
ENG
62701
Eng. Throt. Command
%
%
%
ENG
62700
IntakeThrot.Position
%
%
%
ENG
63200
Basic Inj. Timing
CA
CA
CA
ENG
63201
Terget Inj. Amount
mm3/st
mm3/st
mm3/st
ENG
63300
Pre Inj. Amount
mm3/st
mm3/st
mm3/st
ENG
63301
Main Inj. Amount
mm3/st
mm3/st
mm3/st
ENG
63000
After Inj. Amount
mm3/st
mm3/st
mm3/st
ENG
63100
Post Inj. Amount
mm3/st
mm3/st
mm3/st
ENG
14300
Total Fuel Used
L
L
L
ENG
37300
Instantaneous Fuel Consumption
ℓ/h
ℓ/h
gal/h
ENG
62500
Total Inj. Amount
mm3/st
mm3/st
mm3/st
ENG
62003
Engine ECU MSW P/N
-
-
-
ENG
62004
Engine ECU MAP P/N
-
-
-
ENG
62002
Engine ECU No.
-
-
-
ENG
62001
Engine Serial No.
-
-
-
ENG
62005
Engine ECU S/N
-
-
-
ENG
62000
Engine Model No.
-
-
-
ENG
63700
KDPF Inlet Pressure
kPa
kgf/cm2
psi
KDPF
47100
KDPF Differential Pressure
kPa
kgf/cm2
psi
KDPF
47300
KDPF Intake GasTemp.
°C
°C
℉
KDPF
47400
KDPF Intmdt.GasTemp.
°C
°C
℉
KDPF
47800
KDPF AshAccumulation
g/L
g/L
g/gal
KDPF
47700
KDPF Amount of PM(C)
g/L
g/L
g/gal
KDPF
PC45MR-5, PC55MR-5
ON/OFF
Applicable component
Remarks
ENG
(*1)
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Set and Operate Machine Monitor
Code No.
30 Testing and Adjusting
Unit Monitoring item (display on the screen)
SI
Metric
Imperial
Applicable component
63800
KDPF Amount of PM(P)
g/L
g/L
g/gal
KDPF
04200
Fuel Level Sensor Voltage
V
V
V
MCN
01601
2nd Eng Spd. Command
r/min
rpm
rpm
MCN
09000
Swing PPC Pressure
MPa
kgf/cm2
psi
MCN
07101
Travel PPC pressure
MPa
kgf/cm2
psi
MCN
01300
PC-EPC solenoid current
mA
mA
mA
MCN
03200
Battery Voltage
V
V
V
MCN
01602
2nd Eng. Spd.Command
%
%
%
MCN
13113
Main Pump Absorb Torque
Nm
kgfm
lbft
MCN
01701
01702
01703
01704
42008
42009
42010
30-120
ATT Sol2 Current
ATT Sol3 Current
ATT Sol4 Current
ATT Sol5 Current
LeverPot.1 Volt Main
LeverPot.1 Volt Sub
LeverPot.2 Volt Main
mA
mA
mA
mA
V
V
V
mA
mA
mA
mA
V
V
V
mA
mA
mA
mA
V
V
V
Remarks
MCN
Only model with 1st-line attachment proportional switch
MCN
Only model with 1st-line attachment proportional switch
MCN
Only model with 1st-line attachment proportional switch
MCN
Only model with 1st-line attachment proportional switch
MCN
Only model with 1st-line attachment proportional switch
MCN
Only model with 1st-line attachment proportional switch
MCN
Only model with 2nd-line attachment proportional switch
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Code No.
42011
42012
Set and Operate Machine Monitor
Unit Monitoring item (display on the screen)
LeverPot.2 Volt Sub
Lever Pot.1 Stroke
SI
V
%
Metric
V
%
Imperial
V
%
Applicable component
Remarks
MCN
Only model with 2nd-line attachment proportional switch
MCN
Only model with 1st-line attachment proportional switch Only model with 2nd-line attachment proportional switch
42013
Lever Pot.2 Stroke
%
%
%
MCN
01141
Service Press. Sens1
MPa
kgf/cm2
psi
MCN
01142
Service Press. Sens2
MPa
kgf/cm2
psi
MCN
01900
Pressure SW 1
Travel
ON/OFF
MCN
Swing or Arm IN
ON/OFF
MCN
Work Equipment
ON/OFF
MCN
02300
Solenoid 1
Travel Speed
ON/OFF
MCN
02301
Solenoid 2
PPC lock relay
ON/OFF
MCN
03701
Controller Output 1
Travel Alarm
ON/OFF
MCN
02200
SW Input 1
Key SW
ON/OFF
MCN
Start
ON/OFF
MCN
Lock Lever SW
ON/OFF
MCN
Lock Lever SW 2
ON/OFF
MCN
PPC Lock Solenoid State
ON/OFF
MCN
lock lever automatic lock cancel switch
ON/OFF
MCN
02203
SW Input 2
02202
SW Input 3
02201
SW Input 5
20294
MCN Con. Ass'y P/N
-
-
-
MCN
20430
MCN Con. Serial No
-
-
-
MCN
20295
MCN Con. Prog. P/N
-
-
-
MCN
20296
MCN Con. Prog. Ver
-
-
-
MCN
PC45MR-5, PC55MR-5
Breaker Sw
ON/OFF
MCN
Model Selection 1
ON/OFF
MCN
Model Selection 2
ON/OFF
MCN
Only model with 1st-line attachment proportional switch
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Code No. 04500
04507
04508
30 Testing and Adjusting
Unit Monitoring item (display on the screen)
Monitor Input 1
Monitor 1st Switches
Monitor 2nd Switches
SI
Metric
Imperial
Applicable component
Key SW
ON/OFF
MON
ENG Shtdwn Secondary
ON/OFF
MON
F1
ON/OFF
MON
F2
ON/OFF
MON
F3
ON/OFF
MON
F4
ON/OFF
MON
F5
ON/OFF
MON
F6
ON/OFF
MON
F7
ON/OFF
MON
F8
ON/OFF
MON
20227
Assembly P/N (MON)
-
-
-
MON
20402
Serial No. (MON)
-
-
-
MON
20228
Software P/N (MON)
-
-
-
MON
20200
Application (MON)
-
-
-
MON
20260
AssemblyP/N(KOMTRAX)
-
-
-
MON
20418
KOMTRAX S/N
-
-
-
MON
20261
SoftwareP/N(KOMTRAX)
-
-
-
MON
20273
KOMTRAX Prog.Version
-
-
-
MON
20262
Assembly P/N (IDKey)
-
-
-
MON
20419
Serial No. (IDKey)
-
-
-
MON
20263
Software P/N (IDKey)
-
-
-
MON
Remarks
•
Listing order in table The monitoring items are listed in the order of the display on Monitoring Selection Menu screen.
•
Unit The display unit can be set to “SI”, “Metric”, or “Imperial” as required (select a desired unit from “Unit” of “Default” in Service Menu). “mm3/st” in the display unit is an abbreviation for mm3/stroke.
•
Applicable component ENG: The engine controller detects the monitoring information. KDPF: The engine controller detects the monitoring information of KDPF. MCN: The machine controller detects the monitoring information. MON: The machine monitor detects the monitoring information.
*1: “Instantaneous Fuel Consumption” (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a theoretical value, it is slightly different from the actual fuel consumption ratio.)
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Abnormality Record Menu How to See Abnormality Record (Mechanical Systems) The machine monitor logs the failures that occurred in the past and is occurring currently. It classifies them into the mechanical system abnormality and electrical system abnormality. Check the information about “Mechanic Sys Error Record” by performing the following procedures. For the failure code list, see “Failure Code Table” for troubleshooting. 1. Select “Abnormality Record” on “Service Menu” screen. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
2.
On “Abnormality Record” screen, select “Mechanic Sys Error Record” with the function switch. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
3.
Check the following information on “Mechanic Sys Error Record” screen. a: Occurrence order from the latest one/ Total number of records b: Failure code c: Detail of failure d: Number of occurrences (displayable range: 0 to 65535 times) e: Service meter reading at the first occurrence f: Service meter reading at the last occurrence F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns to “Abnormality Record” screen
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30 Testing and Adjusting
REMARK • If no abnormality is recorded, “No Abnormality Record” is displayed. • In the mechanical systems abnormality record screen, up to 20 cases currently stored are displayed. • If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. When the latest service meter reading is recovered, the value at the recovery time is displayed, thus the above readings may not be the same. • If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not confirmed. • For all of the failure codes that the machine monitor can record, see Troubleshooting, “Failure code list”. • If the message of the failure code is too long, the rest of the message is scrolled. • The contents of an abnormality record of the mechanical system cannot be deleted.
How to See Abnormality Record (Electrical Systems) The machine monitor logs the failures that occurred in the past and is occurring currently. It classifies them into the mechanical system abnormality and electrical system abnormality. To check “Electric Sys Error Record”, perform the following procedures. For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, “FAILURE CODES TABLE”. 1. Select “Abnormality Record” on “Service Menu” screen. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
2.
On “Abnormality Record” screen, select “Electric Sys Error Record” with the function switch. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
3.
Check the following information on “Electric Sys Error Record” screen. a: Occurrence order from the latest one/ Total number of records b: Failure code c: Detail of failure d: Number of occurrences (displayable range: 0 to 65535 times) e: Service meter reading at the first occurrence f: Service meter reading at the last occurrence F1: Moves the selected item down by one item
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F2: Moves the selected item up by one item F3: Returns the screen to “Abnormality Record” screen REMARK • If no abnormality is recorded, “No Abnormality Record” is displayed. • The screen shows 20 cases of the electrical systems abnormality which currently stored in the system. If the number of cases exceeds 21, the monitor displays the latest occurrence code and deletes the oldest case. • If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. • If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not confirmed. • For all of the failure codes that the machine monitor can record, see Troubleshooting, “Failure code list”. • If the message of the failure code is too long, the rest of the message is scrolled. 4.
Delete the information about abnormality record by performing the following operations with the function switches while “Electric Sys Error Record” screen is displayed. 1) Switch operation (While pressing F8, press other switches in order): F8 + F1 → F2 → F3
2)
Check that the display on the screen becomes the delete mode, then clear the individual information one by one or all together by using the function switches. REMARK The screen is in delete mode if “CLEAR” is displayed above F8. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the screen to “Abnormality Record” screen F4: Executes the deletion of the selected abnormality records. F8: Executes the deletion of all the abnormality records. REMARK • To delete a selected abnormality record, select the abnormality record with F1 or F2, and then press F4 to execute the deletion of abnormality record. • To clear all abnormality records together, press F8, and then all the records are deleted regardless of the selected item. • If “E” is displayed on the left of a failure code, the clearing operation is received but the information is not cleared.
3)
After the “Electri Sys Error Record Reset” screen is displayed, operate the function switches to delete all the records. F3: Returns to “Electric Sys Error Record” (Delete mode) F4: Executes the deletion
PC45MR-5, PC55MR-5
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REMARK • This is the screen when a selected abnormality record is going to be deleted.
• This is the screen when all the abnormality records are going to be deleted.
4)
When the screen to notify the completion of the deletion is displayed and then “Electric Sys Error Record” (Delet mode) screen is displayed, the deletion of the selected abnormality record is completed. REMARK • This is the screen displayed when the deletion of a selected abnormality record is completed.
• This is the screen displayed when the deletion of all abnormality records is completed.
How to See Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and checked by the following operations. If the data are reset in the operator mode when the maintenance is performed, the number of the times of maintenance is recorded here.
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Set and Operate Machine Monitor
1.
Select “Maintenance Record” on “Service Menu” screen.
2.
When the “Maintenance Record” screen is displayed, use the function switch to select the confirmation item. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Returns the screen to “Service Menu” screen F8: Changes the screen to Code Input screen. REMARK Method of selecting is similar to “Service Menu” screen. Items Selectable in Maintenance Record Code
Item
49
Air Cleaner Clean and Change
60
Coolant Change
41
Fuel Prefilter Change
01
Engine Oil Change
02
Engine Oil Filter Change
05
Hyd Oil Tank Breather Change
03
Fuel Main Filter Change
04
Hydraulic Oil Filter Change
08
Final Drive Case Oil Change
10
Hydraulic Oil Change
48
KDPF Filter Cleaning
Items displayed on Maintenance Record screen a: Maintenance items b: Number of replacements up to now c: Service meter reading (SMR) at the last replacement d: Current service meter reading (SMR)
Maintenance Mode Setting Following can be changed from the menu screen. Enable or disable the function of maintenance items and set the replacement interval of maintenance items. •
Enable or disable the function of maintenance items.
PC45MR-5, PC55MR-5
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30 Testing and Adjusting
•
To change the replacement interval setting of maintenance items (by item).
• 1.
To initialize all of the replacement interval setting of maintenance items.
2.
When the “Maintenance Mode Setting” screen is displayed, use the function switch to select items to be modified.
Select “Maintenance Mode Setting” on “Service Menu” screen.
F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Returns the screen to “Service Menu” screen F4: Enters the selection F8: Changes the screen to Code Input screen. REMARK Method of selecting is similar to “Service Menu” screen. Selectable Items on Maintenance Mode Setting Code
Item
00
Maintenance Mode Change
49
Air Cleaner Cleaning or Change
60
Coolant Change
41
Fuel Prefilter Change
01
Engine Oil Change
02
Engine Oil Filter Change
05
Hyd Oil Tank Breather Change
03
Fuel Main Filter Change
04
Hydraulic Oil Filter Change
08
Final Drive Case Oil Change
10
Hydraulic Oil Change
99
All Default Value
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30 Testing and Adjusting
3.
Set and Operate Machine Monitor
Select “Maintenance Mode Change”. The screen is shifted by selecting “Maintenance Mode On/Off”. Select “ON” or “OFF”. ON: Functions of all maintenance items become effective in operator mode OFF: Functions of all maintenance items become ineffective in operator mode F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and returns the screen to the “Maintenance Mode Setting” screen F4: Enters the selection and returns the screen to “Maintenance Mode Setting” screen REMARK Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual setting.
4.
Select “Maintenance Notice Time Setting” and when “Maintenance Notice Time Setting” screen is displayed, perform the setting with the function switches. Default value: Maintenance notice time set on the machine monitor (Recommended by the manufacturer and not changeable). Set value: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (the time increases or decreases in units of 10 h). F1: Decreases the set value F2: Increases the set value F3: Cancels the selection and returns the screen to the “Maintenance Mode Change” screen F4: Enters the set value and returns the screen to “Maintenance Mode Change” screen. F8: Cancels unconfirmed contents of settings REMARK • After pressing F4 and confirming the value,the screen returns to “Maintenance Mode Change” screen. • If the value of an item which is set to “ON” is changed after more than 1 h from the setup, the change is recognized as a reset operation.
5.
Select one of each maintenance item and when the each maintenance item screen is displayed, select “On or Off Setting”. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and returns the screen to the “Maintenance Mode Setting” screen F4: Enters the selection and proceeds to “ON” or “OFF” setting of each maintenance item F8: Changes the screen to Code Input screen.
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30 Testing and Adjusting
REMARK • Displayed screen is an example of “Engine Oil Change”. • Method of selecting is similar to “Service Menu” screen. 6.
When each maintenance item screen is displayed, select “ON” or “OFF” with function switches. “ON”: Function of the particular maintenance item becomes effective in “operator mode”. “OFF”: Function of the particular maintenance item becomes ineffective in “operator mode”. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and returns the screen to each maintenance item screen. F4: Enters the setting and returns the screen to each maintenance item screen.
7.
Select “Set” of each maintenance item. When the screen of each maintenance item is displayed, perform the setting with the function switches. Default value: Maintenance notice time set on the machine monitor (Recommended by the manufacturer and not changeable). Set value: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (the time increases or decreases in units of 25 h). F1: Decreases the set value F2: Increases the set value F3: Cancels the set value and returns the screen to each maintenance item screen. F4: Enters the set value and returns the screen to each maintenance item screen. F8: Cancels unconfirmed contents of settings REMARK • After pressing F4 and confirming the value, the screen returns to maintenance item screen. • If the value of an item which is set to “ON” is changed after more than 1 h from the setup, the change is recognized as a reset operation.
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30 Testing and Adjusting
8.
Set and Operate Machine Monitor
The screen is shifted by selecting “All Default Value”, perform the setting with the function switches. If the operation for this function is executed, the set values of all the maintenance items return to the default values. F3: Returns the screen to “Maintenance Mode Setting” screen. F4: Executes initialization. REMARK Press F4, and the initialization completion screen is displayed after a short while. When “Maintenance Mode Setting” screen is displayed, initialization has completed.
Set Phone Number Entry The telephone number can be displayed together with “Current Abnormality” in the operator mode. Phone number can be registered and changed according to the following procedure. Phone number must be registered in order to display the number while in operator mode. 1. Select “Phone Number Entry” from the “Service Menu” screen. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
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2.
30 Testing and Adjusting
On “Phone Number Entry” screen, register/correct the phone number with the function switches. F1: Number gets smaller F2: Number gets larger F3: Returns the display to the “Service Menu” screen F4: Enters the input. F6: Moves the input position to the next left place (if not blank). F7: Moves the input position to the right (if not blank) F8: Deletes all the numbers. REMARK • Up to 14 digits can be inputted from the left. Leave the surplus places without inputting any digit. • If an inputted numeral is wrong, move the cursor (orange background) to that digit and overwrite it with the correct numeral. • If the phone number is not registered, no phone number is displayed in the operator mode when F4 is pressed.
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Set and Operate Machine Monitor
Default Menu Default Setting Menu (KEY-ON MODE) Default menu is used to check or change default values of the machine monitor and machine. Use “Key-on Mode” to set the working mode selected and displayed on the machine monitor when the starting switch is turned to ON position. 1. Select “Default” from the “Service Menu” screen. REMARK Selecting method is the same as on “Service Menu” screen.
2.
On “Default” screen, select “Key-on Mode” with the function switch. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
3.
On the “Key-on Mode” screen, select the mode to be set with the function switches. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Cancels the selection and returns the screen to “Default” screen F4: Enters the selected item and returns the screen to “Default” screen “Power Mode”: monitor displays “P” when the starting switch is turned on “Economy Mode”: monitor displays “E” when the starting switch is turned on “Attachment-P Mode”: monitor displays “ATT/P” (if attachment is installed) when the starting switch is turned on “Attachment-E Mode”: monitor displays “ATT/E” (if attachment is installed) when the starting switch is turned on “Mode at Previous Key-off”: monitor displays the mode which used from the previous operation when the starting switch is turned on REMARK • Default setting at shipment is “Mode at Previous Key-off”. • If “With Attachment” is not selected, “Attachment-P Mode” and “Attachment-E Mode” are unselectable. • If the attachment setting is changed to “without attachment” when either “Attachment-P Mode” or “Attachment-E Mode” is selected, the monitor displays P(“Power Mode”). • If the engine is stopped during operator mode when “Breaker Mode” is selected, the monitor displays “Breaker Mode” (“B”) regardless of the setting.
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Default Setting Menu (UNIT SELECTION) Default menu is used to check or change default values of the machine monitor and machine. The unit selecting function is used to select units of data displayed for monitoring, etc. 1. Select “Default” from the “Service Menu” screen. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
2.
On “Default” screen, select “Unit” with the function switch. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
3.
On the “Unit” screen, select the unit to be set with the function switches. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Cancels the selection and returns the screen to “Default” screen F4: Enters the selected item and returns the screen to “Default” screen
How to Set with Default Setting Menu (With/Without Attachment) Default menu is used to check or change default values of the machine monitor and machine. Use the sub menu of “With/Without Attachment” to configure attachment setting when the attachment is installed or removed. The settings can be changed if the machine is equipped with proportional lever. 1. Select “Default” from the “Service Menu” screen. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
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On “Default” screen, select “With/Without Attachment” with the function switch. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen REMARK Attachment function does not appear on the screen except for machine equipped with proportional lever.
3.
On “With/Without Attachment” screen, select a setting with the function switch. Without attachment: When attachment is not installed With 1 attachment: When 1 attachment is installed With 2 attachment: When 2 attachment is installed F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Cancels the selection and returns the screen to “Default” screen F4: Enters the selected item and returns the screen to “Default” screen REMARK When an attachment is installed, if this setting is not configured correctly, the attachment setting in the operator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic components may be damaged.
Default Setting Menu (Auto Idle Stop Time Fixing) Default menu is used to check or change default values of the machine monitor and machine. Auto idle stop timer fixing function sets the selectable time on “Auto Idle Stop Timer Set” in the operator mode. 1. Select “Default” from the “Service Menu” screen. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
2.
On “Default” screen, select “Auto Idle Stop Time Fixing” with the function switch. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
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On “Auto Idle Stop Time Fixing” screen, choose the setting of time with the function switch. “Flexible”: Set the time (“OFF” to “60 min”) on “Auto Idle Stop Timer Set” screen in operator mode. “OFF”: Hide the setting menu of “Auto Idle Stop Timer Set” screen in operator mode. x-minute fixing: Turn off the timer or the selected time cannot be extended on “Auto Idle Stop Timer Set” screen in the operator mode. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Cancels contents of setting before the entry and returns the screen to “Default” screen F4: Goes to confirmation screen of “Auto Idle Stop Time Fixing” REMARK • If this setting is turned “OFF”, “Auto Idle Stop Timer Set” cannot be performed in operator mode, and the auto idle stop function does not work. • The maximum value of the auto idle stop time must be set after checking compliance with the applicable law, which differs by region.
4.
On “Auto Idle Stop Time Fixing” screen, enter the setting with the function switch. F3: Cancels and returns the screen to the previous screen F4: Enters the change
•
This is an example of screen when setting changed successfully. If the setting changed, the screen returns to “Default” screen after pressing F4 again.
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This is an example of screen when your change was not applied successfully. When the setting is not applied successfully, the screen returns to “Auto Idle Stop Time Fixing” screen after pressing F3.
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Diagnostic Tests Menu Testing Menu (Cylinder Cutout Mode Operation) Testing menu is used to check the machine or reset the settings of the machine monitor. Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power normally (combustion in it is abnormal). NOTICE Do not perform “Cylinder Cutout Mode Operation” while connecting to Smart Assist Direct. 1. Select “Diagnostic Tests” on “Service Menu” screen.
2.
When “Diagnostic Tests” screen is displayed, use function switch to select “Cylinder Cutout Mode Operation”. REMARK Method of selecting is similar to “Service Menu” screen.
3.
On “Cylinder Cutout Mode Operation” screen, select a cylinder to be cut out with the function switches. F1: Selects ON/OFF of auto-deceleration function F2: Selects HOLD or releasing HOLD (If HOLD is selected, “HOLD” part is hatched) F3: Returns the screen to “Diagnostic Tests” screen F4: Enters the selection F6: Moves the selection leftward F7: Moves the selection rightward REMARK • This operation can be performed while the engine is running. • If background (a) of the selected cylinder number becomes white after pressing F4, the cylinder is cutout. • If the machine monitor cuts out a cylinder but the engine controller cannot cutout that cylinder, the background (a) of the cylinder number becomes yellow. • One or more cylinders can be cutout. • In Cylinder Cutout Mode Operation, the auto-deceleration function can be selected. When the auto-deceleration function is on, auto-deceleration pilot lamp (b) lights up. • The holding function is available for a cylinder, regardless of whether it is cutout or not.
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If a normally operating cylinder is cut out, the following phenomena occur. If the engine is running at near high idle, however, the engine speed may not be lowered for the reason of engine control. In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command with monitoring code: 62500 “Fuel Injection Rate (Total)”.
4.
•
Reduction of engine speed
•
Increase of fuel injection rate (total)
When changing a cylinder to be cutout or when cylinder cutout operation is finished, select a cutout cylinder to be reset with the function switches. NOTICE The cutout cylinder mode operation is not automatically released after the screen returns to the operator mode. Accordingly, be sure to perform the releasing operation after the cylinder cutout mode operation is finished. REMARK • This operation can be performed while the engine is running. • If background (a) of the selected cylinder No. becomes blue after pressing F4, the cylinder is reset. • If the machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cylinder, the background (a) of the cylinder number becomes red.
Testing Menu (Active Regeneration for Service) Testing menu is used to check the machine or reset the settings of the machine monitor. Active regeneration for service refers to the method of burning soot by performing aftertreatment devices regeneration, regardless of the soot accumulation. NOTICE Do not perform “Active Regeneration for Service” while connecting to Smart Assist Direct. 1. Select “Diagnostic Tests” on “Service Menu” screen.
2.
When the “Diagnostic Tests” screen is displayed, use the function switch to select “Active Regeneration for Service”. REMARK • Method of selecting is similar to “Service Menu” screen. • While the Aftertreatment Devices Regeneration status is in Manual Stationary Regeneration or stopped, “Active Regeneration for Service” cannot be selected.
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When the “Active Regeneration for Service” screen is displayed, the following information is displayed corresponding to the Aftertreatment Devices Regeneration condition. Set the Aftertreatment Devices Regeneration according to the given messages. a: Soot accumulation level b: Aftertreatment devices regeneration status c: Selectable items d: Message
4.
Select “Manual Stationary Regeneration” on the “Active Regeneration for Service” screen. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Returns the screen to “Diagnostic Tests” screen F4: Enters the selection
5.
When “Manual Stationary Regeneration” screen is displayed, press F4 to perform the manual stationary regeneration.
REMARK • The active regeneration for service cannot be started before completion of warm-up operation. • Press F3, the screen returns to “Active Regeneration for Service” screen. • The screen changes to the “Monitoring Selection Menu” screen which enables monitoring of machine information during active regeneration by performing the following switch operation during Active Regeneration for Service: Switch operation (While pressing F8, press other switches in order): F8 + F1 → F2 → F3 • Press F3 on “Monitoring” screen and the screen returns o the “Active Regeneration for Service” screen. • For the monitoring operation, see “How to Examine Self-Define Monitor Information” of “SET AND OPERATE MACHINE MONITOR”.
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• “Active Regeneration for Service” can be performed only when the lock lever is in LOCK position and the fuel control dial is in the MIN (Low idle) position. • Before performing Manual Stationary Regeneration, secure the safety of the surroundings, no people and no combustible are in the area. When the machine needs to be moved again for the sake of security, move it to a safe place and repeat the operation from the start. • “Active Regeneration for Service” stops automatically in about 30 minutes. • Select “Regeneration Disable” and press F4 during the manual stationary regeneration. The screen moves to “Regeneration Disable” screen, and the message of “Do you stop regeneration?” appears. You can stop by pressing F4. After the active regeneration for service is complete, “Regeneration completed.” is displayed on the screen. F3: Does not stop regeneration (manual stationary regeneration is continued) F4: Stops regeneration
Testing Menu (KDPF Memory Reset) Testing menu is used to check the machine or reset the settings of the machine monitor. “KDPF Memory Reset” resets KDPF information saved in the machine. Refer to this section to reset KDPF memory when KDPF is cleaned or replaced. NOTICE Do not perform “KDPF Memory Reset” while connecting to Smart Assist Direct. 1. Select “Diagnostic Tests” on “Service Menu” screen.
2.
On the “Diagnostic Tests” screen, use the function switch to select “KDPF Memory Reset”. REMARK Method of selecting is similar to “Service Menu” screen.
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On “KDPF Memory Reset” screen, select an item to be reset. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Returns the screen to “Diagnostic Tests” screen F4: Enters the selection F8: Changes the screen to Code Input screen. After cleaning or replacing KDOC, rest “KDOC Change”.
4.
After “Do you want to reset?” is displayed, enter the reset with the function switch. F3: Returns to the previous screen F4: Executes resetting
•
This is an example of screen when resetting is performed normally. When resetting is performed normally, if you press F3 again, the screen returns to “Diagnostic Tests” screen.
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This is an example of screen when resetting fails. When resetting fails, press F3 and the screen returns to “KDPF Memory Reset” screen.
Testing Menu (Rail Pressure Memory Reset) Testing menu is used to check the machine or reset the settings of the machine monitor. “Rail Pressure Memory Reset” resets the operation information of pressure limiter valve saved in the machine. Perform this when the common rail assembly or pressure limiter valve is replaced. NOTICE Do not perform “Rail Pressure Memory Reset” while connecting to Smart Assist Direct. 1. Select “Diagnostic Tests” on “Service Menu” screen.
2.
On the “Diagnostic Tests”, use the function switch to select “Rail Pressure Memory Reset”. REMARK Method of selecting is similar to “Service Menu” screen.
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When “Rail Pressure Memory Reset” screen is displayed, select “Common Rail Change”. F3: Returns the screen to “Diagnostic Tests” screen F4: Enters the selection
4.
After “Do you want to reset?” is displayed, enter the reset with the function switch. F3: Returns the screen to “Rail Pressure Memory Reset” screen F4: Executes resetting
•
This is an example of screen when resetting is performed normally. When resetting is performed normally, if you press F3 again, the screen returns to “Diagnostic Tests” screen.
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This is an example of screen when resetting fails. When resetting fails, if you press F3, the screen returns to “Rail Pressure Memory Reset” screen.
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Adjustment Menu Adjustment Menu (Pump Absorption Torque) Adjustment menu is used to check the various settings of the machine or to adjust the value. Function of Pump Absorption Torque adjusts the absorption torque of the main pump. 1. Select “Adjustment” on “Service Menu” screen.
2.
On “Adjustment” screen, use the function switch to select “Pump Absorption Torque”. REMARK Method of selecting is similar to “Service Menu” screen.
3.
After the “Pump Absorption Torque” screen is displayed, select the desired value at the right side by using the function switches. Set value: For the actual torque adjustment value, see table. F1: Decreases the set value F2: Increases the set value F4: Checks and enters setting. Returns to “Adjustment” screen. REMARK The 3-digit number in the left column does not change since it is the code of this function. Relational Table of Set Values and Torque Adjustment Values Code
021
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Set value
Torque adjustment value
000
+14.7 Nm {+1.5 kgfm}
001
+9.8 Nm {+1 kgfm}
002
+4.9 Nm {+0.5 kgfm}
003
0 Nm {0 kgfm}
004
-4.9 Nm {-0.5 kgfm}
005
-9.8 Nm {-1 kgfm}
006
-14.7 Nm {-1.5 kgfm}
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Adjustment Menu (Attachment EPC 2 Adjustment) Adjustment menu is used to check the various settings of the machine or to adjust the value. “Attachment EPC 2 Adjustment” function adjusts the current of attachment EPC2. 1. From “Service Menu” screen, select “Adjustment”. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
2.
On “Adjustment” screen, select “Attachment EPC 2 Adjustment” with the function switches. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
3.
On “Attachment EPC 2 Adjustment” screen, select the desired value at the right side by using the function switches. Set value: For the actual adjustment value of attachment EPC current, see the table. F1: Decreases the set value F2: Increases the set value F4: Checks and enters setting. Returns to “Adjustment” screen. REMARK The 3-digit number in the left column does not change since it is the code of this function.
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Relationship Between Set Value and Attachment EPC Current Adjustment Value Code
049
Set value
Attachment EPC current adjustment value
000
-100 mA
001
-90 mA
002
-80 mA
003
-70 mA
004
-60 mA
005
-50 mA
006
-40 mA
007
-30 mA
008
-20 mA
009
-10 mA
010
0 mA
011
10 mA
012
20 mA
013
30 mA
014
40 mA
015
50 mA
016
60 mA
017
70 mA
018
80 mA
019
90 mA
020
100 mA
Adjustment Menu (Attachment EPC 3 Adjustment) Adjustment menu is used to check the various settings of the machine or to adjust the value. “Attachment EPC 3 Adjustment” function adjusts the current of attachment EPC3. 1. From “Service Menu” screen, select “Adjustment”. REMARK For the selection method, see “How to Operate Service Mode” in “SERVICE MODE”.
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Set and Operate Machine Monitor
On “Adjustment” screen, select “Attachment EPC 3 Adjustment” with the function switches. F1: Moves the selected item down by one item F2: Moves the selected item up by one item F3: Returns the display to the “Service Menu” screen F4: Enters the selected item F8: Moves to the code entry screen
3.
On “Attachment EPC 2 Adjustment” screen, select the desired value at the right side by using the function switches. Set value: For the actual adjustment value of attachment EPC current, see the table. F1: Decreases the set value F2: Increases the set value F4: Checks and enters setting. Returns to “Adjustment” screen. REMARK The 3-digit number in the left column does not change since it is the code of this function.
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Relationship Between Set Value and Attachment EPC Current Adjustment Value Code
048
Set value
Attachment EPC current adjustment value
000
-100 mA
001
-90 mA
002
-80 mA
003
-70 mA
004
-60 mA
005
-50 mA
006
-40 mA
007
-30 mA
008
-20 mA
009
-10 mA
010
0 mA
011
10 mA
012
20 mA
013
30 mA
014
40 mA
015
50 mA
016
60 mA
017
70 mA
018
80 mA
019
90 mA
020
100 mA
How to Operate Battery Disconnect Switch Setting “Batt. Disconnect Set” enables and disables the setting of the system operating lamp. Battery disconnect setting is valid when the system operating lamp is installed. NOTICE • When the setting is invalid, open or short circuit error in system operating lamp cannot be detected even though the system operating lamp is installed. • Open circuit error occurs if the system operating lamp is not installed and the setting of battery disconnect is valid. Always select the setting of battery disconnect to invalid. 1. Select “Batt. Disconnect Set” on “Service Menu” screen.
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After “Batt. Disconnect Set” screen is displayed, select a setting with the function switch. F1: Moves the selection down by one item F2: Moves the selection up by one item F3: Cancels the selection and the screen returns to “Service Menu” screen F4: Enters the selection and the screen returns to “Service Menu” screen
3.
After entering the selection and retuning the screen to “Service Menu” screen, turn the starting switch to OFF position. When starting switch is turned to OFF position, the setting becomes valid.
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KOMTRAX Settings Menu Examine KOMTRAX Settings (Terminal State) The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Settings. “Terminal Setting State” is used to check the setting condition of the KOMTRAX terminal. 1. Select “KOMTRAX Settings” on “Service Menu” screen.
2.
When the “KOMTRAX Settings” screen is displayed, use the function switch to select “Terminal Status”. REMARK Method of selecting is similar to “Service Menu” screen.
3.
On “Terminal Status” screen, the following items of information are displayed. Terminal Type: Model name of the KOMTRAX communication modem KOMTRAX Communication Inspection: State of radio station establishment GMT time: Greenwich Mean Time (add 9 hours to it for Japan time) F3: Returns the screen to “KOMTRAX Settings” screen.
Examine KOMTRAX Settings (GPS & Communication State) The setting and operating state of KOMTRAX can be checked on KOMTRAX settings screen. “GPS & Communication Status” is used to check the positioning and communication condition of KOMTRAX terminal. 1. Select “KOMTRAX Settings” on “Service Menu” screen.
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Set and Operate Machine Monitor
When “KOMTRAX Settings” screen is displayed, use the function switch to select “GPS & Communication State”. REMARK Method of selecting is similar to “Service Menu” screen.
3.
On the “GPS & Communication Status” screen, the following items of information are displayed. Positioning: GPS positioning state Communication: Communication environment and connection state of the communication modem Number of messages not yet sent: Number of mails that are saved on the machine monitor and have not yet been transmitted F1: Moves the screen to the next page F2: Returns the screen to the previous page F3: Returns the screen to “KOMTRAX Settings” screen
Examine KOMTRAX Settings (Modem Information) The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Settings. “Modem Information” is used to check the phone number and IMSI of the KOMTRAX communication modem. 1. Select “KOMTRAX Settings” on “Service Menu” screen.
2.
When the “KOMTRAX Settings” screen is displayed, use the function switch to select “Modem Information”. REMARK Method of selecting is similar to “Service Menu” screen.
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Display the phone number and IMSI. F3: Returns the screen to “KOMTRAX Settings” screen
Show Service Message Special messages for the technician sent from KOMTRAX base station (a distributor, etc.) can be checked with this function. 1. Select “Service Message” on “Service Menu” screen.
2.
Displaying message •
Displaying message (read only) If there is a message, its contents are displayed. If there is no message, “No message.” is displayed. F1: Moves to the next page (when a message is more than 2 pages long) F2: Moves to the previous page (when a message is more than 2 pages long) F3: Returns the screen to “Service Menu” screen REMARK • The message is different from that sent to the operator in the operator mode. • This message is only for the technician. Even if a message is received, the message monitor is not displayed in the same way as the display in the operator mode.
•
Display of message (with message return function) When the guidance icon of F4 is displayed, press F4 and display the message reply screen.
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When the message return screen displays, input a number with the function switch, and confirm the number. After confirming the number, the message of “Do you send Numeric Input?” appears. F1: Decreases the input value by 1 F2: Increases the input value by 1 F3: Cancels the input and returns the screen to “Service Menu” screen F4: Enters the input value
2)
When “Do you send Numeric Input?” is displayed, input a number with the function switch, and confirm the number. The entered information is returned to KOMTRAX base station F3: Cancels the transmission and returns to “Message Return” screen F4: Enters the transmission REMARK • The message is different from that sent to the operator in the operator mode. • This message is only for the technician. Even if a message is received, the message monitor is not displayed in the same way as the display in the operator mode.
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How to Start Up KOMTRAX Terminal Observe the following for using KOMTRAX. 1. KOMTRAX key person performs “Machine Registration” by using KOMTRAX client PC. 2.
Perform “KOMTRAX Communication Inspection”. •
For operation procedures, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
•
Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor. Therefore, consult the KOMTRAX key person before using it.
When KOMTRAX Terminal is Replaced Observe the following when replacing KOMTRAX terminal and using it again. 1. Our technician provides a new terminal, and records the part number and serial number. 2.
Our technician replaces the terminal, and perform “KOMTRAX Communication Inspection”. Our technician notifies KOMTRAX key person of the completion of inspection work and new terminal information.
3.
KOMTRAX key person performs “Terminal Replacement” by using KOMTRAX client PC.
4.
KOMTRAX key person fills in required items on “Terminal Replacement Sheet”, and send it by email to KOMTRAX support center via KOMTRAX administrator in the subsidiary. •
For details, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
•
Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor. Therefore, consult the KOMTRAX key person before using it.
Communication Inspection on the Machine Side •
KOMTRAX Communication Inspection must be done to check whether normal communication is available from the terminal when the KOMTRAX terminal is replaced or started up.
•
By performing this inspection, KOMTRAX starts communication.
•
GPS and data communication are checked during the radio station establishment. Accordingly, it is preferable to place the machine under the open sky where radio wave from the satellite is not blocked. The radio station establishment may not be completed when the machine is placed indoor where radio wave from the satellite is blocked.
1.
Check the machine for KOMTRAX Communication Inspection Observe the following when checking if KOMTRAX Communication Inspection is to be performed or not. 1) On “Service Menu” screen, use the function switch to select “KOMTRAX Settings”.
2)
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When the “KOMTRAX Settings” screen is displayed, use the function switch to select “Terminal Status”.
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Electrical System
On “Terminal Status” screen, check the state of “KOMTRAX Comm Inspection”. REMARK When the state of “KOMTRAX Communication Inspection” shows “KOMTRAX Communication Not Open”, perform step 2. When “Already Open” is displayed, there is no need of radio station establishment.
2.
KOMTRAX Communication Inspection Observe the following when performing KOMTRAX Communication Inspection. 1) On “Service Menu” screen, use the function switch to select “KOMTRAX Settings”.
2)
On “KOMTRAX Settings” screen, select “GPS & Communication State” with the function switches.
3)
After “GPS & Communication State” screen is displayed, press the function switch F8 to select following switches (F8 + F1 → F2 → F3).
4)
After “Are you sure you want to inspect?” is displayed, execute the inspection with the function switch. F3: Returns the screen to “GPS & Communication State” screen F4: Executes KOMTRAX Communication Inspection.
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The screen displays the state of KOMTRAX Communication inspection. Check on this screen that all item are “OK”. “Modem”: “OK” is displayed when communication area is confirmed. “GPS”: “OK” is displayed when it acquires GPS data. “Transmission”: “OK” is displayed when it transmits data correctly. “Inspection State”: When all items of “Modem”, “GPS”, and “Transmission” are “OK”, “OK” is displayed on “Inspection State”.
6)
•
It takes 90 seconds to 15 minutes for all items to be “OK”.
•
While waiting for all items to be “OK”, operation such as turning the starting switch to OFF position or starting the engine will not be a problem. If there is nothing abnormal, KOMTRAX Communication Inspection finishes automatically. Select “KOMTRAX Settings” → “Terminal Status” of “Service Menu” to make sure that “Already Open” is indicated for the item in “KOMTRAX Comm Inspection”.
•
KOMTRAX Communication Inspection may not be completed when the machine is placed indoor where radio wave from the satellite is blocked.
When all items are “OK”, “Inspection finished normally.” screen automatically displayed. REMARK • Press function switch F4. When “GPS & Communication State” appears, the KOMTRAX Communication Inspection for machine side has completed. • Other than the above, perform step 3.
3.
Troubleshooting when KOMTRAX Communication Inspection is finished unsuccessfully •
If any of 1) to 5) in step 2 is finished unsuccessfully, perform inspection from 1) in step 2.
•
If 6) in step 2 is finished unsuccessfully, following problems are suspected. Troubleshooting When the Failure Occurs in the "Communication Inspection"
Phenomenon
Cause
Something on the cab blocks off GPS satGPS does not be- ellites acquisition. come OK. GPS antenna cable is not connected to
Required action Remove the obstacle on the cab.
Check for the connection. If the connection is loose, the KOMTRAX terminal, or they are loose. secure it. Check for state of in/out communication range with The mobile phone is out of communication your mobile phone. range. If it is out of communication range, move into communication reception range and perform inspection.
Modem does not become OK.
Communication antenna cable is not connected to the KOMTRAX terminal, or they are loose.
Check for the connection. If the connection is loose, secure it.
KOMTRAX terminal is not connected to machine side wiring harness, or they are loose.
Check for the connection. If the connection is loose, secure it.
When the problems are not solved, contact your KOMTRAX support center. 4.
After troubleshooting, perform 1) in step 2 again.
30-158
PC45MR-5, PC55MR-5
30 Testing and Adjusting
PC45MR-5, PC55MR-5
Electrical System
30-159
Handle Voltage Circuit of Engine Controller
30 Testing and Adjusting
Handle Voltage Circuit of Engine Controller NOTICE • Before connecting the wiring harness connector, be sure to completely remove sand, dust, water, etc., inside the connector on the controller side. • Disconnecting or connecting work of the connector between the engine controller and the engine must be performed only when the starting switch and battery disconnect switch are in OFF position. • Even when you perform troubleshooting, do not start the engine while a T-adapter is inserted into or connected to the connector between the engine controller and engine. REMARK You may turn the starting switch to OFF or ON position but do not turn it to START position. (Do not start the engine).
30-160
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Examine Diodes
Examine Diodes Test the diode array (8-pin) and the single diode (2-pin) according to the following procedure. The continuity directions of the diode array are as shown in the figure. REMARK The continuity direction of the single diode is indicated on the surface of the diode.
Examine Diodes by Digital Tester 1.
Select the screen to the diode range to check the displayed values. REMARK When an ordinary circuit multimeter is used, the voltage of the internal battery is indicated.
2.
Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N) side, and check the indicated value.
3.
Evaluate the condition of the diode by the indicated value. Indicated value does not change: No continuity (defective) Indicated value changes: Continuity (normal) (*) In the case of a silicon diode, a value in the range between 460 to 600 mV is indicated.
How to Examine Diodes by Analog Tester 1.
Selects the screen for resistance range.
2.
Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N) side, and check that the pointer moves.
3.
Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to the anode (P) side, and check that the pointer moves.
4.
Evaluate the condition of the diode by the movement of the pointer. Result of movement of the pointer Step 2
Step 3
Judgment Normal (however, the movement of the pointer (resistance) varies by type of tester, or selection of measuring range).
Moves
Does not move
Moves
Moves
Defective (internal short circuit)
Does not move
Does not move
Defective (internal open circuit)
PC45MR-5, PC55MR-5
30-161
Pm Clinic Service
30 Testing and Adjusting
Pm Clinic Pm Clinic Service Machine model
Serial No.
Service meter
□ PC45MR-5
h
□ PC55MR-5 User name
Date of inspection
Inspector
SPECIFICATIONS Main parts
Attachment
□ Boom, standard
□
□ Breaker
□ Arm, standard
□
□
□ Bucket, standard
□
□
Shoe width □ 400mm □
Check of oil and coolant levels □ Radiator coolant
When necessary
□ Engine oil
□ PTO gear case oil
□ Machinery case oil
□ Hydraulic oil
□ Final drive case oil
□
Ambient temperature
Altitude °C
m
Operator's comment
Result of visual inspection
B@BCNS
Times/First time
h/Latest
h
Times/First time
h/Latest
h
989EKX
Times/First time
h/Latest
h
Times/First time
h/Latest
h
Maximum Range of the Engine Coolant Temperature Gauge Coolant temperature Coolant temperature gauge level
30-162
5
110 °C
4
107 °C
3
105 °C
2
86 °C
1
59 °C
Color of monitor light (a) Red
Blue White
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Pm Clinic Service
Pm Clinic Check Sheet: PC45MR-5 NOTICE Perform the checks after sufficient warm-up operation of the engine. Machine model
Serial No.
Service meter
User name
Date of inspection
Inspector
PC45MR-5
Engine Machine model
PC45MR-5
Engine
4D88E-7
Item
Testing conditions •
•
Unit
Engine coolant temperature: 60 to 100 °C
Maximum value during the swing opFuel control dial: eration or MAX (High idle) po- travelling
Standard value for new machine
Repair limit
No Go go Meas- od od ured value
2500 to 2600 2500 to 2600 {2500 to 2600} {2500 to 2600}
sition Engine speed at high idle (*1)
Engine speed at low idle (*1)
Engine oil pressure
•
Working mode: P (Power Mode)
•
Travel speed: Hi
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
•
Engine coolant temperature: 60 to 100 °C
•
Fuel control dial: MIN (Low idle) position
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
•
Engine coolant temperature: 60 to 100 °C
•
Working mode: P (Power Mode)
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
•
Engine oil (*2) EO10W30-LA
min-1 {rpm} Each control lever: NEUTRAL position
2380 to 2480 2380 to 2480 {2380 to 2480} {2380 to 2480}
min-1 {rpm}
Fuel control dial: MAX (High idle) position
1175 to 1275 1175 to 1275 {1175 to 1275} {1175 to 1275}
0.32 to 0.47
Min. 0.05
{3.3 to 4.8}
{Min. 0.51}
Min. 0.06
Min. 0.05
{Min. 0.6}
{Min. 0.51}
MPa Fuel control dial: MIN (Low idle) position
{kgf/cm2}
EO15W40-LA EO30-DH *1: Item that can be checked in monitoring function of machine monitor PC45MR-5, PC55MR-5
30-163
Pm Clinic Service
30 Testing and Adjusting
*2: KES diesel engine oil Work Equipment Speed
Item
PC45MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move the bucket between ground level and rising stroke end (just before cushion)
Boom RAISE
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 8”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move arm between arm OUT stroke end and arm IN stroke end
Arm IN
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 9”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Between arm IN stroke end and arm OUT stroke end (just before cushion)
Arm OUT
•
30-164
Machine model
Unit
Standard value for new machine
Repair limit
Sec.
2.5 to 3.1
Max. 3.4
Sec.
2.7 to 3.3
Max. 3.6
Sec.
2.2 to 2.8
Max. 3.0
No Go go Meas- od od ured value
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 9”.
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Item
Pm Clinic Service
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move bucket between DUMP stroke end and CURL stroke end
Bucket CURL •
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 10”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move bucket between DUMP stroke end and CURL stroke end
Bucket DUMP •
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 10”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move blade between ground level and rising end
Blade RAISE •
Unit
Standard value for new machine
Repair limit
Sec.
2.6 to 3.2
Max. 3.0
Sec.
1.7 to 2.3
Max. 2.4
Sec.
0.8 to 1.4
Max. 1.4
No Go go Meas- od od ured value
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 11”.
PC45MR-5, PC55MR-5
30-165
Pm Clinic Service
Item
Blade LOWER
30 Testing and Adjusting
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move blade between ground level and rising end
•
Unit
Standard value for new machine
Repair limit
Sec.
0.8 to 1.4
Max. 1.4
No Go go Meas- od od ured value
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 11”.
Swing Speed
Item
Time required to finish swinging
30-166
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions •
Work equipment: No load, max. reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Contents of measurement: Time required to complete 5 swings after 1 swing
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 2”.
Unit
Standard value for new machine
Repair limit
Sec.
30 to 36
Max. 38
No Go go Meas- od od ured value
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Pm Clinic Service
Travel Speed
Item
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to travel 20 m after running up 10 m on a level ground
•
Contents of measurement: Time required to complete 5 idle turns of track off ground after 1 idle turn
Travel speed
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 4”.
•
Value in ( ): Time required for steel shoe specification machine
PC45MR-5, PC55MR-5
Unit
Lo
Sec. Hi
Standard value for new machine
Repair limit
25.7 to 29.7
23.7 to 31.7
(28.0 to 32.0)
(26.0 to 34.0)
13.7 to 17.7
11.7 to 19.7
(14.7 to 18.7)
(12.7 to 20.7)
No Go go Meas- od od ured value
30-167
Pm Clinic Service
30 Testing and Adjusting
Hydraulic drift of work equipment
Item
Whole work equipment (Hydraulic drift measured at tooth tip)
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions •
Level and flat ground
•
Hydraulic oil temperature: 45 to 55 °C
•
Stop the engine
•
All control levers and pedals: NEUTRAL position
•
Bucket: Rated load (rated load 2254 N {230 kgf})
•
Start the measuring immediately after setting the machine in measuring posture
•
Measure hydraulic drift every 5 minutes and judge after 15 minutes
•
Measuring posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 7”.
Unit
Standard value for new machine
Repair limit
mm
Max. 300
Max. 450
No Go go Meas- od od ured value
Hydraulic Circuit
Item
Control circuit oil pressure (*1)
Unload pressure (*1)
30-168
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions
Unit
Standard value for new machine
Repair limit
MPa
5.0 to 5.49
5.0 to 5.49
{51 to 56}
{51 to 56}
MPa
2.45 to 3.43
2.45 to 3.43
{kgf/cm2}
{25 to 35}
{25 to 35}
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode) {kgf/cm2} Auto-deceleration: OFF
• •
All control levers and pedals: NEUTRAL position
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
No Go go Meas- od od ured value
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Item
Arm relief pressure (*1)
Swing relief pressure (*1)
Travel relief pressure (*1)
LS differential pressure (*1)
Pm Clinic Service
Machine model
PC45MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Work equipment control lever: Arm IN relief
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Work equipment control lever: Swing relief
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Each controllever: Bucket CURL (with no load)
•
LS differential pressure = Pump discharge pressure - LS pressure
Unit
Standard value for new machine
MPa
25.52 to 27.48 25.52 to 27.48
{kgf/cm2}
MPa {kgf/cm2}
MPa
{260 to 280}
Repair limit
No Go go Meas- od od ured value
{260 to 280}
18.62 to 20.58 18.62 to 20.58 {190 to 210}
{190 to 210}
25.52 to 27.48 25.52 to 27.48
{kgf/cm2}
{260 to 280}
{260 to 280}
MPa
1.47 to 1.67
1.47 to 1.67
{kgf/cm2}
{15 to 17}
{15 to 17}
*1: Item that can be checked in monitoring function of machine monitor
PC45MR-5, PC55MR-5
30-169
Pm Clinic Service
30 Testing and Adjusting
Pm Clinic Check Sheet: PC55MR-5 NOTICE Perform the checks after sufficient warm-up operation of the engine. Machine model
Serial No.
Service meter
User name
Date of inspection
Inspector
PC55MR-5
Engine Machine model
PC55MR-5
Engine
4D88E-7
Item
Testing conditions •
•
Unit
Engine coolant temperature: 60 to 100 °C
Maximum value during the swing opFuel control dial: eration or MAX (High idle) po- travelling
Standard value for new machine
Repair limit
No Go go Meas- od od ured value
2500 to 2600 2500 to 2600 {2500 to 2600} {2500 to 2600}
sition Engine speed at high idle (*1)
Engine speed at low idle (*1)
Engine oil pressure
•
Working mode: P (Power Mode)
•
Travel speed: Hi
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
•
Engine coolant temperature: 60 to 100 °C
•
Fuel control dial: MIN (Low idle) position
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
•
Engine coolant temperature: 60 to 100 °C
•
Working mode: P (Power Mode)
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
•
Engine oil (*2) EO10W30-LA
min-1 {rpm} Each control lever: NEUTRAL position
2380 to 2480 2380 to 2480 {2380 to 2480} {2380 to 2480}
min-1 {rpm}
Fuel control dial: MAX (High idle) position
1175 to 1275 1175 to 1275 {1175 to 1275} {1175 to 1275}
0.32 to 0.47
Min. 0.05
{3.3 to 4.8}
{Min. 0.51}
Min. 0.06
Min. 0.05
{Min. 0.6}
{Min. 0.51}
MPa Fuel control dial: MIN (Low idle) position
{kgf/cm2}
EO15W40-LA EO30-DH *1: Item that can be checked in monitoring function of machine monitor 30-170
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Pm Clinic Service
*2: KES diesel engine oil Work Equipment Speed
Item
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move the bucket between ground level and rising stroke end (just before cushion)
Boom RAISE
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 8”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move arm between arm OUT stroke end and arm IN stroke end
Arm IN
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 9”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Between arm IN stroke end and arm OUT stroke end (just before cushion)
Arm OUT
•
Unit
Standard value for new machine
Repair limit
Sec.
2.5 to 3.1
Max. 3.4
Sec.
2.8 to 3.4
Max. 3.7
Sec.
2.3 to 2.9
Max. 3.0
No Go go Meas- od od ured value
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 9”.
PC45MR-5, PC55MR-5
30-171
Pm Clinic Service
Item
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move bucket between DUMP stroke end and CURL stroke end
Bucket CURL •
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 10”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move bucket between DUMP stroke end and CURL stroke end
Bucket DUMP •
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 10”.
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move blade between ground level and rising end
Blade RAISE •
30-172
30 Testing and Adjusting
Unit
Standard value for new machine
Repair limit
Sec.
2.5 to 3.1
Max. 3.4
Sec.
1.7 to 2.3
Max. 2.4
Sec.
1.0 to 1.6
Max. 1.6
No Go go Meas- od od ured value
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 11”.
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Item
Blade LOWER
Pm Clinic Service
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Measurement range: Time required to move blade between ground level and rising end
•
Unit
Standard value for new machine
Repair limit
Sec.
1.0 to 1.6
Max. 1.6
No Go go Meas- od od ured value
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 11”.
Swing Speed
Item
Time required for swing
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions •
Work equipment: No load, max. reach
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Contents of measurement: Time required to complete 5 swings after 1 swing
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 2”.
PC45MR-5, PC55MR-5
Unit
Standard value for new machine
Repair limit
Sec.
30 to 36
Max. 38
No Go go Meas- od od ured value
30-173
Pm Clinic Service
30 Testing and Adjusting
Travel Speed
Item
PC55MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Time required to travel 20 m after running up 10 m on a level ground
•
Contents of measurement: Time required to complete 5 idle turns of track off ground after 1 idle turn
Travel speed
30-174
Machine model
•
See measuring posture, STANDARD VALUE TABLE, “MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE”, “Fig. 4”.
•
Value in ( ): Time required for steel shoe specification machine
Unit
Lo
Sec. Hi
Standard value for new machine
Repair limit
25.7 to 29.7
23.7 to 31.7
(28.0 to 32.0)
(26.0 to 34.0)
13.7 to 17.7
11.7 to 19.7
(14.7 to 18.7)
(12.7 to 20.7)
No Go go Meas- od od ured value
PC45MR-5, PC55MR-5
30 Testing and Adjusting
Pm Clinic Service
Hydraulic drift of work equipment
Item
Whole work equipment (Hydraulic drift measured at tooth tip)
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions •
Level and flat ground
•
Hydraulic oil temperature: 45 to 55 °C
•
Stop the engine
•
All control levers and pedals: NEUTRAL position
•
Bucket: Rated load (rated load 2450 N {250 kgf})
•
Start the measuring immediately after setting the machine in measuring posture
•
Measure hydraulic drift every 5 minutes and judge after 15 minutes
•
Measuring posture: See “Machine Posture and Procedures to Measure Performance”, “Fig. 7”.
Unit
Standard value for new machine
Repair limit
mm
Max. 300
Max. 450
No Go go Meas- od od ured value
Hydraulic Circuit
Item
Control circuit oil pressure (*1)
Unload pressure (*1)
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions
Unit
Standard value for new machine
Repair limit
MPa
5.0 to 5.49
5.0 to 5.49
{51 to 56}
{51 to 56}
MPa
2.45 to 3.43
2.45 to 3.43
{kgf/cm2}
{25 to 35}
{25 to 35}
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode) {kgf/cm2} Auto-deceleration: OFF
• •
All control levers and pedals: NEUTRAL position
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Auto-deceleration: OFF
•
All control levers and pedals: NEUTRAL position
PC45MR-5, PC55MR-5
No Go go Meas- od od ured value
30-175
Pm Clinic Service
Item
Arm relief pressure (*1)
Swing relief pressure (*1)
Travel relief pressure (*1)
LS differential pressure (*1)
30 Testing and Adjusting
Machine model
PC55MR-5
Engine
4D88E-7
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Work equipment control lever: Arm IN relief
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Work equipment control lever: Swing relief
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P (Power Mode)
•
Each controllever: Bucket CURL (with no load)
•
LS differential pressure = Pump discharged pressure - LS pressure
Unit
Standard value for new machine
MPa
25.52 to 27.48 25.52 to 27.48
{kgf/cm2}
MPa {kgf/cm2}
MPa
{260 to 280}
Repair limit
No Go go Meas- od od ured value
{260 to 280}
18.62 to 20.58 18.62 to 20.58 {190 to 210}
{190 to 210}
25.52 to 27.48 25.52 to 27.48
{kgf/cm2}
{260 to 280}
{260 to 280}
MPa
1.47 to 1.67
1.47 to 1.67
{kgf/cm2}
{15 to 17}
{15 to 17}
*1: Item that can be checked in monitoring function of machine monitor
30-176
PC45MR-5, PC55MR-5
40 Troubleshooting
PC45MR-5, PC55MR-5
40-1
Table of Contents
40 Troubleshooting
Table of Contents Abbreviation List ............................................................................................................................................ 40-6 Precautions Before Work ............................................................................................................................. 40-12 Related Information to Troubleshooting........................................................................................................ 40-13 General Troubleshooting Points ............................................................................................................ 40-13 Sequence of Events in Troubleshooting ................................................................................................ 40-14 Checks Before Troubleshooting ............................................................................................................ 40-16 Inspection Procedure Before Troubleshooting....................................................................................... 40-18 Walk-Around Check ....................................................................................................................... 40-18 Test in Accordance with Testing Procedure ........................................................................................... 40-20 Examine Fuel Level and Type ........................................................................................................ 40-20 Examine Fuel Prefilter.................................................................................................................... 40-21 Examine Water Separator, Drain Water and Sediment................................................................... 40-23 Examine Fuel Main Filter ............................................................................................................... 40-24 Examine Engine Oil Level (Oil Quantity in Oil Pan) ........................................................................ 40-27 Examine Coolant Level (Reservoir Tank) ....................................................................................... 40-28 Examine Air Cleaner Clogging ....................................................................................................... 40-29 Clean Outer Element (Single Element)........................................................................................... 40-30 Clean Outer Element (Double Element) ......................................................................................... 40-33 Replace Single Element................................................................................................................. 40-35 Replace Double Element ............................................................................................................... 40-37 Examine Hydraulic Oil Level .......................................................................................................... 40-39 Examine Hydraulic Oil Strainer ...................................................................................................... 40-43 Examine Hydraulic Oil Filter ........................................................................................................... 40-44 Examine Oil Level in Final Drive Case ........................................................................................... 40-46 Bleed Air from Fuel System............................................................................................................ 40-46 Bleed Air from Hydraulic System.................................................................................................... 40-46 How to Examine Electric Equipment .............................................................................................. 40-46 Preparation for Troubleshooting of Electrical System ............................................................................ 40-54 Procedure for Troubleshooting .............................................................................................................. 40-58 Symptom and Troubleshooting Numbers .............................................................................................. 40-61 Information Shown in Troubleshooting Table......................................................................................... 40-65 Connector List and Layout .................................................................................................................... 40-67 Connector Contact Identification (For 4D88E-7 Engine)........................................................................ 40-83 T-Branch Box and T-Branch Adapter Table ........................................................................................... 40-87 Fuse Location Table .............................................................................................................................. 40-93 Precautions When You Clean and Replace KDPF (KCSF and KDOC).................................................. 40-97 Failure Code Table ................................................................................................................................ 40-99 Troubleshooting by Failure Code (Display of Code) ....................................................................................40-109 Failure Code [989L00]..........................................................................................................................40-109 Failure Code [989M00].........................................................................................................................40-110 Failure Code [989N00] ......................................................................................................................... 40-111 Failure Code [AQ20R1]........................................................................................................................40-112 Failure Code [B@BCNS]......................................................................................................................40-113 Failure Code [D19JKZ].........................................................................................................................40-114 Failure Code [D811MC]........................................................................................................................40-117 Failure Code [D862KA] ........................................................................................................................40-118 Failure Code [D8ALKA]........................................................................................................................40-119 Failure Code [D8ALKB]........................................................................................................................40-121 Failure Code [D8AQKR] .......................................................................................................................40-123 Failure Code [DAF0KT]........................................................................................................................40-125 Failure Code [DAF0MB] .......................................................................................................................40-126 Failure Code [DAF0MC] .......................................................................................................................40-127 Failure Code [DAF3KK]........................................................................................................................40-128 Failure Code [DAF9KQ] .......................................................................................................................40-130 Failure Code [DAFGMC] ......................................................................................................................40-131 Failure Code [DAFLKA]........................................................................................................................40-132 40-2
PC45MR-5, PC55MR-5
40 Troubleshooting
Table of Contents
Failure Code [DAFLKB]........................................................................................................................40-134 Failure Code [DAFQKR].......................................................................................................................40-136 Failure Code [DB2QKR] .......................................................................................................................40-137 Failure Code [DBH0MC] ......................................................................................................................40-141 Failure Code [DBH2KK] .......................................................................................................................40-142 Failure Code [DBH5KP] .......................................................................................................................40-145 Failure Code [DBH5KP] .......................................................................................................................40-147 Failure Code [DBH9KQ] .......................................................................................................................40-149 Failure Code [DBHLKA] .......................................................................................................................40-151 Failure Code [DBHLKB] .......................................................................................................................40-153 Failure Code [DBHQKR] ......................................................................................................................40-155 Failure Code [DDNRKA] ......................................................................................................................40-160 Failure Code [DDNRKY] ......................................................................................................................40-162 Failure Code [DDNS00] .......................................................................................................................40-164 Failure Code [DDWLKA] ......................................................................................................................40-166 Failure Code [DDWLKB] ......................................................................................................................40-168 Failure Code [DFB1KZ]........................................................................................................................40-170 Failure Code [DFB3L8] ........................................................................................................................40-172 Failure Code [DFB5KZ]........................................................................................................................40-174 Failure Code [DHS1MA].......................................................................................................................40-176 Failure Code [DHS5MA].......................................................................................................................40-178 Failure Code [DKULKA] .......................................................................................................................40-180 Failure Code [DKULKB] .......................................................................................................................40-182 Failure Code [DKULKY] .......................................................................................................................40-184 Failure Code [DV00KB]........................................................................................................................40-186 Failure Code [DV20KB]........................................................................................................................40-187 Failure Code [DW43KA] .......................................................................................................................40-189 Failure Code [DW43KB] .......................................................................................................................40-191 Failure Code [DW43KY] .......................................................................................................................40-193 Failure Code [DW4CKY] ......................................................................................................................40-194 Failure Code [DXA8KA] .......................................................................................................................40-196 Failure Code [DXA8KB] .......................................................................................................................40-198 Failure Code [DXE7KA] .......................................................................................................................40-200 Failure Code [DXE7KB] .......................................................................................................................40-202 Failure Code [DXE7KY] .......................................................................................................................40-204 Failure Code [DXEAKA] .......................................................................................................................40-206 Failure Code [DXEAKB] .......................................................................................................................40-208 Failure Code [DXEAKY] .......................................................................................................................40-210 Troubleshooting of Electrical System (E-Mode)...........................................................................................40-212 E-1 Engine Does Not Start (Engine Does Not Crank)...........................................................................40-212 E-2 Engine Does Not Start (Fuel Feed Pump System).........................................................................40-218 E-3 Automatic Preheating System Does Not Operate ..........................................................................40-220 E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing......................40-222 E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs..............................40-225 E-6 Charge Level Monitor Comes On in Red While Engine is in Operation..........................................40-226 E-7 Fuel Level Monitor Comes On in Red While Engine Runs .............................................................40-227 E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation ..................40-228 E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation ................................40-229 E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum ................................................40-230 E-11 Display of Fuel Gauge is Different from Actual Fuel Level............................................................40-232 E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum ......................40-233 E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature.................40-234 E-14 Some Areas of Machine Monitor Screen are Not Shown .............................................................40-235 E-15 Function Switch Does Not Operate..............................................................................................40-236 E-16 Auto-Decelerator is Not Operated or Canceled with Lever...........................................................40-237 E-17 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed .........40-238 E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change ....................40-239 E-19 Alarm Buzzer Does Not Sound ....................................................................................................40-241 PC45MR-5, PC55MR-5
40-3
Table of Contents
40 Troubleshooting
E-20 Alarm Buzzer Cannot be Canceled..............................................................................................40-242 E-21 Service Meter is Not Shown, While Starting Switch is in OFF Position ........................................40-243 E-22 Service Mode Cannot be Selected...............................................................................................40-244 E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move...........................................40-245 E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock............................................40-247 E-25 Alarm Does Not Sound During Travel ..........................................................................................40-249 E-26 Travel Alarm Does Not Stop When Machine Stops......................................................................40-251 E-27 Horn Does Not Sound..................................................................................................................40-252 E-28 Horn Does Not Sound (For Proportional Lever Spec) ..................................................................40-254 E-29 Horn Does Not Stop ....................................................................................................................40-256 E-30 Horn Does Not Stop (For Proportional Lever Spec) .....................................................................40-258 E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec).............................................40-260 E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec) ......................40-264 E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate .......................................40-268 E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate.........................40-270 E-35 Travel Indicator is Not Shown Correctly with Monitoring Function................................................40-272 E-36 Swing or Arm IN is Not Shown Normally in Monitoring Function ..................................................40-273 E-37 Work Equipment is Not Shown Normally in Monitoring Function..................................................40-274 E-38 KOMTRAX System Does Not Operate Normally..........................................................................40-276 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)..............................................................40-277 Information Shown in Troubleshooting Table (H-Mode) ........................................................................40-277 H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate ........................................................40-278 H-2 All Work Equipment or Travel Does Not Operate...........................................................................40-279 H-3 Travel or Blade Does Not Operate.................................................................................................40-280 H-4 Swing or Blade Does Not Operate.................................................................................................40-281 H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low..........................................40-282 H-6 All Work Equipment and Travel Speed or Power is Low ................................................................40-283 H-7 Travel and Blade Speed or Power is Low ......................................................................................40-284 H-8 Swing and Blade Speed or Power is Low ......................................................................................40-285 H-9 Fine Control Performance or Response is Unsatisfactory..............................................................40-286 H-10 Unusual Noise is Heard from Around Hydraulic Pump.................................................................40-287 H-11 Engine Speed Drops Largely or Engine Stops .............................................................................40-288 H-12 All Work Equipment Speed or Power is Low................................................................................40-290 H-13 All Work Equipment and Blade Speed or Power is Low...............................................................40-291 H-14 Blade Does Not Operate .............................................................................................................40-292 H-15 All Work Equipment Do Not Operate ...........................................................................................40-293 H-16 All Work Equipment or Blade Do Not Operate .............................................................................40-294 H-17 Speed or Power of Boom is Low .................................................................................................40-295 H-18 Arm Speed or Power is Low ........................................................................................................40-297 H-19 Bucket Speed or Power is Low....................................................................................................40-298 H-20 Blade Speed or Power is Low......................................................................................................40-299 H-21 Boom Swing Speed or Power is Low...........................................................................................40-301 H-22 Work Equipment Does Not Move in Single Operation..................................................................40-302 H-23 Hydraulic Drift of Boom is Large ..................................................................................................40-303 H-24 Hydraulic Drift of Arm is Large.....................................................................................................40-304 H-25 Hydraulic Drift of Bucket is Large.................................................................................................40-305 H-26 Hydraulic Drift of Blade is Large ..................................................................................................40-306 H-27 Time Lag of Work Equipment is Large .........................................................................................40-308 H-28 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower.......40-309 H-29 Machine Does Not Travel Straight ...............................................................................................40-310 H-30 Machine Does Not Move Off Straight ..........................................................................................40-312 H-31 Machine is Not Steered Correctly or Steering Power is Low ........................................................40-313 H-32 Travel Speed is Low ....................................................................................................................40-315 H-33 Two Sides of Crawlers Do Not Move ...........................................................................................40-317 H-34 One of Tracks Does Not Run.......................................................................................................40-318 H-35 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast ........................................40-320 H-36 Upper Structure Does Not Swing to Right and Left......................................................................40-321 H-37 Upper Structure Swings Only to Right or Left ..............................................................................40-323 40-4
PC45MR-5, PC55MR-5
40 Troubleshooting
Table of Contents
H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions......................................40-325 H-39 Swing Acceleration or Swing Speed is Low in Only One Direction ..............................................40-327 H-40 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)................40-328 H-41 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) ........40-329 H-42 Shock is Large When Upper Structure Stops Swing Operation ...................................................40-330 H-43 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation............................40-331 H-44 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) .....................................40-332 H-45 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) ..................................40-333 Troubleshooting of Engine (S-Mode)...........................................................................................................40-334 Information Shown in Troubleshooting Table (S-Mode) ........................................................................40-334 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position.....................................40-335 S-2 Engine Cranks but No Exhaust Smoke Comes Out .......................................................................40-336 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).............40-337 S-4 Engine Startability is Unsatisfactory...............................................................................................40-338 S-5 Engine Does Not Pick Up Smoothly...............................................................................................40-340 S-6 Engine Stops During Operation .....................................................................................................40-342 S-7 Engine Runs Rough or is Not Stable .............................................................................................40-343 S-8 Engine Lacks Power ......................................................................................................................40-344 S-9 KDPF Becomes Clogged in a Short Time ......................................................................................40-346 S-10 Engine Oil Consumption is Excessive..........................................................................................40-347 S-11 Oil Becomes Dirty Quickly............................................................................................................40-348 S-12 Fuel Consumption is Excessive ...................................................................................................40-349 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant....................................................................40-350 S-14 Oil Pressure Drops ......................................................................................................................40-351 S-15 Fuel Mixes Into Engine Oil ...........................................................................................................40-353 S-16 Water Mixes Into Engine Oil (Milky) .............................................................................................40-354 S-17 Coolant Temperature Increases Too High (Overheating) .............................................................40-355 S-18 Unusual Noise is Heard ...............................................................................................................40-356 S-19 Vibration is Excessive..................................................................................................................40-357 S-20 Air Cannot be Bled from Fuel Circuit............................................................................................40-358
PC45MR-5, PC55MR-5
40-5
Abbreviation List
40 Troubleshooting
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
40-6
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
PC45MR-5, PC55MR-5
40 Troubleshooting
Abbreviation
Actual word spelled out
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
PC45MR-5, PC55MR-5
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
40-7
Abbreviation List
40 Troubleshooting
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
40-8
Mass Air Flow
PC45MR-5, PC55MR-5
40 Troubleshooting
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
PC45MR-5, PC55MR-5
Urea SCR system
Electrical system
40-9
Abbreviation List
Abbreviation
TOPS
40 Troubleshooting
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
40-10
PC45MR-5, PC55MR-5
40 Troubleshooting
Abbreviation S/T STRG
Actual word spelled out Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
Abbreviation List
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
40-11
Precautions Before Work
40 Troubleshooting
Precautions Before Work Before you start, read the “Safety Notice for Operation” of the “Index and Foreword” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a dan-
ger that you can get caught in the machine. •
Do not wear oversized clothes or accessories.
•
Be sure to tie the long hair that comes out from the helmet.
•
Decide on the work procedure.
•
Obey the specified signal during the work.
k When you work together with more than one person, do the preparation that follows.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange an
observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not to
let the machine move. •
Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
•
Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts, there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.
40-12
PC45MR-5, PC55MR-5
40 Troubleshooting
General Troubleshooting Points
Related Information to Troubleshooting General Troubleshooting Points
k If you remove the radiator cap while the engine is still hot, hot coolant may spout out and can scald
you. Wait until the engine cools down.
k Take extreme care not to touch a hot portion or not to be wound in a turning portion.
k Before removing a plug or a cap of a portion where oil pressure, hydraulic pressure, or air pressure
is applied, release the internal pressure first, then connect the measuring tool securely.
k When disconnecting wiring, remove the key and turn the battery disconnect switch to OFF position. k Park the machine on a level place and check the frame lock bar, chocks, parking brake, etc.
k When working in a group, make signs and allow only the persons concerned to approach the ma-
chine. •
Troubleshooting means to investigate the root cause of a failure, repair immediately, and prevent recurrence of the failure.
•
One important thing when you perform troubleshooting is to understand the structure and operation.
•
It is important to have an interview with the operator and set up an aim of failure cause for performing a troubleshooting effectively.
•
If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions and may not be able to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may increase, and you may lose the confidence of the users and operators. Accordingly, sufficient advance check and proper procedure are necessary for troubleshooting.
1.
Ask users or operators the following questions. 1) Have any other problems occurred apart from the problem that has been reported?
2.
3.
2)
Is 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 performed before the failure? When were these repairs performed?
6)
Has the same kind of failure occurred before?
Perform the following checks before troubleshooting. 1) Check the machine for a symptom of abnormality. 2)
Perform the Check before starting items.
3)
Check the other check items.
4)
Check other maintenance matters which can be checked externally and are considered to be necessary.
Check the degree of the trouble by yourself and judge if it is a real failure or it is a problem of handling or operation. When reproducing the trouble phenomenon by operating the machine, do not perform check or measurement that can increase the failure.
4.
Use the results of the investigation and inspection to narrow down the probable causes of the failure, then use the troubleshooting flow chart (matrix) to locate the failure exactly. The basic troubleshooting procedure is as follows.
5.
•
Start from the simple points.
•
Start from the most likely points.
•
Investigate other related parts or information.
If the root cause is not corrected, a similar failure may occur again even if the apparent failure has been repaired. Always find out the cause of a failure first and remove the root cause of each failure.
PC45MR-5, PC55MR-5
40-13
Sequence of Events in Troubleshooting
40 Troubleshooting
Sequence of Events in Troubleshooting
40-14
PC45MR-5, PC55MR-5
40 Troubleshooting
PC45MR-5, PC55MR-5
Sequence of Events in Troubleshooting
40-15
Checks Before Troubleshooting
40 Troubleshooting
Checks Before Troubleshooting Engine, Lubricating Oil, and Coolant No.
Item
Criteria
Remedy
1
Check for unusual noise and smell
-
Repair
2
Check around engine for dirt
-
Remove
3
Check around engine for water leakage
-
Repair
4
Check around engine for oil leakage
-
Repair
5
Check fuel line for leakage
-
Repair
6
Check radiator for clogging
-
Remove
7
Check fuel level and type
-
Refill with oil
8
Check foreign material in fuel
-
Clean and drain
9
Check fuel prefilter
-
Replace
10
Check fuel main filter
-
Replace
11
Check of engine oil level (in oil pan) and type
Between H and L
Refilling with oil
12
Check of coolant level (in sub tank)
Between H and L
Refilling with coolant
Clean or replace
13
Check air cleaner for clogging
Red piston is not projected into the transparent part of the dust indicator.
14
Check around KDPF for dirt
-
Remove
15
Check around KDPF for gas leakage
-
Repair
Criteria
Remedy
Hydraulic System and Machine Devices No.
Item
1
Check for unusual noise and smell
-
Repair
2
Check for oil leakage
-
Repair
3
Check hydraulic oil level
Between H and L
Refilling with oil
4
Check hydraulic oil strainer
-
Clean and drain
5
Check hydraulic oil filter
-
Replace
6
Check oil level in final drive case
-
Refill with oil
7
Bleed air
-
Bleed air from cylinder
Criteria
Remedy
Electrical Components No.
Item
1
Check battery terminal for looseness and corrosion
-
Retighten or replace
2
Check battery disconnect switch terminal for looseness and corrosion
-
Retighten or replace
3
Check alternator terminal for looseness and corrosion
-
Retighten or replace
4
Check starting motor terminal for looseness and corrosion
-
Retighten or replace
5
Check battery voltage (with engine stopped)
10 to 15 V
Charge or replace
6
Check battery electrolyte level
Between H and L
Refill or replace
40-16
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Checks Before Troubleshooting
Item
Criteria
Remedy
7
Check wiring harness for discoloration, burnt areas and cover peeling
-
Repair or replace
8
Check for coming off of wiring harness clamp and sagging of wiring harness
-
Repair
9
Check grounding
-
Repair
10
Check for loose connector and damaged lock
-
Repair or replace
11
Check connector pin for corrosion, bends and deformation
-
Repair or replace
12
Check connector for entering of water and foreign material
-
Dry, clean or replace
13
Check wiring harness for open or short circuit
-
Repair or replace
14
Check fuse for blowing out and corrosion
-
Replace
15
Check alternator voltage (when engine speed is medium or higher)
After few minutes of operation13.5 to 14.5 V
Replace
16
Check battery relay operation sound (when starting switch is turned to ON or OFF position)
-
Replace
Criteria
Remedy
External Parts No.
Item
1
Check undercarriage
-
Repair
2
Check handrails
-
Repair
3
Check mirrors
-
Clean or repair
Criteria
Remedy
Interior No.
Item
1
Check gauges and monitors
-
Clean or replace
2
Check seat belt
-
Replace
PC45MR-5, PC55MR-5
40-17
Inspection Procedure Before Troubleshooting
40 Troubleshooting
Inspection Procedure Before Troubleshooting Walk-Around Check Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach high temperatures.
k Accumulated combustibles and fuel or oil leakages around hot engine parts such as engine, after-
treatment devices, etc. may cause a machine fire. Be sure to check thoroughly and repair any failures. •
Check of unusual noise and smell Check for unusual noise or smell. If the machine is operated under the unusual noise or smell, the cause of it may damage the machine, so stop the operation immediately once you recognize it.
•
Check around engine and removal of dirt Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.) on hot engine parts such as the aftertreatment devices, etc.
•
Check around engine for water leakage
•
Check around engine for oil leakage Check for oil leakage from engine and coolant leakage from cooling system. If any abnormality is found, repair it.
•
Check of fuel line for leakage Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it.
•
Check of radiator and removal of dirt Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radiator. If any, remove them. For removal of foreign article in the radiator, see “Operation and Maintenance Manual”.
•
Check around the aftertreatment devices and removal of dirt Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the aftertreatment devices. If any, remove them.
•
Check around the aftertreatment device for gas leakage Check the pipe the KDPF, and also the aftertreatment devices connection for leakage of exhaust gas (or sticking of soot, etc.). If any abnormality is found, repair it.
•
Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnormality is found, repair it.
•
Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage Check for oil leaks. If any abnormality is found, repair it.
•
Air bleeding For the bleeding air from the fuel system, see Testing and Adjusting, “Bleed Air from Fuel System”. For the bleeding air from the hydraulic system, see Testing and Adjusting, “Bleed Air from Hydraulic System”.
•
Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers If any abnormality is found, repair it.
•
Check of handrails for abnormality and looseness of bolts If any abnormality is found, repair it and tighten any loose bolts.
•
Check and clean of rearview mirrors Check rearview mirror for abnormality. If any, repair it. Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from the operator's seat.
•
Check of gauges and monitors for abnormality
40-18
PC45MR-5, PC55MR-5
40 Troubleshooting
Inspection Procedure Before Troubleshooting
Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it with a new one. Clean up the surfaces. •
Check of seat belt and mounting hardware Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, repair it.
PC45MR-5, PC55MR-5
40-19
Test in Accordance with Testing Procedure
40 Troubleshooting
Test in Accordance with Testing Procedure Examine Fuel Level and Type
k Fuel is highly flammable and dangerous. Keep open flame away. k When adding fuel, be careful not to overflow it.
k Wipe off any spilled fuel. If fuel spills over soil or sand, remove all the fuel and soil or sand together.
1.
Turn the engine starting switch to ON position and check the fuel level with the fuel gauge (2) on the monitor panel. After checking, turn the switch back to OFF position.
2.
Open dirt cover (3). Open dirt cover (3) fully and it will be secured by cover support lever (4).
3.
If the fuel level is low, open fuel filler cap (F) of the fuel tank and add fuel through the fuel filler port to the necessary level, referring to the position of float gauge (G).
4.
Tighten the cap of oil filler port (F) securely. REMARK If breather hole (5) in the oil filler cap is clogged, the pressure in the tank decreases and fuel may not be supplied. To prevent this, clean the breather hole.
40-20
PC45MR-5, PC55MR-5
40 Troubleshooting
Test in Accordance with Testing Procedure
Examine Fuel Prefilter 1.
2.
Set the machine in the posture shown in the figure. 1) Start the engine.
2)
Set the lock lever to FREE position (F).
3)
Operate the work equipment control lever slowly to right and left to swing the upper structure so that the fuel prefilter comes between the tracks
4)
Operate the work equipment control levers, and lower the work equipment to the ground.
5)
Set the lock lever to LOCK position (L).
6)
Stop the engine.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
3.
Pull cooling cover (3) toward you to open it.
PC45MR-5, PC55MR-5
40-21
Test in Accordance with Testing Procedure
4.
Turn rod (4) to LOCK position (L), and fix cooling cover (3) with the rod.
5.
Loosen bolts (5) and remove undercover (6).
6.
Place a container under the fuel prefilter to receive the fuel.
7.
Turn handle (7) to CLOSE position (S), and loosen drain plug (8).
8.
Drain the water until red ring (9) contacts to the bottom of transparent cup (10).
9.
Tighten drain plug (8).
40 Troubleshooting
10. Turn transparent cup (10) counterclockwise to remove it. Remove transparent cup (10) without spilling the fuel. If the fuel spills, wipe it off with cloth thoroughly. Be careful not to lose red ring (9) in transparent cup (10).
11. Remove element (11) from top of the fuel prefilter, and replace it with a new element. 12. Check the condition of O-ring (12) installed to transparent cup (10). Replace the O-ring with a new one if needed. 13. Clean the inside of transparent cup (10) with diesel fuel or flushing oil. 14. Install the element (11) and O-ring (12) to transparent cup (10). 15. Insert red ring (9) into transparent cup (10) and fill it with fuel.
40-22
PC45MR-5, PC55MR-5
40 Troubleshooting
Test in Accordance with Testing Procedure
16. Install transparent cup (10) to bottom of fuel prefilter. 3 Tightening torque: 27 to 33 Nm {2.8 to 3.4 kgfm}
17. Turn handle (7) to OPEN position (O). 18. Install undercover (6) with bolts (5). 19. After replacement of the element is completed, bleed air from the fuel circuit. 20. Set rod (4) to FREE position (F), and close cooling cover (3). 21. Close engine rear cover (1).
Examine Water Separator, Drain Water and Sediment 1.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
2.
Pull cooling cover (3) toward you to open it.
3.
Set rod (4) to LOCK position (L), and fix cooling cover (3) with the rod.
PC45MR-5, PC55MR-5
40-23
Test in Accordance with Testing Procedure
4.
40 Troubleshooting
Check for water and sediment. If red ring (5) of water separator sinks at the bottom of transparent cup (6), water is not mixed. If red ring (5) floats, water enters up to under red ring (5). Drain the mixed water according to the following procedure.
1)
Set the machine in the posture shown in the figure. 1] Start the engine. 2]
Set the lock lever to FREE position.
3]
Operate the work equipment control lever slowly to right and left to swing the upper structure so that the fuel prefilter comes between the tracks
4]
Operate the work equipment control levers, and lower the work equipment to the ground.
5]
Set the lock lever to LOCK position.
6]
Stop the engine.
2)
Place a container under the fuel prefilter to receive the fuel.
3)
Turn handle (7) to CLOSE position (S), and loosen drain plug (8).
4)
Drain the water until red ring (5) contacts to the bottom of transparent cup (6).
5)
Tighten drain plug (8), and turn handle (7) to OPEN position (O).
5.
Set rod (4) to FREE position (F), and close cooling cover (3).
6.
Close engine rear cover (1).
Examine Fuel Main Filter
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the filter.
k Keep open flame away.
40-24
PC45MR-5, PC55MR-5
40 Troubleshooting
Test in Accordance with Testing Procedure
NOTICE • Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties. Komatsu recommends using Komatsu genuine parts when replacing. • The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine fuel filter cartridge is used, foreign materials may enter and problem may occur in the injection system. Do not use substitute parts. • During testing or maintenance of the fuel system, take extreme care that any foreign material does not enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean fuel. •
Prepare a container to receive drained fuel.
• 1.
Prepare a filter wrench. Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
2.
Pull cooling cover (3) toward you to open it.
3.
Turn rod (4) to LOCK position (L), and fix cooling cover (3) with the rod.
4.
Turn handle (6) of fuel prefilter (5) to CLOSE position (S).
PC45MR-5, PC55MR-5
40-25
Test in Accordance with Testing Procedure
5.
Place a container under the fuel filter to receive the fuel.
6.
Turn fuel filter cartridge (7) counterclockwise by using the filter wrench, and remove it.
40 Troubleshooting
After removing fuel filter cartridge (7), fuel drips down from the fuel filter head. In order to prevent the fuel from flowing out, be sure not to leave the machine without fuel filter cartridge (7). 7.
Clean the mounting face of the fuel filter cartridge. Do not fill the new fuel filter cartridge with fuel.
8.
Remove cap (B) at the center, and install the fuel filter cartridge to the mounting face of fuel filter cartridge. When installing it, apply a thin film of oil to the packing surface, contact it to the sealing surface of filter cartridge (7), and then tighten it 1/4 to 1/2 turn. If the fuel filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If it is tightened too loose, fuel will also leak from the packing, so always tighten to the specified angle. When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
9.
Turn handle (6) of fuel prefilter (5) to OPEN position (O).
10. After completing the replacement of the fuel filter cartridge, bleed air according to the following procedure. 1)
40-26
Fill up the fuel tank with fuel to the level where the float is at the highest position.
PC45MR-5, PC55MR-5
40 Troubleshooting
2)
Turn the starting switch to ON position (B).
3)
10 to 15 seconds later, return it to OFF position (A).
Test in Accordance with Testing Procedure
The air is bled automatically with automatic air bleeding device. REMARK When the engine runs out of fuel, use the same procedure to bleed the air. 11. After replacing the fuel filter cartridge, start the engine and run it at low idle for 10 minutes. 12. Check the filter seal surface and the mounting face of the transparent cup for fuel leakage. If the fuel leaks, check according to the following procedure. 1) Check the fastening condition of the fuel filter cartridge. 2)
If the fuel leaks, remove the fuel filter cartridge in step 4 to 6.
3)
Check the packing surface for damage and pinching of foreign material. If it has damage or pinching of foreign material, replace the fuel filter cartridge with a new one.
4)
Install the fuel filter cartridge in step 6 to 10.
5)
Check the filter seal surface and the mounting face of the transparent cup for fuel leakage, and if the fuel leaks, heck again.
13. Set rod (4) to FREE position (F), and close cooling cover (3). 14. Close engine rear cover (1).
Examine Engine Oil Level (Oil Quantity in Oil Pan)
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until all parts have cooled down before starting the work. REMARK • When checking the oil level after the engine has been operated, wait at least 15 minutes after stopping the engine. • If the machine is inclining, make it level before checking. 1. Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
PC45MR-5, PC55MR-5
40-27
Test in Accordance with Testing Procedure
2.
Pull out dipstick (G) and wipe the oil off with a cloth.
3.
Fully insert dipstick (G) into the dipstick pipe, then remove it.
4.
Check if the oil is sticking up to between marks H and L on dipstick (G).
40 Troubleshooting
It is appropriate if the oil level is between marks H and L. If the oil level is below mark L, add oil through oil filler port (F). 5.
If the oil level is higher than mark H, decrease it to a proper level according to the following procedure.
1)
Drain excess engine oil through drain plug (P).
2)
Check the oil level again.
6.
If the oil level is proper, tighten the oil filler cap securely.
7.
Close engine rear cover (1).
Examine Coolant Level (Reservoir Tank)
k The radiator cap does not need to be opened for standard checks. When checking the coolant level,
check it in reservoir tank when the engine is cooled down.
k Immediately after the engine is stopped, the coolant is still very hot and the pressure is accumulated
in the radiator. If the cap is opened under these conditions, you may be scalded. If you need to remove the radiator cap, wait for the temperature to drop before you do. Then turn the cap slowly to release the pressure and remove it with care. 1.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
40-28
PC45MR-5, PC55MR-5
40 Troubleshooting
2.
Pull cooling cover (3) toward you to open it.
3.
Move rod (4) to LOCK position (L), and secure cooling cover (3) with the rod.
4.
Check the coolant level in reservoir tank (5).
Test in Accordance with Testing Procedure
If the coolant level is within FULL - LOW range when the engine is cooled down, it is appropriate. If the coolant level is below LOW, add coolant to FULL level through the filler port of reservoir tank (5). REMARK • If the reservoir tank is empty, coolant probably leaks. If any abnormality is found after check, repair it immediately. If no abnormality is found, check the level of the coolant in the radiator. If it is low, add coolant to the radiator and then to the reservoir tank. • If reservoir tank (1) is dirty and it is difficult to check the coolant level, clean it. 5.
Tighten the water filler cap of reservoir tank (5) securely.
6.
Move rod (4) to FREE position (F), and close cooling cover (3).
7.
Close engine rear cover (1).
Examine Air Cleaner Clogging
k When using compressed air for cleaning, put on personal protective items such as protective eye-
glasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out.
k When removing the outer element from the air cleaner body, do not forcibly pull it out, otherwise it
can be dangerous. k When working in high places or on poor footing, be careful not to fall because of the reaction when pulling out the outer element.
PC45MR-5, PC55MR-5
40-29
Test in Accordance with Testing Procedure
40 Troubleshooting
Open the engine hood, and check if the red piston is protruding into the transparent part of dust indicator (1). If it is protruding, clean the air cleaner element. REMARK • Do not clean the element before the red piston is projected into the transparent part of dust indicator (1). • If the element is cleaned frequently before the red piston is projected, the air cleaner will not deliver the optimum performance, and the cleaning effect will decrease.
Clean Outer Element (Single Element) 1.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
NOTICE Do not clean the outer element before the red piston is projected into the transparent part of dust indicator (3). If the outer element is cleaned frequently before the red piston is projected, the air cleaner will not deliver the optimum performance, and the efficiency of filtration will decrease. 2. Check if the red piston is projected into the transparent part of dust indicator (3). If the red piston is projected, clean the air cleaner outer element. 3.
Release hooks (4) and remove cover (5).
40-30
PC45MR-5, PC55MR-5
40 Troubleshooting
Test in Accordance with Testing Procedure
4.
Hold outer element (6), rock it lightly up and down and to the right and left, and pull it out while turning it clockwise and counterclockwise.
5.
After removing outer element (6), cover the air connector side at the bottom of air cleaner body (7) with a clean cloth or tape to prevent dirt or dust from entering.
6.
Clean dust sticking inside air cleaner body (7) and on cover (5) by using a clean cloth or brush.
7.
If any dust is attached to vacuator valve (8) installed to cover (5), remove it.
8.
When outer element (6) has been cleaned 5 times or used for 1 year, replace it.
9.
Blow dry compressed air (max. 0.2 MPa {max. 2.1 kgf/cm2} ) from the inside of outer element (6) along the pleats.
10. Blow along the pleats from the outside, then blow again from the inside.
11. After cleaning, illuminate the inside of the element with an electric bulb to check. If any holes or thin places are found, replace the outer element with a new one. 12. Remove the cover of cloth or tape attached to the air connector side at the bottom of air cleaner body (7).
NOTICE • Do not use the outer element with damaged pleats or a damaged gasket or seal. • If the outer element and O-ring are cleaned and used again after they are used for more than 1 year, it will cause problems. Do not use them again. 13. Check the seal of cleaned or new outer element (6) for adhesion of dusts and oil. If there is adhesion of dusts and oil, wipe them off. NOTICE • Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element (a) (face where no hole is drilled) comes to cover (5) end. If it is installed in wrong direction, it may cause breakage of the air cleaner element or serious damage to the engine. • When inserting the element into the body, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (5) is installed by force with hook (4), there is a danger that hook (4) and air cleaner body may be damaged, so be careful when installing. 14. Push outer element (6) straight into air cleaner body (7) with your hand. PC45MR-5, PC55MR-5
40-31
Test in Accordance with Testing Procedure
40 Troubleshooting
Hold outer element (6), and rock it lightly up and down and to the right and left while pushing it in, the element can be inserted easily. 15. Install cover (5). Install cover (5) as follows. 1) Align the mark on cover (5) with the mark on air cleaner body (7).
2)
Lock the tip of hook (4) on the protrusion of air cleaner body (7).
3)
Check that TOP mark arrow (A) on cover (5) is pointing upward.
4)
When cover (5) is installed, check that the clearance between air cleaner body (7) and cover (5) is not too large. If the clearance is too large, remove cover (5), and then install it again.
16. Press the button of dust indicator (3) and return the red piston. NOTICE Replace the outer element when the dust indicator indicates red soon after cleaning the outer element, even though it has not been cleaned 5 times yet.
40-32
PC45MR-5, PC55MR-5
40 Troubleshooting
Test in Accordance with Testing Procedure
Clean Outer Element (Double Element) 1.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
NOTICE Do not clean the outer element before the red piston is projected into the transparent part of dust indicator (3). If the outer element is cleaned frequently before the red piston is projected, the air cleaner will not deliver the optimum performance, and the efficiency of filtration will decrease. 2. Check if the red piston is projected into the transparent part of dust indicator (3). If the red piston is projected, clean the air cleaner outer element. 3.
Release hooks (4) and remove cover (5).
4.
Hold outer element (6), rock it lightly up and down and to the right and left, and pull it out while turning it clockwise and counterclockwise.
5.
When outer element (6) is removed, check that inner element (9) does not come off or incline. If it is at an angle, push it straight to the bottom with your hand.
6.
After removing outer element (6), cover the inner element (9) with a clean cloth or tape to prevent dirt or dust from entering.
7.
Clean dust sticking inside air cleaner body (7) and on cover (5) by using a clean cloth or brush.
8.
If any dust is attached to vacuator valve (8) installed to cover (5), remove it.
9.
When outer element (6) has been cleaned 5 times or used for 1 year, replace it.
PC45MR-5, PC55MR-5
40-33
Test in Accordance with Testing Procedure
40 Troubleshooting
10. Blow dry compressed air (max. 0.2 MPa {max. 2.1 kgf/cm2} ) from the inside of outer element (6) along the pleats. 11. Blow along the pleats from the outside, then blow again from the inside.
12. After cleaning, illuminate the inside of the element with an electric bulb to check. If any holes or thin places are found, replace the outer element with a new one. 13. Remove the cover of cloth or tape attached to the air connector side at the bottom of air cleaner body (7).
NOTICE • Do not use the outer element with damaged pleats or a damaged gasket or seal. • If the outer element and O-ring are cleaned and used again after they are used for more than 1 year, it will cause problems. Do not use them again. 14. Check the seal of cleaned or new outer element (6) for adhesion of dusts and oil. If there is adhesion of dusts and oil, wipe them off. NOTICE • Be sure to install the air cleaner element facing in the correct direction. Install so that the bottoms (a) and (b) of the air cleaner element (face where no hole is drilled) come to cover (5) end. If it is installed in wrong direction, it may cause breakage of the air cleaner element or serious damage to the engine. • When inserting the element into the body, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (5) is installed by force with hook (4), there is a danger that hook (4) and air cleaner body may be damaged, so be careful when installing. 15. Push outer element (6) straight into air cleaner body (7) with your hand. Hold outer element (6), and rock it lightly up and down and to the right and left while pushing it in, the element can be inserted easily. 16. Install cover (5).
40-34
PC45MR-5, PC55MR-5
40 Troubleshooting
1)
Align the mark on cover (5) with the mark on air cleaner body (7).
2)
Lock the tip of hook (4) on the protrusion of air cleaner body (7).
3)
Check that TOP mark arrow (A) on cover (5) is pointing upward.
4)
When cover (5) is installed, check that the clearance between air cleaner body (7) and cover (5) is not too large.
Test in Accordance with Testing Procedure
If the clearance is too large, remove cover (5), and then install it again.
17. Press the button of dust indicator (3) and return the red piston. NOTICE Replace both inner and outer elements when the dust indicator indicates red soon after cleaning the outer element even though it has not been cleaned 5 times yet.
Replace Single Element 1.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
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Test in Accordance with Testing Procedure
40 Troubleshooting
NOTICE Do not clean the outer element before the red piston is projected into the transparent part of dust indicator (3). If the outer element is cleaned frequently before the red piston is projected, the air cleaner will not deliver the optimum performance, and the efficiency of filtration will decrease. 2. Check if the red piston is projected into the transparent part of dust indicator (3). If the red piston is projected, clean the air cleaner outer element. 3.
Release hooks (4) and remove cover (5).
4.
Hold outer element (6), rock it lightly up and down and to the right and left, and pull it out while turning it clockwise and counterclockwise.
5.
Clean dust sticking inside air cleaner body (7) and on cover (5) by using a clean cloth or brush.
6.
If any dust is attached to vacuator valve (8) installed to cover (5), remove it.
NOTICE • The sealing portion of the improper part lacks precision, and allows the entry of dust, which leads to damage of the engine. Do not use such improper part. • Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element (a) (face where no hole is drilled) comes to cover (5) end. If it is installed in wrong direction, it may cause breakage of the air cleaner element or serious damage to the engine. • When inserting the element into the body, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (5) is installed by force with hook (4), there is a danger that hook (4) and air cleaner body may be damaged, so be careful when installing. 7. Push the new outer element in straight with your hand to air cleaner body (7). Hold the new outer element, and rock it lightly up and down and to the right and left while pushing it in, the element can be inserted easily. 8.
Install cover (5).
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PC45MR-5, PC55MR-5
40 Troubleshooting
1)
Align the mark on cover (5) with the mark on air cleaner body (7).
2)
Lock the tip of hook (4) on the protrusion of air cleaner body (7).
3)
Check that TOP mark arrow (A) on cover (5) is pointing upward.
4)
When cover (5) is installed, check that the clearance between air cleaner body (7) and cover (5) is not too large.
Test in Accordance with Testing Procedure
If the clearance is too large, remove cover (5), and then install it again.
9.
Press the button of dust indicator (3) and return the red piston.
Replace Double Element 1.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
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Test in Accordance with Testing Procedure
40 Troubleshooting
NOTICE Do not clean the outer element before the red piston is projected into the transparent part of dust indicator (3). If the outer element is cleaned frequently before the red piston is projected, the air cleaner will not deliver the optimum performance, and the efficiency of filtration will decrease. 2. Check if the red piston is projected into the transparent part of dust indicator (3). If the red piston is projected, clean the air cleaner outer element. 3.
Release hooks (4) and remove cover (5).
4.
Hold outer element (6), rock it lightly up and down and to the right and left, and pull it out while turning it clockwise and counterclockwise. Do not remove inner element (9) at this time.
5.
When outer element (6) is removed, check that the inner element does not come out of position and is not at an angle. If it is at an angle, push it straight to the bottom with your hand.
6.
Clean dust sticking inside air cleaner body (7) and on cover (5) by using a clean cloth or brush.
7.
If any dust is attached to vacuator valve (8) installed to cover (5), remove it.
NOTICE • Do not clean and reuse the inner element. When replacing the outer element, replace the inner element with a new one at the same time. • If the outer element and cover are installed while the inner element is not installed properly, the outer element may be damaged. • The sealing portion of the improper part lacks precision, and allows the entry of dust, which leads to damage of the engine. Do not use such improper part. • Be sure to install the air cleaner element facing in the correct direction. Install so that the bottom of the air cleaner element (a) (face where no hole is drilled) comes to cover (5) end. If it is installed in wrong direction, it may cause breakage of the air cleaner element or serious damage to the engine. • When inserting the element into the body, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (5) is installed by force with hook (4), there is a danger that hook (4) and air cleaner body may be damaged, so be careful when installing. 8. Remove inner element (9), and then quickly install the new inner element. Install the inner element securely so that it does not move. 9.
Push the new outer element in straight with your hand to air cleaner body (7).
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40 Troubleshooting
Test in Accordance with Testing Procedure
Hold the outer element, and rock it lightly up and down and to the right and left while pushing it in, the element can be inserted easily. 10. Install cover (5). 1)
Align the mark on cover (5) with the mark on air cleaner body (7).
2)
Lock the tip of hook (4) on the protrusion of air cleaner body (7).
3)
Check that TOP mark arrow (A) on cover (5) is pointing upward.
4)
When cover (5) is installed, check that the clearance between air cleaner body (7) and cover (5) is not too large. If the clearance is too large, remove cover (5), and then install it again.
11. Press the button of dust indicator (3) and return the red piston.
Examine Hydraulic Oil Level
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
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Test in Accordance with Testing Procedure
1.
40 Troubleshooting
Set the machine in the posture shown in the figure. If it is not set in the posture shown in the figure, set it according to the following procedure. 1) Start the engine.
2.
2)
Set the lock lever to FREE position (F).
3)
Operate the blade control lever to lower the blade to the ground.
4)
Operate the work equipment control levers, and retract arm cylinder and bucket cylinder to their stroke end (maximum reach posture of arm and bucket).
5)
Operate the boom swing control pedal to swing the boom to the center position.
6)
Operate the work equipment control lever slowly to the boom LOWER direction, and lower the boom and make tooth contact to the ground.
7)
Set the lock lever to LOCK position (L).
8)
Stop the engine.
Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2).
3.
Pull cooling cover (3) toward you to open it.
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40 Troubleshooting
4.
Set rod (4) to LOCK position (L), and fix cooling cover (3) with the rod.
5.
Check the oil level through sight gauge (G).
Test in Accordance with Testing Procedure
It is appropriate if the oil level is between H and L. If the oil level is below level L, the hydraulic oil is insufficient. If the hydraulic oil is insufficient, add oil according to the following procedure.
1)
Open dirt cover (5). Open dirt cover (5) fully and it will be secured by cover support lever (6).
2)
Loosen bolt (7) of the hydraulic tank, move plate (8) on oil filler port (F), turn the cap of oil filler port (F) slowly to remove it, and release the internal pressure.
3)
Add hydraulic oil through oil filler port (F) until the oil level comes between levels H and L of sight gauge (G).
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Test in Accordance with Testing Procedure
40 Troubleshooting
NOTICE Do not add oil above H line. It may damage the oil circuit and cause the oil to spurt out. If oil has been added exceeding level H, swing the upper structure until drain plug (P) under the hydraulic tank comes between the right and left tracks and stop the engine. Wait for the hydraulic oil to cool down sufficiently, then drain the excess oil through drain plug (P). REMARK The oil level vary with the oil temperature. Accordingly, use the following as a guide for check:
Before starting the operation: Around L level Oil temperature: 10 to 30 °C
In normal operation: Around H Level Oil temperature: 50 to 80 °C 4)
Start the engine.
5)
Set the lock lever to FREE position (F).
6)
Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end. Set the work equipment in the posture shown in the figure.
7)
Set the lock lever securely to LOCK position (L).
8)
Stop the engine.
9)
Tighten the cap of oil filler port (F) on the hydraulic tank securely. REMARK By doing so, the hydraulic tank is pressurized. NOTICE If the hydraulic tank is not pressurized, air is sucked in the pump and it affects the components badly.
10) Return plate (8) on oil filler port (F) of the hydraulic tank to its original position, and fix it with bolt (7). 40-42
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40 Troubleshooting
Test in Accordance with Testing Procedure
11) Close dirt cover (6). 6.
Set rod (4) to FREE position (F), and close cooling cover (3).
7.
Close engine rear cover (1).
Examine Hydraulic Oil Strainer
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it. 1.
Open dirt cover (1). Open dirt cover (1) fully and it will be secured by cover support lever (2).
2.
Loosen bolt (3) of the hydraulic tank, move plate (4) on oil filler port (F), turn the cap of oil filler port (F) slowly to remove it, and release the internal pressure.
3.
Loosen bolts (5) at the bottom of hydraulic tank, and remove undercover (6).
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Test in Accordance with Testing Procedure
4.
Loosen hose clamp (7) and remove hose (8).
5.
Loosen bolts (9) and remove tube (10).
6.
Remove O-ring (11) and strainer (12) from tube (10), remove dirt, etc. stuck to the tube, and then wash it in clean diesel fuel or flushing oil.
40 Troubleshooting
Replace O-ring (11) with a new O-ring. If strainer (12) is damaged, replace it with a new strainer. 7.
Fix strainer (12) with bolt (9).
8.
Install hose (8) and fix it with hose clamp (7).
9.
Install undercover (6) with bolts (5) to the bottom of the hydraulic tank.
10. Tighten the cap of oil filler port (F) on the hydraulic tank securely. 11. Return plate (4) on oil filler port (F) of the hydraulic tank to its original position, and fix it with bolt (3). 12. Close dirt cover (1).
Examine Hydraulic Oil Filter
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it. 1.
Open dirt cover (1). Open dirt cover (1) fully and it will be secured by cover support lever (2).
2.
Loosen bolt (3) of the hydraulic tank, move plate (4) on oil filler port (F), turn the cap of oil filler port (F) slowly to remove it, and release the internal pressure.
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40 Troubleshooting
3.
Test in Accordance with Testing Procedure
Remove cover mounting bolt (5), and remove cover (6). The cover (6) may be jumped out by spring (7). While pressing down cover (6), remove cover mounting bolt (5).
4.
After removing spring (7) and valve (8), take out element (9).
5.
Remove all dirt from the parts taken out, then wash it in clean diesel fuel or flushing oil.
6.
Install new element (9).
7.
Check O-ring (10),and replace it with a new one if it is damaged.
8.
Place valve (8) and spring (7) on top of the element temporarily.
9.
While pressing cover (6) by hand, tighten cover mounting bolt (5).
10. Start the engine.
11. Set the lock lever to FREE position (F).
12. Operate the work equipment control levers, and extend the boom cylinder, bucket cylinder, and arm cylinder to their stroke end.
13. Set the lock lever securely to LOCK position (L). 14. Stop the engine. 15. Tighten the cap of oil filler port on the hydraulic tank securely. By doing so, the hydraulic tank is pressurized. NOTICE If the hydraulic tank is not pressurized, air is sucked in the pump and it affects the components badly. 16. Return plate (4) on oil filler port (F) of the hydraulic tank to its original position, and fix it with bolt (3). 17. Close dirt cover (1). PC45MR-5, PC55MR-5
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Test in Accordance with Testing Procedure
40 Troubleshooting
Examine Oil Level in Final Drive Case
k Since the oil may spurt out due to internal pressure, rotate the plug gradually to release the internal
pressure from its side, and then remove it carefully.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work. 1.
Be sure that plug (P) is at the right below.
2.
Place a container under plug (G) to catch the drained oil.
3.
Remove plug (G) with the hexagonal wrench.
4.
Check the oil level. The oil level should be near the lower edge of the hole of plug (G).
5.
If the oil level is low, remove plug (F) with the hexagonal wrench and add oil. Add oil until it overflows from the hole of plug (G).
6.
After checking, tighten plugs (F) and (G).
Bleed Air from Fuel System For the bleeding air from the fuel system, see “30 Testing and Adjusting”, “BLEED AIR FROM FUEL SYSTEM”.
Bleed Air from Hydraulic System For bleeding air from the hydraulic system, see Testing and Adjusting, “Bleed Air from Hydraulic System”.
How to Examine Electric Equipment Check of battery terminal for looseness and corrosion 1. Open dirt cover (1). Open dirt cover (1) fully and it will be secured by cover support lever (2). 2.
Remove the battery cover on the battery.
3.
Check the battery cable terminals for looseness and corrosion.
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40 Troubleshooting
Test in Accordance with Testing Procedure
Check of battery disconnect switch position and check of battery ground for looseness and corrosion (Optional mounting machine) 4. This is installed in the battery box inside the dirt cover.
5.
Lift up rubber cover (2), and check that battery disconnect switch (1) is ON position (marked with O). REMARK When shutting off the battery power supply before testing, removal and installation, and etc., turn battery disconnect switch (1) to OFF position (marked with I).
NOTICE When turning battery disconnect switch (1) to OFF position (marked with I), check that the system operating lamp is off.
6.
Check the battery ground terminal at the back of battery disconnect switch (1) for looseness and corrosion. Also, check the connected ground wiring terminal for looseness and corrosion.
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40 Troubleshooting
Check of alternator terminal for looseness and corrosion 7. Pull engine rear cover (1) toward you to open it. Open engine rear cover (1) fully and it is secured by rod (2). 8.
Open the floor.
9.
Check alternator B terminal (3) for open circuit, looseness and corrosion.
Check of starting motor terminal for looseness and corrosion 10. Check starting motor terminal B (1) and C terminal (2) for open circuit, looseness and corrosion.
Check of battery voltage (with engine stopped) 11. Check the battery voltage by using the battery tester while the engine is stopped. Check of battery electrolyte level 12. Check before operating the machine.
k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that
condition, its inside becomes deteriorate, its service life is shortened, and it may lead to an explosion.
k Since the battery produces combustible gas that can explode, do not bring any open flame near
it.
k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or
skin. If it does, wash it away with water and contact your doctor. REMARK • Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts. • When adding purified water in cold weather, add it before starting operations in the morning to prevent the purified water from freezing. •
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When checking the electrolyte level through the side face of the battery
PC45MR-5, PC55MR-5
40 Troubleshooting
1)
Test in Accordance with Testing Procedure
Open dirt cover (1). Open dirt cover (1) fully and it will be secured by cover support lever (2).
2)
Wipe and clean the battery surface, especially around the battery level lines with a wet cloth, and check to see that the battery fluid is between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines. NOTICE Do not clean the battery with a dry cloth since static electricity may cause an explosion.
3)
If the electrolyte level is below the center between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines, remove cap (3) and add purified water (example: commercially available battery fluid) to the UPPER LEVEL (U.L.) line immediately.
4)
After adding the purified water, tighten cap (3) securely. REMARK If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water.
•
When electrolyte level cannot be checked through the side face of the battery 1) Remove cap (3) on the top of battery. (described previously) 2)
3)
Look into filler port (5) and check the surface of fluid. If the fluid level is below sleeve (6), always add the purified water (such as a commercial battery fluid) until it reaches the bottom of sleeve (the UPPER LEVEL). •
(A) Correct level: Since the electrolyte level reaches to the sleeve bottom, the shape of the electrode plates will appear distorted due to the surface tension.
•
(B) Low level: Electrolyte level does not reach the bottom of sleeve, so pole plate appears straight and not to be warped.
After adding fluid, tighten cap (3). REMARK If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water.
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Test in Accordance with Testing Procedure
40 Troubleshooting
Check wiring harness for discoloration, burnt areas and cover peeling 13. Check the wiring harness and cables for discoloration and burn. If discolored or burnt, the circuit may be shorted or grounded. 14. Check the wiring harnesses and cables for damage and peeling of the covers. If any abnormality is found, repair or replace the wiring harness or cables. Check for coming off of wiring harness clamp and sagging of wiring harness 15. Check wiring harness for sagging and looseness due to coming off of harness clamp NOTICE In particular, carefully check the wiring harness around the hot and movable parts. 16. If removed from the clamp, secure it with the clamp.
Check of grounding NOTICE Take special care of ground terminals for looseness and corrosion. 17. Open the front left cover at the lower part of the cab. 18. Check the connection of ground terminals (between cab and revolving frame (1)) and (T01). 19. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
20. Check the connection of ground terminal (2) of engine controller.
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40 Troubleshooting
Test in Accordance with Testing Procedure
21. Check the connection of ground terminals (T02) and (T03).
Check for loose connector and damaged lock 22. Check the connectors for unlocking, and check the lock and connector housing for cracking. 23. Check lock of connectors (CE1) and (CE2) of engine controller (1) for looseness.
Check of connector pin for corrosion, bends and deformation 24. Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and extension of female pins. •
If pins are defective, repair or replace them.
•
If the pins are not shiny, apply contact restorer to them and connect and disconnect the connectors several times to shine them. (If the pins do not become shiny, connect and disconnect the connectors 10 times)
Check of connector for entering of water and foreign material 25. Disconnect connectors, and check them for entering of water or foreign material inside the connector. NOTICE If water or foreign material enters inside connector, the seals may be defective. Check the seals for damage.
•
If the seal is defective, repair or replace it.
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Test in Accordance with Testing Procedure
•
Dry the inside of the connector with a dryer.
•
Wipe and remove any foreign material inside connector with a cloth or others, and blow the air to clean the connector.
40 Troubleshooting
Check of wiring harness for open or short circuit 26. Check the connection (crimped part) between connector pins and wiring harness. If it is open as shown as (A), repair or replace the wiring harness or connector. 27. Visually check wiring harnesses for peeling of harness covers and the pins for contact with adjacent pins due to defective crimping.
Check fuse for blowing out and corrosion 28. When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the battery disconnect switch to OFF position. •
A fusible link is a large-capacity fuse.
•
If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder, replace the fuse.
•
Replace each fuse with the one of the same capacity.
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Test in Accordance with Testing Procedure
29. The fuse holder is provided inside the cover under the operator's seat.
30. Open the dirt cover and you will see fusible links of M09 (1), M05 (2), TM14 (3), and TM15 (4).
Check of alternator voltage (when engine speed is medium or higher) 31. Open the engine hood. 32. Connect the positive (+) lead of the multimeter to alternator (B) terminal and connect the negative (-) lead to the chassis ground. 33. Start the engine and warm it up, and measure the voltage while running the engine at a medium or a higher speed. REMARK If the voltage is abnormal, repair or replace the alternator.
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Related Information to Troubleshooting
40 Troubleshooting
Preparation for Troubleshooting of Electrical System •
When performing troubleshooting of electric circuits of machine monitor, machine controller, engine controller, and KOMTRAX terminal, expose the applicable connector part according to the following procedure.
Machine Monitor 1.
Remove floor mat (1).
2.
Remove screws (2) (2 pieces), and remove cover (3).
3.
Remove screws (4) (2 pieces), and remove cover (5).
4.
Remove clamp (6), and disconnect connector F18 (7).
5.
Remove mounting bolts (8) (4 pieces), and pull out machine monitor assembly (9) in the direction of the arrow.
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40 Troubleshooting
6.
Remove screws (10) (8 pieces), and remove covers (11) and (11a).
7.
Connect or insert T-adapter for troubleshooting to connector (F15).
Related Information to Troubleshooting
Machine Controller 1.
Remove KOMTRAX terminal.
2.
Remove mounting bolts (1) (4 pieces), and remove cover (2).
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Related Information to Troubleshooting
3.
40 Troubleshooting
Connect the adapter for troubleshooting to connector CP01 (3) and connector CP02 (4). REMARK Pull up lever (5) of connector CP01 (3) and connector CP02 (4) in the direction of the arrow while pressing hook (b).
KOMTRAX Terminal 1.
Remove bolts (1), and remove cover (2). (For the canopy spec)
(For the operator's cab spec)
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40 Troubleshooting
2.
Related Information to Troubleshooting
Connect T-adapter for troubleshooting to connectors CK01 and CK02 of KOMTRAX terminal (3).
Engine Controller 1.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
2.
Connect or insert T-adapter for troubleshooting to connectors (CE1) and (CE2) of engine controller (1).
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Procedure for Troubleshooting
40 Troubleshooting
Procedure for Troubleshooting Type to Troubleshoot Mode
Content
Display of code
Troubleshooting by failure code
E mode
Troubleshooting of electrical system
H mode
Troubleshooting of hydraulic and mechanical systems
S mode
Troubleshooting of engine
1.
Check if action level and failure code are displayed on machine monitor: REMARK If multiple failure codes are displayed simultaneously, all codes are displayed repeatedly in order. Write down those codes. If action level and failure code are displayed on the standard screen of the machine monitor, perform the troubleshooting for the “Display of code” corresponding to the displayed failure code.
2.
Check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. 1)
Press F1, F2, and F3 in this order on the standard screen while pressing F8 of the function switch.
2)
On the service menu screen, press switch F1 twice on the function switch, and select “03 Abnormality Record”.
3)
Press switch F4 on the function switch to confirm, and go to “Abnormality Record” screen.
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40 Troubleshooting
4)
Press switch F4 on the function switch to confirm it, and go to “Mechanical Sys Abnormality Record” screen.
5)
Press switch F1 on the function switch to see if the next failure code is displayed and write down all of the failure codes.
Procedure for Troubleshooting
REMARK A failure code of the mechanical system cannot be deleted. 6)
Press switch F3 on the function switch to return to “Abnormality Record” screen.
7)
On the service menu screen, press switch F1 twice on the function switch, and select “03 Abnormality Record”.
8)
Press switch F4 on the function switch to confirm, and go to “Abnormality Record” screen.
9)
Press switch F4 on the function switch to confirm it, and go to “Electrical Sys Abnormality Record” screen.
10) Press switch F1 on the function switch to see if the next failure code is displayed and write down all of the failure codes. REMARK “E” on the left of a failure code indicates that the failure code is “active” (the failure remains or restoration to normal has not been checked). A failure code having no “E” on its left is a “non-active” one. Since it disappears in clear mode, be sure to write it down. •
When a failure code is recorded: Perform the troubleshooting for the “Display of code” corresponding to the displayed failure code. REMARK • If an electrical system failure code is recorded, clear all the codes once and reproduce them, and then see if the failure is still detected. • A failure code of the mechanical system cannot be deleted.
•
When no failure code is recorded on abnormality record:
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Procedure for Troubleshooting
3.
40 Troubleshooting
•
A failure in electrical system that the machine cannot perform self-diagnosis or a failure in hydraulic and mechanical system may have occurred, so check a phenomenon which seems to be a failure again.
•
Select the corresponding phenomenon from the table of “Symptom and troubleshooting numbers”, and then perform troubleshooting corresponding to that phenomenon in “E mode”, “H mode”, and “S mode”.
Clear all the failure codes in the electrical system abnormality record after the failure is repaired. 1) Press F1, F2, and F3 in this order while pressing F8 of the function switch to go to “clear mode”. 2)
Press switch F8 on the function switch.
3)
Press switch F4 on the function switch to clear all failure codes once
4)
Press switch F3 on the function switch to return to “Electrical Sys Abnormality Record” screen. See if any failure code is still displayed and write down the displayed one.
5)
Press switch F3 on the function switch to return to “Abnormality Record” screen.
6)
Write down the information of all the column. REMARK “E” on the left of a failure code as with “Electrical Sys Abnormality Record” screen indicates that the failure code is “active” (the failure remains or restoration to normal has not been checked).
7)
Press switch F8 on the function switch to clear all failure codes. Check if “Abnormality” is still displayed or not, and write it down on a paper.
8)
Press switch F3 on the function switch to return to “Abnormality Record” screen.
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40 Troubleshooting
Symptom and Troubleshooting Numbers
Symptom and Troubleshooting Numbers No.
Symptom of failure
Troubleshooting Index
Action level and failure code 1
Action level is displayed on the machine monitor. Press function switch [F3] to display “Current Abnormality”
2
Failure code is displayed on mechanical system abnormality record.
3
Failure code is displayed on Electrical Sys Abnormality Record.
Perform troubleshooting for failure code
Symptom related to engine 4
Engine startability is poor.
S-4
5
Engine does not start.
6
Engine does not crank when starting switch is turned to “START” position.
7
Engine cranks but no exhaust smoke comes out.
S-2
8
Fuel is being injected but engine does not start (misfiring: engine cranks but does not start).
S-3
9
Engine does not pick up smoothly.
S-5
10
Engine stops during operation.
S-6, H-7
11
Engine runs rough or is unstable.
S-7
12
Engine lacks power.
S-8
13
KDPF gets clogged in a short time.
S-9
14
Engine oil consumption is excessive.
S-10
15
Engine oil becomes contaminated prematurely.
S-11
16
Fuel consumption is excessive.
S-12
17
Oil is in coolant (or coolant spurts back or coolant level goes down).
S-13
18
Oil pressure drops.
S-14
19
Fuel mixes into engine oil.
S-15
20
Water mixes into engine oil (milky).
S-16
21
Coolant temperature rises too high (overheating).
S-17
22
Unusual noise is heard.
S-18
23
Vibration is excessive.
S-19
24
Air cannot be bled from fuel circuit.
S-20
25
Automatic preheating system does not work.
E-3
26
Auto-deceleration function does not operate or is not canceled while lever is operated.
E-16
E-1, E-2, S-1 S-1, E-1
Symptom related to work equipment, and swing and travel and blade system 27
All work equipment and travel speed or power is low.
H-2
28
Swing and blade speed is low or power is low.
H-3
29
Travel and blade speed or power is low.
H-5
30
All work equipment, travel, swing and blade speed or power is low.
H-6
31
Engine speed drops largely or engine stops.
H-7
PC45MR-5, PC55MR-5
40-61
Symptom and Troubleshooting Numbers
No.
40 Troubleshooting
Symptom of failure
Troubleshooting Index
32
All work equipments or travel does not operate.
H-10
33
Swing or blade does not operate.
H-11
34
Travel or blade does not operate.
H-13
35
All work equipment, travel, swing or blade does not operate.
H-14
36
Unusual noise is heard from around hydraulic pump.
H-15
37
Fine control performance or response is poor.
H-16
38
None of work equipment, swing or travel works.
E-23
39
Any of work equipment, swing, and travel cannot be locked.
E-24
Symptom related to work equipment 40
All work equipments speed or power is low.
H-1
41
All work equipments and blade speed or power is low.
H-4
42
All work equipments do not operate.
H-9
43
All work equipments or blade does not operate.
H-12
44
Boom speed or power is low.
H-17
45
Arm speed or power is low.
H-18
46
Bucket speed or power is low.
H-19
47
Boom swing speed or power is low.
H-21
48
Work equipment does not move in single operation.
H-22
49
Hydraulic drift of boom is large.
H-23
50
Hydraulic drift of arm is large.
H-24
51
Hydraulic drift of bucket is large.
H-25
52
In combined operation of work equipment, equipment having heavier load moves slower.
H-27
53
Time lag of work equipment is large.
H-28 Symptom related to blade
54
Blade does not operate.
H-8
55
Blade speed is low or power is low.
H-20
56
Hydraulic drift of blade is large (during blade RAISE or blade thrusting condition).
H-26
Symptom related to travel 57
Machine does not travel straight.
H-29
58
Machine deviates when moving off.
H-30
59
Machine is not steered well or steering power is low.
H-31
60
Travel speed is slow.
H-32
61
Travel do not operate (both sides of tracks).
H-33
62
One of tracks does not run.
H-34
63
Travel speed does not change, or travel speed is too slow or fast.
H-35
64
Travel speed does not change after the travel speed is changed.
E-18
65
Alarm does not sound during travel.
E-25
40-62
PC45MR-5, PC55MR-5
40 Troubleshooting
No. 66
Symptom and Troubleshooting Numbers
Symptom of failure Alarm does not stop sounding while machine is stopped.
Troubleshooting Index E-26
Symptom related to swing 67
Upper structure does not swing both to the right and left.
H-36
68
Upper structure swings only to the right or left.
H-37
69
Swing acceleration or swing speed is low in both directions of right and left.
H-38
70
Swing acceleration performance is poor or swing speed is slow in only one direction.
H-39
71
Upper structure overruns excessively when it stops swinging (both right and left).
H-40
72
Upper structure overruns excessively when it stops swinging (either right or left).
H-41
73
Shock is large when upper structure stops swinging.
H-42
74
Large unusual noise is heard when upper structure stops swinging.
H-43
75
Swing drift on a slope is large (while swing parking brake is applied).
H-44
76
Swing drift on a slope is large (while swing parking brake is released).
H-45
Symptom related to machine monitor 77
While preheating is working, preheating monitor does not light up.
E-4
78
Coolant temperature monitor lights up in white while engine is running.
E-5
79
Charge level monitor lights up in red while engine is running.
E-6
80
Fuel level monitor lights up in red while engine is running.
E-7
81
Engine coolant temperature monitor lights up in red while engine is running.
E-8
82
Engine oil pressure monitor lights up in red while engine is running.
E-9
83
Fuel gauge display does not move from minimum or maximum.
E-10
84
Fuel gauge indicates incorrect amount (indicates neither full nor empty)
E-11
85
Engine coolant temperature gauge display does not move from minimum or maximum.
E-12
86
Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty)
E-13
87
Some areas of machine monitor screen are not displayed.
E-14
88
Function switch does not work.
E-15
89
Alarm buzzer does not sound.
E-19
90
Alarm buzzer does not stop sounding.
E-20
91
Service meter is not displayed while starting switch is in OFF position.
E-21
92
Service mode cannot be selected.
E-22
93
Horn does not sound.
E-27, E-28
94
Horn does not stop sounding.
E-29, E-30
95
Lever operation signal is not displayed correctly with monitoring function.
E-35 to E-37
Others 96
Working lamp or travel lamp does not light up (canopy spec).
E-31
97
None of working lamp, travel lamp, or additional lamp lights up (cab spec).
E-32
98
Windshield wiper does not operate while wiper switch is operated.
E-33
PC45MR-5, PC55MR-5
40-63
Symptom and Troubleshooting Numbers
No.
Symptom of failure
40 Troubleshooting
Troubleshooting Index
99
Window washer does not operate while window washer switch is operated.
E-34
100
KOMTRAX system does not operate normally.
E-38
101
40-64
Air conditioner does not operate normally.
“PROCEDURE FOR TESTING AND TROUBLESHOOTING” in Chapter 80
PC45MR-5, PC55MR-5
40 Troubleshooting
Information Shown in Troubleshooting Table
Information Shown in Troubleshooting Table The following types of information are described in the troubleshooting list and related circuit diagram. Fully understand the description and perform troubleshooting. Action level
Failure code
Display on machine monitor
Display on machine monitor
Details of failure
Description of the failure detected by the machine monitor or controller
Action of controller
An action that is performed to protect the system and devices when a failure is detected by the machine monitor or controller
Problem on machine
A problem that is displayed as a failure on the lift truck as a result of an action (shown above) that is performed by the machine monitor or controller.
Related information
Information related to the occurred failure and its troubleshooting
No.
Cause
Failure
Failure name displayed on “Abnormality Record” screen of the machine monitor
Procedure, measuring location, criteria, and remarks
1
Defective ---
Contents of description
2
Open or short circuit in wiring harness
•
Procedure
•
Measuring point “Between A and B” denotes measuring values such as voltage and resistance between A and B. “Between A and ground” means the measurement of voltage, resistance or others between place A and the place which has a continuity with chassis frame such as unpainted hexagonal head bolt or bolt hole which has no rust, etc.
•
Criteria to judge probable causes (standard value), remarks
Open circuit in wiring harness 3
4
5
(wire breakage or defective contact of connector) Ground fault in wiring harness (contact with ground circuit) Hot short circuit
How to use troubleshooting sheet •
Perform troubleshooting procedures in following order.
•
If the check result does not meet the criteria, the probable cause described on the left column is the actual cause of the failure.
•
If the check result meet the criteria and there is no specific instruction, proceed to the next step (cause).
•
If a defect is found and repaired, check that the defect has been corrected.
Failures in wiring harness
6
Short circuit in wiring harness
PC45MR-5, PC55MR-5
•
Open circuit When the wiring and the internal circuit of the connector are not connected with each other, and there is no continuity
•
Ground fault A wiring harness not to be connected to the GND (ground) circuit comes into contact with the GND (ground) circuit or chassis accidentally.
•
Hot short circuit A wiring harness not to be connected to the power circuit comes into contact with the power circuit accidentally.
•
Short circuit An independent wire in the harness abnormally comes into contact with one of another wire. (Defective insulation in connector or others)
40-65
Information Shown in Troubleshooting Table
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria, and remarks Precautions for troubleshooting (1) Connector number indication method and handling of T-adapter For troubleshooting, insert or connect T-adapters as follows unless otherwise specified.
7
Defective controller
•
When (male) or (female) is not indicated with a connector number, disconnect the connector, and insert T-adapters to both sides of male and female.
•
When (male) or (female) is indicated with a connector number, disconnect the connector, and connect T-adapter to the indicated side of connector.
•
“Male and female” means male and female of connector pins, not connector housings.
•
Male and female of connector pins and housing in DT series, etc, are opposite to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as shown below unless otherwise specified. •
Connect the positive (+) lead to pin or wiring harness indicated first.
•
Connect the negative (-) lead to a pin or wiring harness indicated second.
Circuit Diagram This is the excerpted circuit diagram related to troubleshooting •
The circuit diagram contains the connector No., pin No., and connector color related to the failure.
•
“/” is used in the connector No. in the following 2 cases. •
Abbreviation (3 letters in many cases) Example) T/C: Abbreviation for Torque Converter
•
Male side and female side have different connector Nos. Example) BREAK OUT / E24
•
The circuit diagram contains the destination or source of the branch line in a wiring harness.
•
Arrow (↔): Approximate installation position on the machine NO: Normally Open NC: Normally Closed
•
Signal names such as GND and 24 V are included in addition to connector numbers at junctions, etc. in circuit diagrams.
•
Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to another junction or controller at where the same signal name is indicated.
40-66
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
Connector List and Layout Three-dimensional drawing address
Connector No.
Connector type
Number of pins
A01
SWP
12
Intermediate connector (if equipped)
M-3, AQ-3
A02
DT
2
Intermediate connector (if equipped)
L-4, AP-4
A03
DT
2
Bucket DUMP stop solenoid (if equipped)
I-1, AM-1
CC01
070
14
ID key controller (if equipped)
M-5, AQ-5
CE1
AMP
94
Engine controller
H-1, AK-1
CE2
AMP
60
Engine controller
H-1, AN-1
CK01
070
18
KOMTRAX terminal
R-6, AV-8
CK02
070
12
KOMTRAX terminal
R-6, AV-8
CP01
AMP
81
Machine controller
R-5, AV-9
CP02
AMP
40
Machine controller
R-5, AV-8
D01
SWP
8
Diode
R-3, AV-3
E08
AMP
3
Boom bottom pressure sensor (if equipped)
-
E09
DT
3
Boom angle sensor (if equipped)
-
E10
DT
3
Arm angle sensor (if equipped)
-
E14
SWP
3
Boom swing NEUTRAL proximity switch (if equipped)
-
EGR VALVE
-
4
EGR valve
F01
Y
2
Intermediate connector
M-2, AQ-2
F02
Y
2
Intermediate connector
M-2, AQ-2
F03
DT-C
12
Intermediate connector
O-1, AS-1
F04
DT-B
12
Intermediate connector
O-1, AS-1
F05
DT-D
12
Intermediate connector
N-1, AR-1
F06
DT-A
12
Intermediate connector
O-1, AS-1
F07
DTM
2
Seat belt switch
N-9, AR-9
F08
DT
4
Optional power supply (cab)
AV-6
F09
DT
3
PPC oil pressure lock switch
R-5, AV-5
F10
SWP
6
Engine shutdown secondary switch
R-3, AV-3
F11
DT
3
Intermediate connector (cab)
M-3, AQ-3
F12
DT
2
External power supply socket
M-4, AQ-4
F13
DTM
2
Horn switch
M-6, AQ-6
F14
DT
2, 4
Optional power supply (canopy)
S-4, AW-4
F15
070
12
PM200 monitor
M-5, AQ-5
F16
DTM
6
Engine diagnosis device (SA-D) connector
R-4, AV-4
F17
DT
3
Fuel control dial
M-7, AQ-7
F18
DT-A
12
Intermediate connector
M-3, AQ-3
F19
SUMITOMO
3
Room lamp (cab)
P-9, AT-9
PC45MR-5, PC55MR-5
Location
BN-2
40-67
Connector List and Layout
40 Troubleshooting
Three-dimensional drawing address
Connector No.
Connector type
Number of pins
F21
M
2
Cab revolving lamp (cab) (if equipped)
Q-9, AU-9
F22
M
2
Intermediate connector (cab)
P-9, AS-9
F22A
DT
2
Cab travel lamp (cab)
AD-6, BH-6
F22B
DT
2
Additional working lamp/Cab additional lamp (cab) (if equipped)
Z-8, BD-8
F23
M
3
Intermediate connector (cab)
O-9, AT-9
F24
M
3
Intermediate connector (cab)
Q-9, AU-9
F25
DT-A
8
Intermediate connector
N-1, AR-1
F26
DT-A
12
ATT switch lever (if equipped)
M-6, AQ-6
F27
DT
4
Wiper motor and switch (cab)
Z-1, BD-1
F28
YAZAKI
2
Buzzer
M-6, AQ-6
F29
DT-T
12
Attachment switch lever
F31
-
2
Speaker (left) (cab)
AD-4, BH-4
F32
-
2
Speaker (right) (cab)
AD-3, BH-3
F37
DT
12
Service connector
Q-1, AU-1
F38
DT
2
Travel speed increase switch
M-5, AQ-5
F50
YAZAKI
2
Buzzer
AV-5
F51
DT
2
Quick coupler valve
AR-1
F52
DT
2
Revolving lamp
AU-9
F53
YAZAKI
2
Optional power supply
AR-9
FB1
Terminal
15
Fuse box
HI PRESS PUMP
-
2
SUPPLY PUMP
BK-2
INJECTOR#1
-
2
Injector #1
BK-8
INJECTOR #2
-
2
Injector #2
BL-8
INJECTOR #3
-
2
Injector #3
BM-8
INJECTOR #4
-
2
Injector #4
BN-7
INTAKE THROTTLE
-
6
Intake throttle
BI-3
J01
J
20
Junction connector
R-2, AV-2
J02
J
20
Junction connector
R-2, AV-2
J03
J
20
Junction connector
R-2, AV-2
M01
Y 090 2
2
Horn
I-1, AL-1
M01
YAZAKI PA
9
Radio (if equipped)
AC-2, AL-1
M01A
-
3
Radio (if equipped)
AB-1, BF-1
M01B
M
3
AUX jack (if equipped)
AD-5, AD-5
M02
KES
2
Window washer motor (cab)
D-7, AH-7
M05
L
2
Fusible link
F-9, AJ-9
M06
SDD
3
Fuel level sensor
G-9, AK-9
40-68
Location
AV-5
Q-1, AU-1
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
Three-dimensional drawing address
Connector No.
Connector type
Number of pins
M07
DT
2
TVC resistor
C-7, AG-7
M08
DT
2
Travel alarm
C-7, AG-7
M09
M
2
Fusible link
E-8, AI-8
M10
-
3
Alternator
J-9, AN-9
M11
DT
2
PC-EPC valve (TVC solenoid)
L-4, AP-4
M12
SWP
1
Intermediate connector (cab) (if equipped)
L-5, AP-5
M13
YAZAKI
1
Air conditioner compressor solenoid clutch
K-9, AK-1
M13
-
4
Glow plug relay
G-1, AK-1
M14
X
2
Feed pump
L-5, AP-5
M15
SUMITOMO
6
EGR valve relay
G-1, AK-1
M16
-
4
Starting motor relay
L-2, AP-2
M17
DT
2
Travel speed increase solenoid
J-1, AM-1
M18
DT
2
PPC lock solenoid
K-1, AL-1
M22
DT
2
System operating lamp (if equipped)
F-9, AJ-9
M23
SUMITOMO
1
Glow plug
L-6, AP-6
M24
SUMITOMO
2
Oil pressure switch
L-5, AP-5
M25
AMP
6
KDPF differential pressure sensor
L-8, AP-8
M26
FCI
2
KDPF inlet temperature sensor
L-7, AP-7
M27
FCI
2
KDPF intermediate temperature sensor
L-7, AP-7
M31
AMPSEAL
8
Intermediate connector
L-5, AP-5
M32
AMPSEAL
12
Intermediate connector
L-8, AP-8
M33
AMPSEAL
12
Intermediate connector
L-5, AP-5
M34
AMPSEAL
12
Intermediate connector
L-6, AP-6
P01
X
2
Work equipment PPC pressure switch
K-1, AO-1
P02
AMP
3
Travel PPC pressure sensor
L-2, AP-2
P03
AMP
3
Swing parking brake cancel PPC pressure sensor
K-1, AO-1
P04
DT
4
Connector for service
L-3, AP-4
R01
MICRO ISO
5
Starting motor cut-off relay (PPC lock)
M-2, AQ-2
R02
MICRO ISO
5
PPC lock solenoid relay
R-4, AV-4
R03
MICRO ISO
5
Horn relay
M-2, AQ-2
R04
MICRO ISO
5
Working lamp relay
R-4, AV-4
R05
MICRO ISO
5
Additional lamp relay
N-1, AR-1
R06
MICRO ISO
5
Starting motor cut-off relay (personal code)
R-4, AV-4
R07
MICRO ISO
5
C circuit dummy relay
N-1, AR-1
R08
MICRO ISO
5
Revolving lamp relay
P-1, AV-3
S02
SWP
6
Working lamp switch
M-8, AQ-8
S05_1
Terminal
1
Quick coupler switch
AV-7
PC45MR-5, PC55MR-5
Location
40-69
Connector List and Layout
40 Troubleshooting
Three-dimensional drawing address
Connector No.
Connector type
Number of pins
S05_2
Terminal
1
Quick coupler switch
AV-7
S05_3
Terminal
1
Quick coupler switch
AV-7
S05_4
Terminal
1
Quick coupler switch
AV-7
S21
Terminal
6
Pump secondary drive switch
P-1
S23
Terminal
3
Lock lever automatic lock cancel switch
Q-1
S25
SWP
8
Pump secondary drive switch
P-1
S30
M
3
Model selection connector
R-7
SENSOR, CAM SPEED
-
3
Cam acceleration sensor
AJ-4
SENSOR, COOLANT TEMP
-
2
Coolant temperature sensor
AJ-5
SENSOR, CRANK SPEED
-
2
Crankshaft speed sensor
AE-5
SENSOR, EGR GAS TEMP
-
2
EGR gas temperature sensor
AE-7
SENSOR, EGR PRESS
-
6
EGR pressure sensor
AJ-6
SENSOR, EXHAUST TEMP
-
2
Exhaust gas temperature sensor
AE-6
SENSOR, FRESH INTAKE TEMP
-
2
Fresh air temperature sensor
AF-2
SENSOR, FUEL TEMP
-
2
Fuel temperature sensor
AH-2
SENSOR, INTAKE TEMP
-
2
Intake air temperature sensor
AJ-7
SENSOR, RAIL PRESS
-
3
Rail pressure sensor
AI-2
T01
Terminal
1
Ground (controller)
O-1, AS-1
T02
Terminal
1
Ground
L-2, AP-2
T03
Terminal
1
Ground (engine)
L-3, AP-3
TF1
Terminal
1
Starting switch
N-8, AR-8
TF3
Terminal
1
Starting switch
N-8, AR-8
TF4
Terminal
1
Starting switch
N-8, AR-8
TM1
Terminal
1
Battery
B-6, AF-6
TM2
Terminal
1
Alternator
I-9, AM-9
TM6
Terminal
1
Starting motor
K-9, AO-9
TM13
Terminal
1
Fuse box
A-5, AE-5
TM14
Terminal
1
Fuse box
E-8, AI-8
TM15
Terminal
1
Fuse box
F-1, AJ-1
TM16
Terminal
1
Starting motor
L-4, AP-4
V01
DT
2
EPC (1ST ATT A port) (if equipped)
40-70
Location
-
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
Three-dimensional drawing address
Connector No.
Connector type
Number of pins
V02
DT
2
EPC (1ST ATT B port) (if equipped)
W01
DT
2
Intermediate connector
E-1, AI-1
W02
DT
3
Working lamp
B-2, AF-2
W03
DT
2
Travel lamp (canopy)
L-1, AW-2
PC45MR-5, PC55MR-5
Location
-
40-71
Connector List and Layout
40 Troubleshooting
1/11
40-72
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
2/11
PC45MR-5, PC55MR-5
40-73
Connector List and Layout
40 Troubleshooting
3/11
40-74
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
4/11 (Canopy Specifications)
PC45MR-5, PC55MR-5
40-75
Connector List and Layout
40 Troubleshooting
5/11 (Cab Specifications)
40-76
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
6/11 (Quick Coupler Specifications)
PC45MR-5, PC55MR-5
40-77
Connector List and Layout
40 Troubleshooting
7/11 (Quick Coupler Specifications)
40-78
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
8/11 (Quick Coupler Specifications)
PC45MR-5, PC55MR-5
40-79
Connector List and Layout
40 Troubleshooting
9/11 (Canopy Specifications, Quick Coupler Specifications)
40-80
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector List and Layout
10/11 (Cab Specifications, Quick Coupler Specifications)
PC45MR-5, PC55MR-5
40-81
Connector List and Layout
40 Troubleshooting
11/11
40-82
PC45MR-5, PC55MR-5
40 Troubleshooting
Connector Contact Identification (For 4D88E-7 Engine)
Connector Contact Identification (For 4D88E-7 Engine) Equipment
No. of pins
Equipment (Sec. 90 Electric dia(Engine shop manual) gram)
1
GLOW PLUG
2
SENSOR,EXHAUST Exhaust manifold TEMP temperature sensor
2
Glow plug
SENSOR,EGR GAS TEMP
EGR gas temperature sensor
SENSOR,INTAKE TEMP
Intake manifold temperature sensor
Connecter maker
YAZAKI
FCI
DELPHI
2
SENSOR,FRESH IN- New air temperature TAKE TEMP sensor
Tyco
2
OIL PRESS SWITCH Oil pressure switch
SUMITOMO
2
SENSOR, DPF INLET TEMP
KDPF inlet temperature sensor
SENSOR, DPF INSIDE TEMP
KDPF intermediate temperature sensor
PC45MR-5, PC55MR-5
Detail of interface and pin No.
FCI
40-83
Connector Contact Identification (For 4D88E-7 Engine)
Equipment
No. of pins
Equipment (Sec. 90 Electric dia(Engine shop manual) gram)
2
SENSOR, COOLANT TEMP
Cooling water temperature sensor
Tyco
2
INJECTOR
Injector
BOSCH
HI PRESS PUMP
High-pressure pump
SENSOR, FUEL TEMP
Fuel temperature sensor
BOSCH
2
SENSOR, CRANK SPEED
Crank speed sensor
BOSCH
3
SENSOR, RAIL PRESS
Rail pressure sensor
BOSCH
3
SENSOR, CAM SPEED
Cam speed sensor
BOSCH
2
40-84
40 Troubleshooting
Connecter maker
Detail of interface and pin No.
PC45MR-5, PC55MR-5
40 Troubleshooting
No. of pins
Connector Contact Identification (For 4D88E-7 Engine)
Equipment
Equipment (Sec. 90 Electric dia(Engine shop manual) gram)
STARTER RELAY
Starter relay
Connecter maker
4
GLOW PLUG RELAY
4
EGR VALVE
EGR valve
SUMITOMO
6
EGR VALVE RELAY
EGR valve relay
SUMITOMO
6
SENSOR, DPF DEF PRESS
KDPF differential pressure sensor
Tyco
6
SENSOR, EGR PRESS
EGR pressure sensor Tyco
6
INTAKE THROTTLE
Intake throttle opening sensor
PC45MR-5, PC55MR-5
Glow relay
Detail of interface and pin No.
YAZAKI
YAZAKI
40-85
Connector Contact Identification (For 4D88E-7 Engine)
Equipment
No. of pins
Equipment (Sec. 90 Electric dia(Engine shop manual) gram)
8
HARNESS, ENG
Junction coupler
Tyco
12
HARNESS, ENG
Junction coupler
Tyco
40-86
40 Troubleshooting
Connecter maker
Detail of interface and pin No.
PC45MR-5, PC55MR-5
40 Troubleshooting
T-Branch Box and T-Branch Adapter Table
T-Branch Box and T-Branch Adapter Table (Rev.2014.11)
The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of harness checker assemblies are listed in the horizontal line. Non-kit part
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
●
799-601-8000
37
● ●
799-601-7500
799-601-3200 T-box (for MS)
799-601-7400
●
799-601-7100
37
●
799-601-7000
799-601-3100 T-box (for MS)
●
799-601-2800
21
ID marking
799-601-2700
799-601-2600 T-box (for ECONO)
Part No.
799-601-2500
Part name
Number of pins
T-adapter kit
●
799-601-3380 Plate for MS (14 pins)
●
799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
●
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
●
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
●
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
●
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
●
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
●
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
●
799-601-3470 Case
●
799-601-2710 Adapter for MIC
5
MIC-5P
● ●
●
799-601-2720 Adapter for MIC
13
MIC-13P
● ●
●
799-601-2730 Adapter for MIC
17
MIC-17P
● ● ●
● ●
●
799-601-2740 Adapter for MIC
21
MIC-21P
● ● ●
● ●
●
799-601-2950 Adapter for MIC
9
MIC-9P
● ● ●
●
799-601-2750 Adapter for ECONO
2
ECONO 2P
● ●
799-601-2760 Adapter for ECONO
3
ECONO 3P
● ●
799-601-2770 Adapter for ECONO
4
ECONO 4P
● ●
799-601-2780 Adapter for ECONO
8
ECONO 8P
● ●
799-601-2790 Adapter for ECONO
12
ECONO 12P
● ●
799-601-2810 Adapter for DLI
8
DLI-8P
● ●
799-601-2820 Adapter for DLI
12
DLI-12P
● ●
799-601-2830 Adapter for DLI
16
DLI-16P
● ●
PC45MR-5, PC55MR-5
40-87
T-Branch Box and T-Branch Adapter Table
799-601-2840
Extension cable (ECONO type)
799-601-2850 Case 799-601-4350 T-box (for DRC60, ECONO)
● ●
Non-kit part
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
●
● 60
●
799-601-4360 Case
●
799-601-7010 Adapter for X (T-adapter)
1
●
●
799-601-7020 Adapter for X
2
X2P
● ● ●
●
799-601-7030 Adapter for X
3
X3P
● ● ●
●
799-601-7040 Adapter for X
4
X4P
● ● ●
●
799-601-7050 Adapter for SWP
6
SW6P
● ● ●
799-601-7060 Adapter for SWP
8
SW8P
● ● ●
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
799-601-7090 Adapter for M
2
799-601-7110
Adapter for M
● ●
● ●
●
●
M2P
● ● ●
●
3
M3P
● ● ●
●
799-601-7120 Adapter for M
4
M4P
● ● ●
●
799-601-7130 Adapter for M
6
M6P
● ● ●
●
799-601-7340 Adapter for M
8
M8P
799-601-7140 Adapter for S
8
S8P
● ● ●
●
799-601-7150 Adapter for S (white)
10
S10P
● ● ●
●
799-601-7160 Adapter for S (blue)
12
S12P
● ● ●
799-601-7170 Adapter for S (blue)
16
S16P
● ● ●
799-601-7330 Adapter for S (white)
16
S16PW
799-601-7350 Adapter for S (white)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
●
799-601-7190 Adapter for AMP040
12
A12P
●
●
799-601-7210 Adapter for AMP040
16
A16P
● ● ●
●
799-601-7220 Adapter for AMP040
20
A20P
● ● ●
●
799-601-7230 Short socket adapter for X
2
● ● ●
●
799-601-7240 Case
●
● ● ●
● ●
799-601-7270 Case
●
799-601-7510 Adapter for 070
10
07-10
●
799-601-7520 Adapter for 070
12
07-12
●
40-88
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
ECONO 12P
799-601-2800
12
799-601-2700
ID marking
799-601-2500
Part name
T-adapter kit
Number of pins
Part No.
40 Troubleshooting
PC45MR-5, PC55MR-5
40 Troubleshooting
T-Branch Box and T-Branch Adapter Table
5
REL-5P
●
799-601-7370 Adapter for relay
6
REL-6P
●
799-601-7380 Adapter for JFC
2
799-601-9010 Adapter for DTM
2
DTM2
●
●
799-601-9020 Adapter for DT
2
DT2
●
●
799-601-9030 Adapter for DT
3
DT3
●
●
799-601-9040 Adapter for DT
4
DT4
●
●
799-601-9050 Adapter for DT
6
DT6
●
●
799-601-9060 Adapter for DT (gray)
8
DT8GR
●
●
799-601-9070 Adapter for DT (black)
8
DT8B
●
●
799-601-9080 Adapter for DT (green)
8
DT8G
●
●
799-601-9090 Adapter for DT (brown)
8
DT8BR
●
●
799-601-9110
Adapter for DT (gray)
12
DT12GR
●
●
799-601-9120 Adapter for DT (black)
12
DT12B
●
●
799-601-9130 Adapter for DT (green)
12
DT12G
●
●
799-601-9140 Adapter for DT (brown)
12
DT12BR
●
●
799-601-9210 Adapter for HD30-18
8
D18-8
● ●
799-601-9220 Adapter for HD30-18
14
D18-14
● ●
799-601-9230 Adapter for HD30-18
20
D18-20
● ●
799-601-9240 Adapter for HD30-18
21
D18-21
● ●
799-601-9250 Adapter for HD30-24
9
D24-9
● ●
799-601-9260 Adapter for HD30-24
16
D24-16
● ●
799-601-9270 Adapter for HD30-24
21
D24-21
● ●
799-601-9280 Adapter for HD30-24
23
D24-23
● ●
799-601-9290 Adapter for HD30-24
31
D24-31
● ●
●
799-601-9310 Plate for HD30 (24 pins) 799-601-9320 T-box (for ECONO)
24
799-601-9330 Case
● ●
● ●
● ●
●
● ●
●
●
799-601-9340 Case
●
799-601-9350 Adapter for DRC
40
DRC-40
●
799-601-9360 Adapter for DRC
24
DRC-24
●
799-601-9410* Socket for engine (CRI-T2)
2
G
PC45MR-5, PC55MR-5
Non-kit part
799-601-7360 Adapter for relay
799-601-4201
●
799-601-4101
07-20
799-601-9300
20
799-601-9200
799-601-7550 Adapter for 070
799-601-9100
●
799-601-9000
07-18
799-601-8000
18
799-601-7500
799-601-7540 Adapter for 070
799-601-7400
●
799-601-7100
07-14
799-601-7000
14
799-601-2800
799-601-7530 Adapter for 070
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
●
40-89
T-Branch Box and T-Branch Adapter Table
40 Troubleshooting
S
●
2
C
● ●
795-799-5540* Socket TIM for engine (CRIT3)
2
A
● ●
795-799-5460 Cable for engine (HPI-T2)
3
●
795-799-5470 Cable for engine (HPI-T2)
3
●
795-799-5480 Cable for engine (HPI-T2)
3
●
Non-kit part
2
799-601-4201
795-799-5520* Socket for engine (HPI-T2)
799-601-4101
●
799-601-9300
1, 2, 3
799-601-9200
3
799-601-9100
799-601-9440* Socket for engine (CRI-T2)
799-601-9000
● ●
799-601-8000
P
799-601-7500
2
799-601-7400
799-601-9430* Socket PCV for engine (CRIT3)
799-601-7100
● ●
799-601-7000
A3
799-601-2800
3
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
Adapter for engine (CRI-T2) 799-601-9420
Adapter PFUEL for engine (CRI-T3) Oil pressure sensor Socket for engine (CRI-T2)
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2)
799-601-4110
Adapter PIM for engine (140T3)
4
ITT3N
● ●
799-601-4130
Adapter NE, CAM for engine (CRI-T3)
3
FCIN
● ●
3
FCIG
● ●
3
FCIB
● ●
2
4160
● ●
3
4180
● ●
3
1, 2, 3L
● ●
4
1, 2, 3, 4C
● ●
799-601-4140 799-601-4150 799-601-4160 799-601-4180 799-601-4190* 799-601-4230*
Adapter for engine (CRI-T3) Ambient pressure Adapter POIL for engine (CRI-T3) Adapter for engine (CRI-T3) Oil pressure switch Adapter PEVA for engine (CRI-T3) Socket for engine (CRI-T3) Common rail pressure Socket for engine (CRI-T3) Intake pressure/temperature
799-601-4240*
Socket PAMB for engine (CRI-T3)
3
1, 2, 3A
● ●
799-601-4250*
Socket PIM for engine (CRIT3)
3
1, 2, 3B
● ●
799-601-4330*
Socket G for engine (CRIT3)
3
1, 2, 3G
● ●
40-90
PC45MR-5, PC55MR-5
40 Troubleshooting
T-Branch Box and T-Branch Adapter Table
●
799-601-4220 Adapter for controller (ENG)
60
DRC60
●
799-601-4390*
Socket for controller (95ENG)
Non-kit part
DRC50
799-601-4201
50
799-601-4101
Adapter for controller (ENG)
799-601-9300
799-601-4211
799-601-9200
● ●
799-601-9100
DTP4
799-601-9000
4
799-601-8000
799-601-4260 Adapter for controller (ENG)
799-601-7500
1, 2, 3, 4T
799-601-7400
4
799-601-7100
Socket for engine (CRI-T3) 799-601-4380* (95) Intake pressure/temperature
Pump actuator
799-601-7000
2, PA
Socket for engine (CRI-T3)
799-601-2800
2
799-601-4340*
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
● ●
●
60
●
799-601-4280* Box for controller (PUMP)
121
●
799-601-9720 Adapter for controller (HST)
16
HST16A
●
799-601-9710 Adapter for controller (HST)
16
HST16B
●
799-601-9730 Adapter for controller (HST)
26
HST26A
●
Multi-adapter for DT 2 to 4, DTM 2 pins
2, 3, 4
●
799-902-9600 T-adapter for ICT control box
26
●
799-902-9700 T-box
26
●
7
●
799-601-9890
799-970-1010
Adapter for radio control receiver
*: These are not T-adapters but sockets.
PC45MR-5, PC55MR-5
40-91
T-Branch Box and T-Branch Adapter Table
40 Troubleshooting
4
799-601-4620
●
799-601-4630 Adapter for controller (ENG-T4)
2
799-601-4630
●
799-601-4640 Adapter for controller (ENG-T4)
2
799-601-4640
●
799-601-4651 Adapter for controller (ENG-T4)
24
799-601-4651
●
799-601-4660 Adapter for controller (ENG-T4)
3
799-601-4660
●
799-902-9310 Adapter for control box
19
799-902-9310
●
799-902-9320 Adapter for IMU
10
799-902-9320
●
799-902-9330 Adapter for MS cylinder
6
799-902-9330
●
799T-601-4611
KDPF differential pressure sensor short socket adapter
4
799T-601-4611
●
799T-601-4670
KDPF outlet pressure sensor short socket adapter
4
799T-601-4670
●
799T-601-4680 KDPF dummy temperature sensor
4
799T-601-4680
●
40-92
Non-kit part
799-601-4620 Adapter for controller (ENG-T4)
Part name
799-902-9300
ID marking
Part No.
799-A65-4600
Number of pins
T-adapter kit
PC45MR-5, PC55MR-5
40 Troubleshooting
Fuse Location Table
Fuse Location Table •
This connection table shows the devices which receive supply from each power source of the fuse box. (A switched power supply is the power which is supplied while the starting switch is in ON position and a continuous power supply is the power which is supplied even while the starting switch is in ON and OFF positions.)
•
When performing troubleshooting related to the electrical system, it is desirable to check the fuses and fusible links whether the power supply is normally supplied at first.
Connection Table of Fuse Box Canopy Specifications Type of power supply
Switched power supply
Power supply to fuse
Fusible link M05 (65 A)
Starting switch ACC
Continuous Fusible link power supply M09 (45 A)
PC45MR-5, PC55MR-5
Fuse No.
Fuse capacity
Destination of power
1
5A
Working lamp relay, additional working lamp relay, and pump secondary drive switch
2
10 A
Solenoid valve
3
5A
PPC hydraulic lock solenoid
4
10 A
Spare
5
10 A
Travel alarm, fuel pump, and horn
6
10 A
Spare
7
10 A
Spare
8
10 A
Heater
9
10 A
External power supply
10
5A
ACC signal
11
10 A
Working lamp and travel lamp
12
5A
System operating lamp (if equipped)
13
10 A
Machine monitor and controller
14
20 A
Engine controller
15
20 A
EGR valve
40-93
Fuse Location Table
40 Troubleshooting
Canopy Specifications (Quick Coupler Specifications) Type of power supply
Switched power supply
Power supply to fuse
Fusible link M05 (65 A)
Starting switch ACC
Continuous Fusible link power supply M09 (45 A)
Fuse No.
Fuse capacity
Destination of power
1
5A
Working lamp relay, additional working lamp relay, and pump secondary drive switch
2
10 A
Solenoid valve
3
5A
PPC hydraulic lock solenoid
4
10 A
Spare
5
10 A
Travel alarm, fuel pump, and horn
6
10 A
Spare
7
10 A
Spare
8
10 A
Quick coupler
9
10 A
External power supply
10
5A
ACC signal and fuel pump
11
10 A
Working lamp and travel lamp
12
5A
System operating lamp (if equipped)
13
10 A
Machine monitor and controller
14
20 A
Engine controller
15
20 A
EGR valve
Fuse No.
Fuse capacity
Destination of power
1
5A
Working lamp relay, additional working lamp relay, and pump secondary drive switch
2
10 A
Solenoid valve
3
5A
PPC hydraulic lock solenoid
4
10 A
Room lamp, radio, and windshield wiper
5
10 A
Travel alarm, fuel pump, and horn
6
10 A
Spare
7
10 A
Spare
8
20 A
Air conditioner and heater
9
10 A
External power supply
10
5A
ACC signal
11
30 A
Working lamp, travel lamp, and additional working lamp
12
10 A
System operating lamp (if equipped), radio
13
10 A
Machine monitor and controller
14
20 A
Engine controller
15
20 A
EGR valve
Cab Specifications Type of power supply
Switched power supply
Power supply to fuse
Fusible link M05 (65 A)
Starting switch ACC
Continuous Fusible link power supply M09 (45 A)
40-94
PC45MR-5, PC55MR-5
40 Troubleshooting
Fuse Location Table
Cab Specifications (Quick Coupler Specifications) Type of power supply
Switched power supply
Power supply to fuse
Fusible link M05 (65 A)
Starting switch ACC
Continuous Fusible link power supply M09 (45 A)
Fuse No.
Fuse capacity
Destination of power
1
5A
Working lamp relay, additional working lamp relay, and pump secondary drive switch
2
10 A
Solenoid valve
3
5A
PPC hydraulic lock solenoid
4
10 A
Room lamp, radio, and windshield wiper
5
10 A
Travel alarm, fuel pump, and horn
6
10 A
Revolving lamp
7
10 A
Quick coupler
8
20 A
Air conditioner and heater
9
10 A
External power supply
10
5A
ACC signal
11
30 A
Working lamp, travel lamp, and additional working lamp
12
10 A
Radio and system operating lamp
13
10 A
Machine monitor and controller
14
20 A
Engine controller
15
20 A
EGR valve
Locations of Fusible Links * : Open the dirt cover, and you will see the fusible links M09 (1), M05 (2), TM14 (3), and TM15 (4).
PC45MR-5, PC55MR-5
40-95
Fuse Location Table
40 Troubleshooting
Locations of Fuse Boxes and Fuse No. * : The fuse holder is provided inside the cover under the operator's seat.
40-96
PC45MR-5, PC55MR-5
40 Troubleshooting
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
k Since KDPF and KDOC are heated to 600 °C or above, take care not to get burn injury.
Related Information Soot accumulation amount of KCSF in KDPF is classified in 8 levels. From service menu of machine monitor, display “Diagnostic Tests” screen, and current level of accumulated soot can be checked on “Active Regeneration for Service” screen. •
If the soot accumulation level is 4 or 5, the failure code [AQ20R1] is displayed.
•
If the soot accumulation level is 6 or 7, the failure code [#B1421] is displayed.
•
If the soot accumulation level is 8, the failure code [#B1424] is displayed.
•
•
If the soot accumulation level is 8, the KDPF is completely clogged with soot and needs inspection, cleaning or replacement.
•
Manual stationary regeneration can be performed up to soot accumulation level 7, and soot in KCSF can be burnt and removed.
When soot accumulation level is 4 to 7, the manual stationary regeneration can also be performed from user mode.
How to perform Manual Stationary Regeneration from “Active Regeneration for Service” •
•
When soot accumulation level is 3 or under, the manual stationary regeneration can be performed only from “Active Regeneration for Service”. 1. Start the engine. 2.
Secure the safety of the machine.
3.
From Service Menu of machine monitor, display “Diagnostic Tests” screen, open “Active Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
Time required for the manual stationary regeneration varies depending on soot accumulation amount in KCSF. Rough guide is described below. Soot accumulation level 4 or 5: Approximately 30 minutes
•
•
How to reset after KDPF (KCSF) cleaning From Service Menu of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Reset”, and then perform “KDPF Cleaning” (KDPF cleaning reset).
•
How to reset after KDPF (KCSF) replacement From Service Menu of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Reset”, and then perform “KDPF Replacement” (Reset after KDPF replacement).
How to reset after KDOC replacement •
•
From Service Menu of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Reset”, and then perform “KDOC Replacement” (Reset after KDOC replacement).
If KDPF or KDOC is replaced, perform reset of “KDOC Replacement” but it is not necessary to perform the manual stationary regeneration.
Clean or Replace KCSF •
At the 6000 H period periodical cleaning 1. Check the soot accumulation level, if it is displayed, perform Active Regeneration for Service until it becomes zero. 2. Stop the engine, wait for the piping around the engine to cool, remove the KDPF, and remove the KCSF. 3.
Install an alternative KCSF to the machine.
4.
Turn the starting switch to ON position, and perform the reset of “KDPF Cleaning” from “KDPF Memory Reset” screen.
5.
Perform the reset of “KDPF Replacement” from “KDPF Memory Reset” screen. If “KDPF Replacement” reset is performed, the soot accumulation level is reset. The soot accumulation level can be checked by the following monitoring code.
PC45MR-5, PC55MR-5
40-97
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
40 Troubleshooting
Monitoring code: 47700“KDPF Soot Density(C)” Monitoring code: 47800“KDPF AshAccumulation” 6. •
•
Start the engine and warm up at low idle.
When a crack or damage is found by inspection 1. Stop the engine, wait for the piping around the engine to cool, remove the KDPF, and remove the KCSF. 2. Install alternative KCSF (new or used). 3.
Turn the starting switch to ON position, and perform the reset of “KDPF Cleaning” from “KDPF Memory Reset” screen.
4.
Perform the reset of “KDPF Replacement” from “KDPF Memory Reset” screen.
5.
Start the engine and warm up at low idle.
When [#B1424] “Backup Mode” is displayed. 1. Stop the machine, and check that the failure code [#B1424] is displayed. 2.
Check records for appeared failure codes of [AQ20R1] “KCSF Manual Stationary Regeneration Request”, [#B1421] “Stationary Regeneration Standby”, and [#B1424] “Backup Mode”. <Case1> In case of KCSF replacement KCSF must be replaced because the soot accumulation exceeds the limit which the regeneration can be performed. [Details of work] Case1-1] Stop the engine, wait for the piping around the engine to cool, remove the KDPF, and remove the KCSF. Case1-2] Install a alternative KCSF (new or used). Case1-3] Turn the starting switch to ON position, and perform the reset of “KDPF Cleaning” from “KDPF Memory Reset” screen. If “KDPF Replacement” reset is performed, the soot accumulation level is reset. The soot accumulation level can be checked by the following monitoring code. Monitoring code: 47700“KDPF Soot Density(C)” Monitoring code: 47800“KDPF AshAccumulation” Action level and failure code: [# B1424] disappears. Case1-4] Perform the reset of “KDPF Replacement” from “KDPF Memory Reset” screen. If “KDPF Replacement” reset is performed, the soot accumulation level is reset. The soot accumulation level can be checked by the following monitoring code. Monitoring code: 47700“KDPF Soot Density(C)” Monitoring code: 47800“KDPF AshAccumulation” Case1-5] Start the engine and warm up at low idle.
•
When [#B242F] “Ash Cleaning Request 1” and [#B1420] “Ash Cleaning Request 2” is displayed. When the presumed cause is “Ash Accumulation High Error” as a result of investigation with reference to the failure codes [#B242F] and [#B1420], perform the same contents as the “At the 6000 H period periodical cleaning” of “In case of KCSF cleaning or replacing”.
If You Clean or Change KDOC •
When a crack or damage is found by inspection 1. When damage or crack is found in KDOC, replace KDOC. 2.
40-98
Perform the reset of “KDOC Replacement” from “KDPF Memory Reset” screen.
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code Table
Failure Code Table Failure code
Failure (Displayed on screen)
Applicable component
Action level
History category
989L00
Engine Controller Lock Caution 1
MON
-
Electrical system
989M00
Engine Controller Lock Caution 2
MON
-
Electrical system
989N00
Engine Controller Lock Caution 3
MON
-
Electrical system
AQ20R1
KCSF Manual Stationary Regeneration Request
MACHINE
L01
Electrical system
MACHINE
L02
Mechanical system
MON
L03
Electrical system
B@BCNS Eng Water Overheat D19JKZ
Personal Code Relay Open Circuit or Short Circuit
D811MC
KOMTRAX Malfunction
KOMTRAX
-
Electrical system
D862KA
GPS Antenna Open Circuit
KOMTRAX
-
Electrical system
D8ALKA
System Operating Lamp Open Circuit (KOMTRAX)
KOMTRAX
-
Electrical system
D8ALKB
System Operating Lamp Short Circuit (KOMTRAX)
KOMTRAX
-
Electrical system
D8AQKR CAN 2 Defective Communication (KOMTRAX)
MON
―
Electrical system
DAF0KT
EEPROM Error (Monitor)
MON
L03
Electrical system
DAF0MB Monitor ROM Abnormality
MON
-
Electrical system
DAF0MC Monitor Malfunction
MON
-
Electrical system
DAF3KK
MON
-
Electrical system
MON
L03
Electrical system
KOMTRAX
-
Electrical system
Main Power Voltage Low Error (Monitor)
DAF9KQ Model Selection Signal Mismatch (Monitor) DAFGMC GPS Module Malfunction DAFLKA
System Operating Lamp Open Circuit (Monitor)
MON
-
Electrical system
DAFLKB
System Operating Lamp Short Circuit (Monitor)
MON
-
Electrical system
KOMTRAX
-
Electrical system
MON
L03
Electrical system
MACHINE
-
Mechanical system
DAFQKR CAN 2 Defective Communication (Monitor) DB2QKR
CAN 2 Defective Communication (Engine Controller)
DBH0MC Machine Controller Malfunction
PC45MR-5, PC55MR-5
Remarks
40-99
Failure Code Table
40 Troubleshooting
Applicable component
Action level
History category
DBH2KK Mcn Solenoid Power Low Error
MACHINE
L03
Mechanical system
DBH5KP 5V Sensor 1 Power Voltage Low Error
MACHINE
-
Mechanical system
5V Sensor 1 Power Voltage Low Error (FOR PROPORTIONAL LEVER SPEC)
MACHINE
-
Mechanical system
DBH9KQ Model Selection Signal Mismatch (MCN Controller)
MACHINE
L01
Electrical system
DBHLKA Operating Lamp Open Circuit(Mcn Con)
MACHINE
-
Mechanical system
DBHLKB Operating Lamp Short Circuit(Mcn Con)
MACHINE
-
Mechanical system
MON
L03
Electrical system
DDNRKA W/E Lever Lock SW Open Circuit
MACHINE
L03
Electrical system
DDNRKY W/E Lever Lock SW Short Circuit
MACHINE
L03
Electrical system
DDNS00 Lock Lever Auto Lock Release SW On
MACHINE
-
Electrical system
DDWLKA Breaker Switch Open Circuit or Ground Fault
MACHINE
-
Electrical system
DDWLKB Breaker Switch Hot Short Circuit
MACHINE
-
Electrical system
DFB1KZ
Service Lever Potentio 1 Open or Short Circuit
MACHINE
L01
Electrical system
DFB3L8
Service Lever 1 Potentio Signal Incompatibility
MACHINE
-
Electrical system
DFB5KZ
Service Lever sub-Potentio 1 Open or Short Circuit
MACHINE
-
Electrical system
DHS1MA Swing PPC Pressure Sensor System Abnormality
MACHINE
L01
Electrical system
DHS5MA Travel PPC Pressure Sensor Error
MACHINE
L01
Electrical system
DKULKA PPC Lock Relay Open Circuit
MACHINE
L03
Electrical system
DKULKB PPC Lock Relay Short Circuit
MACHINE
L03
Electrical system
DKULKY PPC Lock Relay Hot Short Circuit
MACHINE
L03
Electrical system
Failure code
DBH5KP
DBHQKR
Failure (Displayed on screen)
Controller Area NW 2 Defect Communicat (Machn Con)
DV00KB
Buzzer Output Short Circuit
MON
L01
Electrical system
DV20KB
Travel Alarm Short Circuit
MACHINE
L01
Electrical system
DW43KA Travel Speed Solenoid Open Circuit
MACHINE
L01
Electrical system
40-100
Remarks
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code Table
Applicable component
Action level
History category
DW43KB Travel Speed Solenoid Short Circuit
MACHINE
L01
Electrical system
DW43KY Travel Speed Solenoid Hot Short Circuit
MACHINE
L01
Electrical system
DW4CKY PPC Lock Solenoid Hot Short Circuit
MACHINE
L03
Electrical system
DXA8KA Pump PC-EPC Solenoid Open Circuit
MACHINE
L03
Electrical system
DXA8KB Pump PC-EPC Solenoid Short Circuit
MACHINE
L03
Electrical system
Failure code
Failure (Displayed on screen)
DXE7KA
Attachment Flow Regulating EPC 2 Solenoid Open Circuit
MACHINE
-
Electrical system
DXE7KB
Attachment Flow Regulating EPC 2 Solenoid Short Circuit
MACHINE
-
Electrical system
DXE7KY
Attachment Flow Regulating EPC 2 Hot Short Circuit
MACHINE
-
Electrical system
DXEAKA
Attachment Flow Regulating EPC 5 Solenoid Open Circuit
MACHINE
-
Electrical system
DXEAKB
Attachment Flow Regulating EPC 5 Solenoid Short Circuit
MACHINE
-
Electrical system
DXEAKY Attachment Flow Regulating EPC 5 Hot Short Circuit
MACHINE
-
Electrical system
Remarks
#B0008
FAILURE CODE [#B0008] No Signal on Both Crank and Cam Speed Sensor
ENG
L04
Electrical system
*1
#B000F
FAILURE CODE [#B000F] PLV Open Valve
ENG
L03
Electrical system
*1
#B0088
FAILURE CODE [#B0088] Actual Rail Pressure Rise Error
ENG
L03
Electrical system
*1
#B0093
FAILURE CODE [#B0093] Rail Press Deviation Error in Act Rail Press Rise
ENG
L03
Electrical system
*1
#B0094
FAILURE CODE [#B0094] Rail Press Deviation Error in Act Rail Press Drop
ENG
L03
Electrical system
*1
#B0112
FAILURE CODE [#B0112] New Air Temperature Sensor Error (Low Voltage)
ENG
L01
Electrical system
*1
#B0113
FAILURE CODE [#B0113] New Air Temperature Sensor Error (High Voltage)
ENG
L01
Electrical system
*1
#B0117
FAILURE CODE [#B0117] Cooling Water Temperature Sensor Error (Low Volt)
ENG
L03
Electrical system
*1
#B0118
FAILURE CODE [#B0118] Cooling Water Temperature Sens Error (High Volt)
ENG
L03
Electrical system
*1
#B0122
FAILURE CODE [#B0122] Accelerator Sensor 1 (Low voltage)
ENG
L03
Electrical system
*1
#B0123
FAILURE CODE [#B0123] Accelerator Sensor 1 (High voltage)
ENG
L03
Electrical system
*1
#B0168
FAILURE CODE [#B0168] Fuel Temperature Sensor Temperature Abnormal High
ENG
L03
Mechanical system
*1
PC45MR-5, PC55MR-5
40-101
Failure Code Table
Failure code
40 Troubleshooting
Failure (Displayed on screen)
Applicable component
Action level
History category
Remarks
#B0182
FAILURE CODE [#B0182] Fuel Temperature Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B0183
FAILURE CODE [#B0183] Fuel Temperature Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B0192
FAILURE CODE [#B0192] Rail Pressure Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B0193
FAILURE CODE [#B0193] Rail Pressure Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B0201
FAILURE CODE [#B0201] Injector of 1st Cylinder OpenC (Inherent Location)
ENG
L03
Electrical system
*1
#B0202
FAILURE CODE [#B0202] Injector of 2nd Cylinder OpenC (Inherent Location)
ENG
L03
Electrical system
*1
#B0203
FAILURE CODE [#B0203] Injector of 3rd Cylinder OpenC (Inherent Location)
ENG
L03
Electrical system
*1
#B0204
FAILURE CODE [#B0204] Injector of 4th Cylinder OpenC (Inherent Location)
ENG
L03
Electrical system
*1
#B0219
FAILURE CODE [#B0219] Overspeed
ENG
L04
Mechanical system
*1
#B0236
FAILURE CODE [#B0236] EGR Low Pres Side Sens Error (Abnorma Learn Value)
ENG
L03
Electrical system
*1
#B0237
FAILURE CODE [#B0237] EGR Low Pressure Side Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B0238
FAILURE CODE [#B0238] EGR Low Pressure Side Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B0262
FAILURE CODE [#B0262] Injector of 1st Cylinder Coil Short Circuit
ENG
L03
Electrical system
*1
#B0265
FAILURE CODE [#B0265] Injector of 2nd Cylinder Coil Short Circuit
ENG
L03
Electrical system
*1
#B0268
FAILURE CODE [#B0268] Injector of 3rd Cylinder Coil Short Circuit
ENG
L03
Electrical system
*1
#B0271
FAILURE CODE [#B0271] Injector of 4th Cylinder Coil Short Circuit
ENG
L03
Electrical system
*1
#B02E8
FAILURE CODE [#B02E8] Intake Throttle Open Position Sens Error (Low V)
ENG
L03
Electrical system
*1
#B02E9
FAILURE CODE [#B02E9] Intake Throttle Open Position Sens Error (High V)
ENG
L03
Electrical system
*1
#B0336
FAILURE CODE [#B0336] Crank Signal Error
ENG
L03
Electrical system
*1
#B0337
FAILURE CODE [#B0337] No Crank Signal
ENG
L03
Electrical system
*1
#B0341
FAILURE CODE [#B0341] Cam Signal Error
ENG
L01
Electrical system
*1
#B0342
FAILURE CODE [#B0342] No Cam Signal
ENG
L01
Electrical system
*1
#B0403
FAILURE CODE [#B0403] Open Circuit Between the EGR Motor Coils
ENG
L03
Electrical system
*1
40-102
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code Table
Failure code
Failure (Displayed on screen)
Applicable component
Action level
History category
#B0404
FAILURE CODE [#B0404] EGR Voltage High Error
ENG
L03
Electrical system
*1
#B040C
FAILURE CODE [#B040C] Intake Manifold Temperature Sens Error (Low Volt)
ENG
L03
Electrical system
*1
#B040D
FAILURE CODE [#B040D] Intake Manifold Temperature Sens Error (High Volt)
ENG
L03
Electrical system
*1
#B041C
FAILURE CODE [#B041C] EGR Gas Temperature Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B041D
FAILURE CODE [#B041D] EGR Gas Temperature Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B0420
FAILURE CODE [#B0420] KDPF Inter Temperature Low Error
ENG
L03
Electrical system
*1
#B0471
FAILURE CODE [#B0471] EGR High Pres Side Sens Error (Abnorm Learn Value)
ENG
L03
Electrical system
*1
#B0472
FAILURE CODE [#B0472] EGR High Pressure Side Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B0473
FAILURE CODE [#B0473] EGR High Pressure Side Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B0488
FAILURE CODE [#B0488] EGR Position Sensor Error
ENG
L03
Electrical system
*1
#B049D
FAILURE CODE [#B049D] EGR Initialization Error
ENG
L03
Electrical system
*1
#B0541
FAILURE CODE [#B0541] Startup Assist Relay GND Short Circuit
ENG
L01
Electrical system
*1
#B0543
FAILURE CODE [#B0543] Startup Assist Relay Open Circuit
ENG
L01
Electrical system
*1
#B0545
FAILURE CODE [#B0545] Exhaust Manifold Temperature Sens Error (Low Volt)
ENG
L03
Electrical system
*1
#B0546
FAILURE CODE [#B0546] Exhaust Manifold Temperature Sens Error (HighVolt)
ENG
L03
Electrical system
*1
#B0601
FAILURE CODE [#B0601] EEPROM Memory Deletion Error
ENG
L03
Electrical system
*1
#B0611
FAILURE CODE [#B0611] Injector Drive IC Error
ENG
L04
Electrical system
*1
#B0627
FAILURE CODE [#B0627] SCV(MPROP) (Open Circuit)
ENG
L03
Electrical system
*1
#B0629
FAILURE CODE [#B0629] SCV(MPROP) (High Side VB Short)
ENG
L03
Electrical system
*1
#B062A
FAILURE CODE [#B062A] SCV(MPROP) (Drive Current High Error)
ENG
L03
Electrical system
*1
#B0660
FAILURE CODE [#B0660] No-load of Throttle Valve Drive H Bridge Circuit
ENG
L03
Electrical system
*1
#B068A
FAILURE CODE [#B068A] Main Relay Early Opening
ENG
L01
Electrical system
*1
#B068B
FAILURE CODE [#B068B] Main Relay Contact Stuck
ENG
L01
Electrical system
*1
PC45MR-5, PC55MR-5
Remarks
40-103
Failure Code Table
Failure code
40 Troubleshooting
Failure (Displayed on screen)
Applicable component
Action level
History category
Remarks
#B1146
FAILURE CODE [#B1146] Injector Drive Circuit (Bank1) Short Circuit
ENG
L03
Electrical system
*1
#B1149
FAILURE CODE [#B1149] Injector Drive Circuit (Bank2) Short Circuit
ENG
L03
Electrical system
*1
#B1192
FAILURE CODE [#B1192] Oil Pressure Switch Open Circuit
ENG
L01
Electrical system
*1
#B1198
FAILURE CODE [#B1198] Oil Pressure Low Error Alarm
ENG
L03
Mechanical system
*1
#B1231
FAILURE CODE [#B1231] Ambient Pressure Sensor Characteristic Error
ENG
L03
Electrical system
*1
#B1262
FAILURE CODE [#B1262] Injector of 1st Cylinder Short Circuit
ENG
L03
Electrical system
*1
#B1265
FAILURE CODE [#B1265] Injector of 2nd Cylinder Short Circuit
ENG
L03
Electrical system
*1
#B1268
FAILURE CODE [#B1268] Injector of 3rd Cylinder Short Circuit
ENG
L03
Electrical system
*1
#B1271
FAILURE CODE [#B1271] Injector of 4th Cylinder Short Circuit
ENG
L03
Electrical system
*1
#B1341
FAILURE CODE [#B1341] Cam Angle Offset Error
ENG
L01
Electrical system
*1
#B1404
FAILURE CODE [#B1404] EGR Voltage Low Error
ENG
L03
Electrical system
*1
#B1405
FAILURE CODE [#B1405] Short Circuit Between the EGR Motor Coils
ENG
L03
Electrical system
*1
#B1409
FAILURE CODE [#B1409] EGR Feedback Error
ENG
L03
Electrical system
*1
#B1410
FAILURE CODE [#B1410] EGR High Temperature Thermistor Error
ENG
L03
Electrical system
*1
#B1411
FAILURE CODE [#B1411] EGR Low Temperature Thermistor Error
ENG
L03
Electrical system
*1
#B1420
FAILURE CODE [#B1420] Ash Cleaning Request 2
ENG
L03
Electrical system
*1
#B1421
FAILURE CODE [#B1421] Stationary Regeneration Standby
ENG
L03
Electrical system
*1
#B1424
FAILURE CODE [#B1424] Backup Mode
ENG
L04
Electrical system
*1
#B1426
FAILURE CODE [#B1426] KDPF InterTemperature High Error (Post-injection)
ENG
L03
Electrical system
*1
#B1427
FAILURE CODE [#B1427] KDPF Inlet Temperature Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B1428
FAILURE CODE [#B1428] KDPF Inlet Temperature Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B1434
FAILURE CODE [#B1434] KDPF Intermediate Temperature Sens Error(HighVolt)
ENG
L03
Electrical system
*1
#B1435
FAILURE CODE [#B1435] KDPF Intermediate Temperature Sens Error (LowVolt)
ENG
L03
Electrical system
*1
40-104
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure code
Failure Code Table
Failure (Displayed on screen)
Applicable component
Action level
History category
Remarks
#B1436
FAILURE CODE [#B1436] KDPF Inlet Temperature High Error
ENG
L03
Electrical system
*1
#B1454
FAILURE CODE [#B1454] KDPF High Pressure Side Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B1455
FAILURE CODE [#B1455] KDPF High Pressure Side Sens Error (High Volt)
ENG
L03
Electrical system
*1
#B1463
FAILURE CODE [#B1463] Overaccumulation (Method P)
ENG
L04
Electrical system
*1
#B1467
FAILURE CODE [#B1467] Actuator Drive Circuit 3 Short to Ground
ENG
L01
Electrical system
*1
#B1469
FAILURE CODE [#B1469] AD Converter Error 1
ENG
L04
Electrical system
*1
#B1470
FAILURE CODE [#B1470] AD Converter Error 2
ENG
L04
Electrical system
*1
#B1471
FAILURE CODE [#B1471] External Monitoring IC and CPU Error 1
ENG
L04
Electrical system
*1
#B1472
FAILURE CODE [#B1472] External Monitoring IC and CPU Error 2
ENG
L04
Electrical system
*1
#B1473
FAILURE CODE [#B1473] ROM Error
ENG
L04
Electrical system
*1
#B1474
FAILURE CODE [#B1474] Shutoff Path Error 1
ENG
L04
Electrical system
*1
#B1475
FAILURE CODE [#B1475] Shutoff Path Error 2
ENG
L04
Electrical system
*1
#B1476
FAILURE CODE [#B1476] Shutoff Path Error 3
ENG
L04
Electrical system
*1
#B1477
FAILURE CODE [#B1477] Shutoff Path Error 4
ENG
L04
Electrical system
*1
#B1478
FAILURE CODE [#B1478] Shutoff Path Error 5
ENG
L04
Electrical system
*1
#B1479
FAILURE CODE [#B1479] Shutoff Path Error 6
ENG
L04
Electrical system
*1
#B1480
FAILURE CODE [#B1480] Shutoff Path Error 7
ENG
L04
Electrical system
*1
#B1481
FAILURE CODE [#B1481] Shutoff Path Error 8
ENG
L04
Electrical system
*1
#B1482
FAILURE CODE [#B1482] Shutoff Path Error 9
ENG
L04
Electrical system
*1
#B1483
FAILURE CODE [#B1483] Shutoff Path Error 10
ENG
L04
Electrical system
*1
#B1484
FAILURE CODE [#B1484] Recognition Error of Engine Speed
ENG
L04
Electrical system
*1
#B148A
FAILURE CODE [#B148A] EGR Stuck Open Valve Error
ENG
L03
Electrical system
*1
#B1562
FAILURE CODE [#B1562] Charge Switch Open Circuit
ENG
L01
Electrical system
*1
PC45MR-5, PC55MR-5
40-105
Failure Code Table
40 Troubleshooting
Applicable component
Action level
History category
FAILURE CODE [#B1568] Charge Alarm
ENG
L03
Mechanical system
*1
#B1608
FAILURE CODE [#B1608] Excessive Voltage of Supply 1
ENG
L04
Electrical system
*1
#B1609
FAILURE CODE [#B1609] Sensor Supply Voltage Error 1
ENG
L01
Electrical system
*1
#B160E
FAILURE CODE [#B160E] EEPROM Memory Read Error
ENG
L03
Electrical system
*1
#B160F
FAILURE CODE [#B160F] EEPROM Memory Writing Error
ENG
L03
Electrical system
*1
#B1613
FAILURE CODE [#B1613] CY146 SPI Communication Error
ENG
L04
Electrical system
*1
#B1617
FAILURE CODE [#B1617] Insufficient Voltage of Supply 1
ENG
L04
Electrical system
*1
#B1618
FAILURE CODE [#B1618] Sensor Supply Voltage Error 2
ENG
L01
Electrical system
*1
#B1619
FAILURE CODE [#B1619] Sensor Supply Voltage Error 3
ENG
L01
Electrical system
*1
#B1626
FAILURE CODE [#B1626] Actuator Drive Circuit 1 Short to Ground
ENG
L01
Electrical system
*1
#B1633
FAILURE CODE [#B1633] Actuator Drive Circuit 2 Short to Ground
ENG
L01
Electrical system
*1
#B1641
FAILURE CODE [#B1641] SCV(MPROP) (Low Side VB Short)
ENG
L03
Electrical system
*1
#B1642
FAILURE CODE [#B1642] SCV(MPROP) (High Side GND Short)
ENG
L03
Electrical system
*1
#B1643
FAILURE CODE [#B1643] SCV(MPROP) (Low Side GND Short)
ENG
L03
Electrical system
*1
#B1645
FAILURE CODE [#B1645] SCV(MPROP) (Pump Overload Error)
ENG
L03
Electrical system
*1
#B1648
FAILURE CODE [#B1648] Injector of 1st Cylinder Compensation Value Error
ENG
L04
Electrical system
*1
#B1649
FAILURE CODE [#B1649] Injector of 2nd Cylinder Compensation Value Error
ENG
L04
Electrical system
*1
#B1650
FAILURE CODE [#B1650] Injector of 3rd Cylinder Compensation Value Error
ENG
L04
Electrical system
*1
#B1651
FAILURE CODE [#B1651] Injector of 4th Cylinder Compensation Value Error
ENG
L04
Electrical system
*1
#B1658
FAILURE CODE [#B1658] Power Short of Throttle Valve Drive H Bridge Out 1
ENG
L03
Electrical system
*1
#B1659
FAILURE CODE [#B1659] GND Short of Throttle Valve Drive H Bridge Out 1
ENG
L03
Electrical system
*1
#B1660
FAILURE CODE [#B1660] O-load on the Drive H Bridge Cir of Throttle Valve
ENG
L03
Electrical system
*1
#B1661
FAILURE CODE [#B1661] VB P Short of Throttle Valve Drive H Bridge Out 2
ENG
L03
Electrical system
*1
Failure code
Failure (Displayed on screen)
#B1568
40-106
Remarks
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure code
Failure Code Table
Failure (Displayed on screen)
Applicable component
Action level
History category
Remarks
#B1662
FAILURE CODE [#B1662] GND Short of Throttle Valve Drive H Bridge Out 2
ENG
L03
Electrical system
*1
#B1665
FAILURE CODE [#B1665] PLV (Malfunction)
ENG
L04
Electrical system
*1
#B1666
FAILURE CODE [#B1666] PLV (Number of times of PLV Valve Opening Error)
ENG
L03
Electrical system
*1
#B1667
FAILURE CODE [#B1667] PLV (Time of PLV Valve Opening Error)
ENG
L03
Electrical system
*1
#B1668
FAILURE CODE [#B1668] PLV (Non-Performance)
ENG
L04
Electrical system
*1
#B1669
FAILURE CODE [#B1669] Rail Press Control (Fuel Temp High in PLV V Open)
ENG
L03
Electrical system
*1
#B1670
FAILURE CODE [#B1670] Rail Press Control (Pump or Fuel Temp Error)
ENG
L04
Electrical system
*1
#B2228
FAILURE CODE [#B2228] Ambient Pressure Sensor Error (Low Voltage)
ENG
L03
Electrical system
*1
#B2229
FAILURE CODE [#B2229] Ambient Pressure Sensor Error (High Voltage)
ENG
L03
Electrical system
*1
#B242F
FAILURE CODE [#B242F] Ash Cleaning Request 1
ENG
L03
Electrical system
*1
#B2452
FAILURE CODE [#B2452] KDPF Differential Pressure High Error
ENG
L03
Electrical system
*1
#B2453
FAILURE CODE [#B2453] KDPF Different Press Sens (Abnormal Learn Value)
ENG
L03
Electrical system
*1
#B2454
FAILURE CODE [#B2454] KDPF Differential Pressure Sens Error (Low Volt)
ENG
L03
Electrical system
*1
#B2455
FAILURE CODE [#B2455] KDPF Differential Pressure Sens Error (High Volt)
ENG
L03
Electrical system
*1
#B2458
FAILURE CODE [#B2458] Defective Regeneration (StationaryRegene. Failure)
ENG
L04
Electrical system
*1
#B2459
FAILURE CODE [#B2459] Defective Regeneration (StationaryR Not Performed)
ENG
L04
Electrical system
*1
#B2463
FAILURE CODE [#B2463] Overaccumulation (Method C)
ENG
L04
Electrical system
*1
#BG10B
FAILURE CODE [#BG10B] CAN1 (for EGR): Reception Time Out
ENG
L03
Electrical system
*1
#BG167
FAILURE CODE [#BG167] Immobilizer CAN communication error
ENG
L04
Electrical system
*1
#BG292
FAILURE CODE [#BG292] TSC1 (CAN Message) Reception Time Out (SA1)
ENG
L01
Electrical system
*1
#BG401
FAILURE CODE [#BG401] EGR ECM Data Error
ENG
L03
Electrical system
*1
#BG426
FAILURE CODE [#BG426] Immobilizer system error
ENG
L04
Electrical system
*1
#BH292
FAILURE CODE [#BH292] Y_ECR1 (CAN Message) Reception Time Out
ENG
L01
Electrical system
*1
PC45MR-5, PC55MR-5
40-107
Failure Code Table
Failure code
40 Troubleshooting
Failure (Displayed on screen)
Applicable component
Action level
History category
Remarks
#BH293
FAILURE CODE [#BH293] Y_EC (CAN Message) Reception Time Out
ENG
L01
Electrical system
*1
#BH303
FAILURE CODE [#BH303] Y_DPFIF (CAN Message) Reception Time Out
ENG
L01
Electrical system
*1
#BH401
FAILURE CODE [#BH401] EGR Target Value Out of Range
ENG
L03
Electrical system
*1
•
In this table, failure codes are arranged in alphabetical order.
•
Applicable component is the controller which checks the system. MON: Machine monitor ENG: Engine controller MACHINE: Machine controller KOMTRAX: KOMTRAX terminal
•
The failure codes that do not have numbers in the action level columns are not displayed on the standard screen even when a failure related to them occurs. They are simply recorded in the abnormality record (electrical system or mechanical system) of the service menu.
•
History category means the classification of either electrical system or mechanical system which is used for storage in the Failure History of the service menu.
*1: For troubleshooting concerning this failure code, see “ Shop Manual Engine 86E-7 to 98E-7 series”.
40-108
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [989L00]
Troubleshooting by Failure Code (Display of Code) Failure Code [989L00] Action level
Failure code
-
989L00
Details of failure Action of machine monitor Phenomenon on machine
No. 1
Engine Controller Lock Caution 1 (Machine monitor system)
Engine controller lock up is detected (Factor 1). •
None in particular
•
If cause of failure disappears, machine becomes normal by itself.
Engine does not start. •
If the failure code is displayed after replacing the machine monitor, user password needs to be changed back to the previous one.
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
Related information
Failure
Cause Machine monitor replaced
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks This failure may occur due to machine monitor replacement.
40-109
Failure Code [989M00]
40 Troubleshooting
Failure Code [989M00] Action level
Failure code
-
989M00
Detail of failure Action of machine monitor Phenomenon on machine
No.
(Machine monitor system)
•
None in particular
•
If cause of failure disappears, machine becomes normal by itself.
Engine does not start. •
If this failure code is displayed after replacing the machine monitor, user password needs to be changed back to the previous one.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
Cause
1
Machine monitor replaced
2
Defective machine monitor
40-110
Engine Controller Lock Caution 2
Machine monitor detects abnormal state of engine controller lock (factor 2).
Related information
Failure
Procedure, measuring location, criteria and remarks This failure may occur due to machine monitor replacement. If this failure code appears even when machine monitor is not replaced, failure in machine monitor may occur. (Because this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [989N00]
Failure Code [989N00] Action level
Failure code
-
989N00
Detail of failure Action of machine monitor
Failure
Engine Controller Lock Caution 3 (Machine monitor system)
Machine monitor detects engine controller lock (Factor 3). •
Tries automatic recovery.
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related
After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: It cannot be reproduced since machine has become normal by itself.
No.
Cause
1
Procedure, measuring location, criteria and remarks
Defective engine control- If this repeatedly occurs, engine controller may be defective. (In case of an internal ler defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
PC45MR-5, PC55MR-5
40-111
Failure Code [AQ20R1]
40 Troubleshooting
Failure Code [AQ20R1] Action level
Failure code
L01
AQ20R1
Details of failure
Failure
KCSF Manual Stationary Regeneration Request (Machine controller system)
The “Manual Stationary Regeneration Request” prompts operator to forcibly perform “Manual Stationary Regeneration”, which is more effective to remove soot, because soot accumulation in the KCSF of KDPF has exceeded the level for automatic regeneration. Soot accumulation reaches level 4 or 5.
Action of controller Phenomenon on machine
Normal control None in particular
NOTICE • If this failure code [AQ20R1] is displayed, perform manual stationary regeneration. • This failure code is displayed during Manual Stationary Regeneration, but it is nor-
mal.
Related information
40-112
k Since KDOC and KDPF are heated to 600 °C or above, be careful not to get burn injury.
•
Time required for manual stationary regeneration is approximately 30 minutes.
•
If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
•
If another failure code is displayed (including when manual stationary regeneration is in progress), perform troubleshooting these first.
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [B@BCNS]
Failure Code [B@BCNS] Action level
Failure code
L02
B@BCNS
Details of
Failure
Engine Water Overheat (Machine controller system)
failure
Machine controller detects engine coolant temperature overheat by the engine coolant temperature information from engine controller while engine is running.
Action of
•
Lights up engine coolant temperature monitor in red on machine monitor.
controller
•
Engine power deration
Phenomenon
•
If machine is used as it is, engine may be seized.
on machine
•
Engine power deration
•
Signal voltage of coolant temperature sensor is input to engine controller, and then it is transmitted from machine controller to machine monitor through CAN communication system.
•
Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature)
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Start engine.
Related information
No.
Cause
1
Overheat of engine coolant (when system works properly)
Engine coolant may overheat. Check coolant temperature and remove cause of failure if engine coolant overheats.
2
Defective engine coolant temperature sensor system
If failure code is still displayed after above checks on cause 1, engine coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [#B0117] and [#B0118].
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks
40-113
Failure Code [D19JKZ]
40 Troubleshooting
Failure Code [D19JKZ] Action level
Failure code
L03
D19JKZ
Detail of failure
Action of machine monitor
Phenomenon on machine
Related
1
(Machine monitor system)
•
None in particular (when open error occurred)
•
Stops driving personal code relay (when short circuit occurred).
•
If cause of failure disappears, machine becomes normal by itself (when open error occurred).
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position (when short circuit occurred).
No •
This failure code is displayed only when engine lock function is enabled.
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position (when open circuit occurred). Failure code cannot be reproduced on the machine (when short circuit occurred).
•
Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box FB1 through primary (coil) circuit of personal code relay R06 to machine monitor.
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse FB1 (No.3) is blown out, circuit probably has ground fault, etc. 1.
Turn the starting switch to OFF position.
2.
Disconnect relay R06, and connect T-adapter to male side.
Resistance 2
Personal Code Relay Open Circuit or Short Circuit
Open error or short circuit occurs in primary (coil) circuit of personal code relay.
information
No.
Failure
Defective personal code relay
Between R06 (male) (1) and (2)
1.
Turn the starting switch to OFF position.
2.
Replace relay R06 with light relay R04.
3.
Turn the starting switch to ON position.
80 to 200 Ω
If this failure code disappears, original personal code relay R06 is defective. 1.
3
Turn the starting switch to OFF position.
2. Remove fuse No.3 in fuse box FB1 Open or short circuit or ground fault in wiring har- 3. Disconnect connectors F15, and connect T-adapter to female side of F15. ness Between FB1-3 and F15 (female) (4) 80 to 200 Ω Resistance Between ground and FB1-3 or F15 (female) (4) Min. 1 MΩ If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position.
4
2. Open circuit in wiring har- 3. ness
Remove fuse No.3 in fuse box FB1 Disconnect connector F15 and relay R06, and connect T-adapters to each female side.
Resistance
40-114
Between FB1-3 and R06 (female) (1)
Max. 1 Ω
Between R06 (female) (2) and F15 (female) (4)
Max. 1 Ω
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Failure Code [D19JKZ]
Cause
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 3, this check is not required. 1. Turn the starting switch to OFF position.
5
Ground fault in wiring harness
2.
Remove fuse No.3 in fuse box FB1
3.
Disconnect connectors F15 and R06, and connect T-adapter to either female side.
Resistance
6
Short circuit in wiring harness
Defective machine monitor
PC45MR-5, PC55MR-5
Min. 1 MΩ
Between ground and R06 (female) (2) or F15 (female) (4)
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Remove fuse No.3 in fuse box FB1
3.
Disconnect connector F15 and relay R06, and connect T-adapter to female side of connector F15.
Check it by using multimeter in continuity mode. Continuity
7
Between ground and FB1-3 or R06 (female) (1)
Between F15 (female) (4) and each pin other than (4)
No continuity
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-115
Failure Code [D19JKZ]
40 Troubleshooting
Circuit Diagram Related to Personal Code Relay
40-116
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [D811MC]
Failure Code [D811MC] Action level
Failure code
-
D811MC
Detail of failure
Failure
KOMTRAX Malfunction (KOMTRAX system)
KOMTRAX Malfunction
Action of controller Phenomenon on machine Related
KOMTRAX system does not operate normally. After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position.
No.
Cause
1
KOMTRAX Error
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks Defective KOMTRAX (In case of an internal defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
40-117
Failure Code [D862KA]
40 Troubleshooting
Failure Code [D862KA] Action level
Failure code
-
D862KA
Details of failure
Failure
GPS Antenna Open Circuit (KOMTRAX system)
Open circuit occurs in GPS antenna circuit.
Action of
•
None in particular
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related
GPS positioning system does not work. After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective GPS antenna or antenna cable
GPS antenna may be defective, or antenna cable may have open or short circuit, or poor contact at terminal area (GPS).
Configuration Diagram of GPS System
40-118
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [D8ALKA]
Failure Code [D8ALKA] Action level
Failure code
-
D8ALKA
Detail of failure Action of controller Phenomenon on machine
Related
1
3
(KOMTRAX system)
None in particular While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. Turning battery disconnect switch to OFF position may destroy data stored in KOMTRAX memory. •
This failure code is displayed only when the battery disconnect switch is set effectively.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
Although KOMTRAX is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position.
•
When controller lights up system operating lamp, output circuit voltage is at low level.
•
Since no controller drives system operating lamp for approximately 3 seconds after starting switch is turned to ON position, open circuit can be detected.
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse No.12 in fuse box FB1 is blown out, circuit probably has ground fault, etc. 1.
2
System Operating Lamp Open Circuit (KOMTRAX)
KOMTRAX terminal determines that system operating lamp circuit is open because voltage of output circuit remains at approximately. 5 V or less for approximately 3 seconds after starting switch is turned to ON position, during which KOMTRAX terminal outputs no current to system operating lamp.
information
No.
Failure
Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse No.12 in fuse box FB1 ness (wire breakage or 3. Disconnect connector CK01 and connect T-adapter to female side. defective contact of conBetween FB1-12 and M22 (female) (1) Max. 1 Ω nector) Resistance Between CK01 (female) (15) and M22 (female) (2) Max. 1 Ω If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case Defective KOMTRAX terof an internal defect, troubleshooting is impossible as an assembly. Replace whole minal assembly.)
PC45MR-5, PC55MR-5
40-119
Failure Code [D8ALKA]
40 Troubleshooting
Circuit Diagram Related to System Operating Lamp
40-120
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [D8ALKB]
Failure Code [D8ALKB] Action level
Failure code
-
D8ALKB
Detail of failure Action of controller Phenomenon on machine
No.
While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. Turning battery disconnect switch to OFF position may destroy data stored in KOMTRAX memory. •
This failure code is displayed only when the battery disconnect switch is set effectively.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
Although KOMTRAX is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position.
•
When controller lights up system operating lamp, output circuit voltage is at low level.
Cause
Procedure, measuring location, criteria and remarks
2. Short circuit in wiring har3. ness
Turn the starting switch to OFF position. Remove fuse No.12 in fuse box FB1 Disconnect connectors F15, CP02, CK01, and M22. Connect T-adapter to female side of M22.
Resistance 2
(KOMTRAX system)
None in particular
1. 1
System Operating Lamp Short Circuit (KOMTRAX)
KOMTRAX terminal determines that system operating lamp circuit shorts because voltage of output circuit does not become low level while KOMTRAX terminal outputs current to system operating lamp.
Related information
Failure
Between M22 (female) (1) and (2)
Min. 1 MΩ
If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case Defective KOMTRAX terof an internal defect, troubleshooting is impossible as an assembly. Replace whole minal assembly.)
PC45MR-5, PC55MR-5
40-121
Failure Code [D8ALKB]
40 Troubleshooting
Circuit Diagram Related to System Operating Lamp
40-122
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [D8AQKR]
Failure Code [D8AQKR] Action level
Failure code
―
D8AQKR
Detail of failure
Failure
CAN 2 Defective Communication (KOMTRAX) (Detected by machine monitor.) (Machine monitor system)
Machine monitor does not recognize KOMTRAX over CAN communication-2 line (KOMNET/c).
Action of maNone chine monitor Phenomenon on machine
Related
None •
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
•
Start of CAN communication is recognized by each controller when ACC signal of starting switch is received.
•
2 different failure codes, [DBHQKR], and [D8AQKR], are used for defective CAN communication by CAN2 when it is detected by machine monitor. When all of these 2 failure codes are displayed, ground fault, short circuit or hot short in wiring harness (CAN communication circuit) can be suspected.
•
Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position.
•
Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.
information
No.
1
Cause
Defective fusible link
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to OFF position.
2.
Disconnect fusible link M09 and connect T-adapter to male side.
Resistance
Between M09 (male) (1) and (2)
Max. 1 Ω
If fusible link is blown, circuit may have ground fault.
2
Defective fuse
1.
Turn starting switch to OFF position.
2.
Remove fuse No.13 in fuse box FB1.
If fuse is blown, circuit probably has ground fault. 3
Defective power supply to KOMTRAX terminal
4
Defective CAN communi- Perform checks on causes 5 to 10 in troubleshooting for failure code [DBHQKR]. cation 2 system
5
Defective KOMTRAX ter- If no failure is found by preceding checks, KOMTRAX terminal is defective. (Since minal this is an internal defect, troubleshooting cannot be performed.)
6
Defective machine monitor
PC45MR-5, PC55MR-5
Perform troubleshooting for “KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY” of E mode.
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-123
Failure Code [D8AQKR]
40 Troubleshooting
Circuit Diagram Related to CAN2 Communication
40-124
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DAF0KT]
Failure Code [DAF0KT] Action level
Failure code
L03
DAF0KT
Detail of failure Action of controller Phenomenon on machine Related
Failure
EEPROM Error (Monitor) (Machine monitor system)
Data cannot be written to or read from non-volatile memory of machine monitor. None in particular Reading of service meter and other set values are changed. After repair is completed, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective machine monitor
Defective machine monitor (Because this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40-125
Failure Code [DAF0MB]
40 Troubleshooting
Failure Code [DAF0MB] Action level
Failure code
-
DAF0MB
Detail of failure Action of controller
Failure
Monitor ROM Abnormality (Machine monitor system)
Machine monitor program is rewritten (program error). Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to OFF position.
Phenomenon
•
Machine monitor display is unreliable.
on machine
•
It can neither transmit the data to controllers nor receive the data from them.
Related
After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective machine monitor
Defective machine monitor (Because this is an internal defect, troubleshooting cannot be performed.)
40-126
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DAF0MC]
Failure Code [DAF0MC] Action level
Failure code
-
DAF0MC
Detail of failure
Failure
Monitor Malfunction (Machine monitor system)
Malfunction of machine monitor
Action of controller Phenomenon
•
Machine monitor display is unreliable.
on machine
•
It can neither transmit the data to controllers nor receive the data from them.
Related
After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective machine monitor
Defective machine monitor (Because this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40-127
Failure Code [DAF3KK]
40 Troubleshooting
Failure Code [DAF3KK] Action level
Failure code
-
DAF3KK
Detail of failure
Failure
Main Power Voltage Low Error (Monitor) (Machine monitor system)
Continuous power supply voltage of monitor controller drops below 9.8 V.
Action of
•
Prohibits writing to memory.
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon
•
Monitor screen may stay blank.
on machine
•
Since writing to non-volatile memory is prohibited, reliability of displayed information is low.
•
Machine monitor does not display any failure code.
•
Operating voltage cannot be measured at monitor controller connector since T-adapter for machine monitor connector is socket-type box.
•
After repair is completed, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective fusible link
If fusible link M09 is burnt out, circuit probably has ground fault. (See cause 4.)
2
Defective fuse
If fuse FB1 (No.13) is blown out, circuit probably has ground fault, etc. (See cause 4.)
3
1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connector F15, and connect T-adapter to female side.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn the starting switch to ON position.
Open circuit in wiring har- Voltage ness (wire breakage or defective contact) REMARK
Between F15 (1) and (2)
10 to 15 V
Between F15 (6) and (7)
10 to 15 V
Replace fuse FB1 (No.13) and fusible link M09 if they are burnt out. 1.
Turn the starting switch to OFF position.
2.
Turn the battery disconnect switch to OFF position.
3.
Disconnect connector F15, and connect T-adapter to female side. Between battery (+) and each of F15 (1) and (6)
Resistance
Check the ground terminal T01 for looseness and rust. Between ground and each of F15 (2) and (7)
4
Ground fault in wiring harness (contact with ground circuit)
Defective machine monitor
40-128
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect fuse FB1 (No.13) and connector F15, and connect T-adapters to female side.
Resistance 5
Max. 1 Ω
Between ground and each of fuse FB1 (No.13), F15 (1), and (6)
Min. 1 MΩ
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DAF3KK]
Circuit Diagram Related to Machine Monitor Power Supply
PC45MR-5, PC55MR-5
40-129
Failure Code [DAF9KQ]
40 Troubleshooting
Failure Code [DAF9KQ] Action level
Failure code
L03
DAF9KQ
Detail of failure
Failure
Model Selection Signal Mismatch (Monitor) (Machine monitor system)
Machine model registered in machine monitor and machine controller differs. (Machine monitor or machine controller of wrong part number is installed for replacement.)
Action of controller Phenomenon on machine
Machine does not operate normally. Signal state (ON/OFF) of model selection signal can be checked with monitoring function. (Code: 02201) •
PC45MR-5 Model selection signal 1: OFF Model selection signal 2: ON
•
PC55MR-5
Related
Model selection signal 1: ON
information
Model selection signal 2: OFF •
Assembly part number of machine controller program can be checked with monitoring function. (Code: 20294)
•
Assembly part number of machine monitor program can be checked with monitoring function. (Code: 20227)
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
No.
Cause
1
Defective machine monitor
Display assembly part number by monitoring function, and check that displayed number is same as the one in the Parts Book.
2
Defective machine controller
Display assembly part No. with monitoring function and check if it is same as part No. in the parts book.
40-130
Procedure, measuring location, criteria and remarks
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DAFGMC]
Failure Code [DAFGMC] Action level
Failure code
-
DAFGMC
Details of
Failure
GPS Module Malfunction (KOMTRAX system)
failure
No position data is sent from GPS module (KOMTRAX terminal) to KOMTRAX communication modem more than 50 seconds since the startup of KOMTRAX.
Action of
•
None in particular
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related
After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position. (Wait for more than 50 seconds after the switch is turned ON.)
No.
Cause
1
Procedure, measuring location, criteria and remarks
Defective KOMTRAX ter- GPS module of KOMTRAX terminal may be defective. (Because this is an internal minal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40-131
Failure Code [DAFLKA]
40 Troubleshooting
Failure Code [DAFLKA] Action level
Failure code
-
DAFLKA
Detail of failure Action of controller Phenomenon on machine
Related
1
3
(Machine monitor system)
None in particular While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. Turning battery disconnect switch to OFF position may destroy data stored in machine monitor memory. •
This failure code is displayed only when the battery disconnect switch is set effectively.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
Although machine monitor is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position.
•
When controller lights up system operating lamp, output circuit voltage is at low level.
•
Since no controller drives system operating lamp for approximately 3 seconds after starting switch is turned to ON position, open circuit can be detected.
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse No.12 in fuse box FB1 is blown out, circuit probably has ground fault, etc. 1.
2
System Operating Lamp Open Circuit (Monitor)
Machine monitor determines that system operating lamp circuit is open because voltage of output circuit remains at approximately. 5 V or less for approximately 3 seconds after starting switch is turned to ON position, during which machine monitor outputs no current to system operating lamp.
information
No.
Failure
Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse No.12 in fuse box FB1 ness (wire breakage or 3. Disconnect connector F15 and connect T-adapter to female side. defective contact of conBetween FB1-12 and M22 (female) (1) Max. 1 Ω nector) Resistance Between F15 (female) (10) and M22 (female) (2) Max. 1 Ω Defective machine monitor
40-132
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DAFLKA]
Circuit Diagram Related to System Operating Lamp
PC45MR-5, PC55MR-5
40-133
Failure Code [DAFLKB]
40 Troubleshooting
Failure Code [DAFLKB] Action level
Failure code
-
DAFLKB
Detail of failure Action of controller Phenomenon on machine
No.
While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. Turning battery disconnect switch to OFF position may destroy data stored in machine monitor memory. •
This failure code is displayed only when the battery disconnect switch is set effectively.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
Although machine monitor is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position.
•
When controller lights up system operating lamp, output circuit voltage is at low level.
Cause
Procedure, measuring location, criteria and remarks
2. Short circuit in wiring har3. ness
Turn the starting switch to OFF position. Remove fuse No.12 in fuse box FB1 Disconnect connectors F15, CP02, CK01, and M22. Connect T-adapter to female side of M22.
Resistance 2
Defective machine monitor
40-134
(Machine monitor system)
None in particular
1. 1
System Operating Lamp Short Circuit (Monitor)
Machine monitor determines that system operating lamp circuit shorts because voltage of output circuit does not become low level while machine monitor outputs current to system operating lamp.
Related information
Failure
Between M22 (female) (1) and (2)
Min. 1 MΩ
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DAFLKB]
Circuit Diagram Related to System Operating Lamp
PC45MR-5, PC55MR-5
40-135
Failure Code [DAFQKR]
40 Troubleshooting
Failure Code [DAFQKR] Action level
Failure code
-
DAFQKR
Detail of failure
Failure
CAN 2 Defective Communication (Monitor) (KOMTRAX system)
KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
Action of controller Phenomenon on machine
Related
System may not operate normally. •
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
ACC signal of starting switch is the command to start CAN communication for each controller.
•
Failure code is transmitted to and displayed on machine monitor by CAN communication. If CAN communication with machine monitor fails, failure code [DAFQKR] is not displayed on machine monitor. It can be observed only through KOMTRAX system.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even after the starting switch is turned to OFF position.
•
Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.
information
No.
Cause
1
Defective power supply to machine monitor
2
Defective CAN communi- Perform checks on cause 4 and subsequent causes in troubleshooting for failure cation code [DBHQKR].
40-136
Procedure, measuring location, criteria and remarks Perform troubleshooting for “When starting switch is turned to ON position, machine monitor displays nothing” of E mode.
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DB2QKR]
Failure Code [DB2QKR] Action level
Failure code
L03
DB2QKR
Detail of failure Action of controller Phenomenon on machine
No. 1
CAN 2 Defective Communication (Engine Controller) (Machine controller system)
Machine controller cannot recognize engine controller on CAN2 communication line (engine only). Retains information at time of occurrence of failure. Information to be obtained from engine controller is not displayed and special functions that need information do not work. Or update of received data is stopped. (Failure codes and monitoring codes sent from the engine controller, etc.) •
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
•
Start of CAN communication is recognized by each controller when ACC signal of starting switch is received.
•
Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position.
•
Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.
Related information
Failure
Cause Defective fuse
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Remove fuses No.10 and No.14 from fuse box FB1 If fuse is blown out, the engine controller probably has short circuit.
Check ground terminal T03 for looseness and rust. 1. Turn the starting switch to OFF position.
2
Defective power supply to engine controller
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connector CE1, and connect T-adapter to female side.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn the starting switch to ON position.
Voltage
3
Defective CAN terminating resistor (internal open or short circuit)
PC45MR-5, PC55MR-5
Between CE1 (female) (1) and (2)
10 to 15 V
Between CE1 (female) (3) and (4)
10 to 15 V
Between CE1 (female) (5) and (6)
10 to 15 V
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01, and CE1, and connect T-adapter to male side.
Resistance
Between CP01 (male) (15) and (45)
120±12 Ω
Between CE1 (male) (53) and (75)
120±12 Ω
40-137
Failure Code [DB2QKR]
No.
40 Troubleshooting
Cause
Procedure, measuring location, criteria and remarks CAN communication line
REMARK CAN terminating resistor of 120 Ω are located in machine controller and engine controller. That is, CAN terminating resistors of 120 Ω are connected in parallel.
4
Open or short circuit in wiring harness
1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect related connectors, and connect T-adapter to connector to be measured.
REMARK If short circuit is found (resistance between 2 terminals is below 1 Ω), disconnect all CAN communication connectors of every controller, and check whether short circuit occurs between wiring harnesses or inside controller. Resistance
Approx. 120 Ω
Between CP01 (female) (45) and (64)
ACC signal of starting switch (start of CAN communication is not recognized) 1. Turn the starting switch to OFF position.
5
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connectors to be measured and insert T-adapters.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn the starting switch to ON position.
Open circuit in wiring harVoltage ness
Between CP01 (17) and (2)
10 to 15 V
Between CE1 (88) and (2) (wire breakage or defective contact of connector) If no failure is found by check on cause 4, this check is not required. 1. Turn the starting switch to OFF position.
10 to 15 V
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect related connectors, and connect T-adapter to each female side connector to be measured.
Resistance
Between CP01 (female) (45) and CE1 (female) (75)
Max. 1 Ω
Between CP01 (female) (64) and CE1 (female) (53)
Max. 1 Ω
Between CP01 (female) (15) and (34)
Max. 1 Ω
If no failure is found by check on cause 4 (no open circuit), measure resistance at any one place. 1. Turn the starting switch to OFF position.
6
Ground fault in wiring harness (contact with ground circuit)
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect related connectors, and connect T-adapter to each female side connector to be measured.
Resistance
40-138
Between ground and any of CP01 (female) (45), and CE1 (female) (75)
Min. 1 MΩ
Between ground and any of CP01 (female) (64), and CE1 (female) (53)
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Failure Code [DB2QKR]
Cause
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 4 (no open circuit), measure resistance at any one place in each case. 1. Turn the starting switch to OFF position.
7
Short circuit or hot short circuit in wiring harness
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Insert T-adapter into connector to measure.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn the starting switch to ON position.
(contact with 12 V circuit)
Voltage
Between ground and any of CP01 (female) (45), and CE1 (female) (75)
1 to 4 V
Between ground and any of CP01 (female) (64), and CE1 (female) (53)
1 to 4 V
8
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is ler an internal defect, troubleshooting cannot be performed.)
9
Defective machine monitor
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
10
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40-139
Failure Code [DB2QKR]
40 Troubleshooting
Circuit Diagram Related to CAN2 Communication
40-140
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBH0MC]
Failure Code [DBH0MC] Action level
Failure code
―
DBH0MC
Detail of failure Action of controller Phenomenon on machine Related
Failure
Pump Controller Malfunction (Machine controller system)
Malfunction of machine controller operation No Machine controller does not operate normally. After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position.
No.
Cause
1
Mulfunction of machine controller
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks If machine operates normally, it is not needed to replace.
40-141
Failure Code [DBH2KK]
40 Troubleshooting
Failure Code [DBH2KK] Action level
Failure code
L03
DBH2KK
Detail of failure Action of controller
Failure
Machine Controller Solenoid Power Voltage Low Error (Machine controller system)
Power supply voltage of controller for driving solenoids is below below. 8 V. •
Stops detection of failures (open circuit and short circuit) in all solenoid systems while this failure code is active.
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon
No solenoid valve is energized properly, so machine does not work properly.
on machine
(Work equipment, swing, and travel systems do not work.) •
As T-adapter for machine controller connector is “socket-type box”, operating voltage cannot be measured at machine controller connector.
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective fusible link
If fusible link M05 is blown out, circuit probably has ground fault, etc. (see cause 6)
2
Defective fuse
If fuse No.2 in fuse box FB1 is blown out, circuit probably has ground fault, etc. (see cause 6)
3
Improper battery voltage
1.
Turn starting switch to OFF position.
2.
After measuring voltage, measure it again when starting engine.
Voltage
4
Defective wiring harness
10 to 15 V
1.
Turn the starting switch to OFF position.
2.
Disconnect ground cable of battery or turn the battery disconnect switch to OFF position.
3.
Disconnect connector CP02, and connect T-adapter to female side.
4.
Connect ground cable of battery or turn the battery disconnect switch to ON position.
5.
Turn the starting switch to ON position.
Voltage
40-142
Between battery (+) and ground
Between ground and each of CP02 (female) (116), (118) and (121)
10 to 15 V
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Failure Code [DBH2KK]
Cause
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 4, this check is not required. If fusible link or fuse is blown, replace it in advance. 1. Turn the starting switch to OFF position.
5
2.
Disconnect ground cable of battery or turn the battery disconnect switch to OFF position.
3.
Disconnect connector CP02, and connect T-adapter to female side.
Between battery (+) terminal and each of CP02 (feMax. 1 Ω Open circuit in wiring har- Resistance male) (116), (118), and (121) ness If no failure is found by preceding checks, this check is not required. Furthermore, disconnect connector M05, and connect T-adapter to male side.
Resistance
Between FB1 (2) and each of CP02 (female) (116), (118), and (121)
Max. 1 Ω
Between FB1 (1A) and TF3
Max. 1 Ω
Between TF1 and M05 (male) (1)
Max. 1 Ω
Between M05 (male) (2) and battery (+) terminal
Max. 1 Ω
If no failure is found by check on cause 4, this check is not required. 1. Turn the starting switch to OFF position.
6
Ground fault in wiring harness
2.
Disconnect ground cable of battery or turn the battery disconnect switch to OFF position.
3.
Disconnect fuse FB1 (2) and connectors M05 and CP02, and connect Tadapter to female side of CP02 and male side of M05.
(Contact with ground circuit) Resistance
7
Defective machine controller
PC45MR-5, PC55MR-5
Between ground and each of CP02 (female) (116), (118), (121), or FB1 (2)
Min. 1 MΩ
Between ground and FB1 (1A) or TF3
Min. 1 MΩ
Between ground and TF1 or M05 (male) (1)
Min. 1 MΩ
Between M05 (male) (2) and ground
Min. 1 MΩ
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-143
Failure Code [DBH2KK]
40 Troubleshooting
Circuit Diagram Related to Machine Controller Solenoid Power Supply
40-144
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBH5KP]
Failure Code [DBH5KP] Action level
Failure code
-
DBH5KP
Detail of failure Action of controller
Phenomenon on machine
Related
Failure
5 V Sensor 1 Power Voltage Low Error (Machine controller system)
Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V. •
Stops output of power from 5 V sensor power supply output 1.
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
•
Signal of pressure sensor is not input properly.
•
The error code for the pressure sensor is displayed at the same time.
•
Travel and work equipment speeds are slow.
•
Auto-decelerator function remains activated or fine control performance of work equipment is poor.
After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors of the following sensors one by one and turn the starting switch to ON position each time. REMARK • If this failure code goes out, disconnected sensor is defective.
1
Defective pressure sensor (internal short circuit)
• Since connector is disconnected, other failure codes are displayed. Ig-
nore all of displayed failure codes other than this one. 3.
Each time troubleshooting is finished, return to step 1.
Connector
2
Hot short circuit in wiring harness (Contact with 12 V circuit)
4
P02
Swing parking brake lock pressure sensor
P03
Service pressure sensor 1 (dummy)
P11
Service pressure sensor 2 (dummy)
P12
Measure voltage before controller stops output of power. 1. Turn the starting switch to OFF position. 2.
Disconnect connectors P02 to P03, P11, and P12.
3.
Connect T-adapter to female side of connector P02.
4.
Turn the starting switch to ON position (with connector disconnected).
Voltage
3
Travel pressure sensor
Between P02 (female) (3) and ground
4.5 to 5.5 V
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01, P02 to P03, P11, and P12.
(Contact with ground circuit)
3.
Connect T-adapter to female side of connector CP01.
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Ground fault in wiring harness
PC45MR-5, PC55MR-5
Resistance
Between CP01 (female) (8) and ground
Min. 1 MΩ
40-145
Failure Code [DBH5KP]
40 Troubleshooting
Circuit Diagram Related to Machine Controller 5V Sensor Power Supply
40-146
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBH5KP]
Failure Code [DBH5KP] Action level
Failure code
-
DBH5KP
Detail of failure Action of controller
Phenomenon on machine
Related
Failure
5 V Sensor 1 Power Voltage Low Error (for proportional lever spec) (Machine controller system)
Voltage of 5 V sensor power supply output 1 circuit is 2.5 V and below or 6.0 V and above. •
Stops output of power from 5 V sensor power supply output 1.
•
Even if cause of failure is eliminated, machine does not become normal until the starting switch is turned to OFF position.
•
Signal of pressure sensor is not input properly.
•
The error code for the pressure sensor is displayed at the same time.
•
Travel and work equipment speeds are slow.
•
Auto-decelerator function remains activated or fine control performance of work equipment is poor.
•
Potentiometer signal of service lever 1 (R.H. lever) is not input correctly.
•
Potentiometer error code of service lever 1 (R.H. lever) is displayed at the same time.
After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position.
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors of the following sensors one by one and turn the starting switch to ON position each time. REMARK • If this failure code goes out, disconnected sensor is defective.
1
Defective pressure sensor (internal short circuit)
• Since connector is disconnected, other failure codes are displayed. Ig-
nore all of displayed failure codes other than this one. 3.
Each time troubleshooting is finished, return to step 1.
Connector
2
Defective service lever 1 (right iever) potentiometer (internal short circuit)
Travel pressure sensor
P02
Swing parking brake lock pressure sensor
P03
Service pressure sensor 1 (dummy)
P11
Service pressure sensor 2 (dummy)
P12
1.
Turn the starting switch to OFF position.
2.
Disconnect connector F26.
3.
Turn the starting switch to ON position.
REMARK • Since connector is disconnected, other failure codes are displayed. Ignore
all of displayed failure codes other than this one. • If this failure code goes out, disconnected sensor is defective.
3
Hot short circuit in wiring harness (Contact with 12 V circuit)
Measure voltage before controller stops output of power. 1. Turn the starting switch to OFF position. 2.
Disconnect connectors P02 to P03, P11, P12, and F26.
3.
Connect T-adapter to female side of connector P02.
4.
Turn the starting switch to ON position (with connector disconnected).
Voltage
PC45MR-5, PC55MR-5
Between P02 (female) (3) and ground
4.5 to 5.5 V
40-147
Failure Code [DBH5KP]
No.
4
40 Troubleshooting
Cause Ground fault in wiring harness (Contact with ground circuit)
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01, P02 to P03, P11, P12, and F26.
3.
Connect T-adapter to female side of connector CP01.
Resistance
Between CP01 (female) (8) and ground
Min. 1 MΩ
Circuit Diagram Related to Machine Controller 5V Sensor Power Supply (Proportional Lever Spec)
40-148
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBH9KQ]
Failure Code [DBH9KQ] Action level
Failure code
L01
DBH9KQ
Detail of failure Action of controller Phenomenon on machine
Failure
Model Selection Signal Mismatch (Machine Controller) (Machine controller system)
Model code signal for model which is not registered in controller is input. Controls machine by regarding it as default model (PC55MR standard specification machine). Even if cause of failure disappears, machine does not become normal until the starting switch is turned to OFF position. No problem appears if machine is PC55MR standard specification machine. •
Part number of machine controller assembly can be checked with monitoring function. (Code: 20294)
•
Signal state (ON/OFF) of model selection signal can be checked with monitoring function. (Code: 02201)
•
PC55MR-5
Related
Model selection signal 1: ON
information
Model selection signal 2: OFF •
PC45MR-5
Model selection signal 1: OFF Model selection signal 2: ON •
No.
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
Cause Defective model selection connector
1
(Internal open or short circuit) (PC55MR-5) Defective model selection connector
2
(Internal open or short circuit) (PC45MR-5)
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to OFF position.
2.
Disconnect connector S30, and connect T-adapter to female side.
Resistance
(Wire breakage or defective contact of connector) (PC55MR-5)
(Wire breakage or defective contact of connector) (PC45MR-5)
PC45MR-5, PC55MR-5
Between S30 (female) (A) and (B)
Min. 1 MΩ
Between S30 (female) (B) and (C)
Min. 1 MΩ
Turn starting switch to OFF position.
2.
Disconnect connector S30, and connect T-adapter to female side.
Resistance
Between S30 (female) (B) and (C)
Max. 1 Ω
Between S30 (female) (A) and (B)
Min. 1 MΩ
Between S30 (female) (A) and (C)
Min. 1 MΩ
Turn starting switch to OFF position. Disconnect connector CP01 and connect T-adapter to female side.
Resistance
Open circuit in wiring har- 1. ness 2. 4
Max. 1 Ω
1.
Open circuit in wiring har- 1. ness 2. 3
Between S30 (female) (A) and (C)
Between CP01 (female) (63) and ground
Max. 1 Ω
Turn starting switch to OFF position. Disconnect connector CP01 and connect T-adapter to female side.
Resistance
Between CP01 (female) (57) and ground
Max. 1 Ω
40-149
Failure Code [DBH9KQ]
No.
5
Cause
(Contact with ground circuit) (PC55MR-5) Ground fault in wiring harness
7
Procedure, measuring location, criteria and remarks
Short circuit in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors CP01 and S30, and insert T-adapters to S30. (PC55MR-5) Resistance Between S30 (A) and (B) Min. 1 MΩ (PC45MR-5) Ground fault in wiring harness
6
40 Troubleshooting
(Contact with ground circuit) (PC45MR-5)
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP01 and connect T-adapter to female side.
Resistance
Between CP01 (female) (57) and ground
Min. 1 MΩ
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP01 and connect T-adapter to female side.
Resistance
Between CP01 (female) (63) and ground
Min. 1 MΩ
8
Machine controller with wrong part number
Display assembly part No. with monitoring function and check if it is same as part No. in the parts book.
9
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit Diagram of Machine Model Setting System
40-150
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBHLKA]
Failure Code [DBHLKA] Action level
Failure code
-
DBHLKA
Detail of failure Action of controller Phenomenon on machine
Related
1
3
(Machine controller system)
None in particular While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. If the battery disconnect switch is turned to OFF position, the memory data stored in the machine controller and the engine controller may be destroyed. •
This failure code is displayed only when the battery disconnect switch is set effectively.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
Although machine controller is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position.
•
When controller lights up system operating lamp, output circuit voltage is at low level.
•
Since no controller drives system operating lamp for approximately 3 seconds after starting switch is turned to ON position, open circuit can be detected.
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse No.12 in fuse box FB1 is blown out, circuit probably has ground fault, etc. 1.
2
System Operating Lamp Open Circuit (Machine Controller)
Machine controller determines that system operating lamp circuit is open because voltage of output circuit remains at approximately. 5 V or less for approximately 3 seconds after starting switch is turned to ON position, during which machine controller outputs no current to system operating lamp.
information
No.
Failure
Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse No.12 in fuse box FB1 ness (wire breakage or 3. Disconnect connector CP02 and connect T-adapter to female side. defective contact of conBetween FB1-12 and M22 (female) (1) Max. 1 Ω nector) Resistance Between CP02 (female) (99) and M22 (female) (2) Max. 1 Ω Defective machine controller
PC45MR-5, PC55MR-5
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-151
Failure Code [DBHLKA]
40 Troubleshooting
Circuit Diagram Related to System Operating Lamp
40-152
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBHLKB]
Failure Code [DBHLKB] Action level
Failure code
-
DBHLKB
Detail of failure Action of controller Phenomenon on machine
No.
While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. If the battery disconnect switch is turned to OFF position, the memory data stored in the machine controller and the engine controller may be destroyed. •
This failure code is displayed only when the battery disconnect switch is set effectively.
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
•
Although machine controller is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position.
•
When controller lights up system operating lamp, output circuit voltage is at low level.
Cause
Procedure, measuring location, criteria and remarks
2. Short circuit in wiring har3. ness
Turn the starting switch to OFF position. Remove fuse No.12 in fuse box FB1 Disconnect connectors F15, CP02, CK01, and M22, and connect T-adapter to female side of M22.
Resistance
2
Hot short circuit in wiring harness
Defective machine controller
PC45MR-5, PC55MR-5
Between M22 (female) (1) and (2)
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M22, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage 3
(Machine controller system)
None in particular
1. 1
System Operating Lamp Short Circuit (Machine Controller)
Machine controller determines that system operating lamp circuit shorts because voltage of output circuit does not become Low level while machine controller outputs current to system operating lamp.
Related information
Failure
Between M22 (female) (2) and ground
Max. 1 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-153
Failure Code [DBHLKB]
40 Troubleshooting
Circuit Diagram Related to System Operating Lamp
40-154
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBHQKR]
Failure Code [DBHQKR] Action level
Failure code
L03
DBHQKR
Detail of failure Action of controller Phenomenon on machine
(Machine monitor system)
Retains information at time of occurrence of failure. Information to be obtained from machine controller is not displayed and special functions that need information do not work. Or update of received data is stopped (such as failure codes and monitoring codes sent from the machine controller and the engine controller). •
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
•
Start of CAN communication is recognized by each controller when ACC signal of starting switch is received.
•
2 different failure codes, [DBHQKR], and [D8AQKR], are used for defective CAN communication by CAN2 when it is detected by machine monitor. When all of these 2 failure codes are displayed, ground fault, short circuit or hot short in wiring harness (CAN communication circuit) can be suspected. Since air conditioner is also operated through CAN communication, you must, in such case, check on air conditioner screen whether air conditioner is operable (ON/OFF and air flow of air conditioner).
•
Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position.
•
Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.
information
1
Controller Area NW 2 Defect Communicat (Machine Controller)
Machine monitor does not recognize machine controller through CAN communication 2 line (KOMNET/c).
Related
No.
Failure
Cause
Defective fusible link
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect fusible link M09 and connect T-adapter to male side.
Resistance
Between M09 (male) (1) and (2)
Max. 1 Ω
REMARK If fusible link is blown out, circuit probably has ground fault. 2
Defective fuse
1.
Turn starting switch to OFF position.
2.
Remove fuse No. 13 in fuse box FB1.
If fuse is blown, circuit probably has ground fault.
REMARK Check ground terminal T01 for looseness and rust. 3
1. Improper power supply to 2. machine controller 3.
Turn starting switch to OFF position. Disconnect connector CP01 and connect T-adapter to female side. Turn starting switch to ON position.
Voltage
PC45MR-5, PC55MR-5
Between CP01 (female) (1) and (2)
10 to 15 V
Between CP01 (female) (4) and (5)
10 to 15 V
40-155
Failure Code [DBHQKR]
No.
40 Troubleshooting
Cause
Procedure, measuring location, criteria and remarks
REMARK If failure code is still displayed after above checks on cause 3, this check is not required.
4
1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
Open circuit in wiring har3. ness 4. (Wire breakage or defective contact of connector)
Remove fuse No. 13 in fuse box FB1. Disconnect fusible link and connector CP01, and connect T-adapters to each female side connector.
Resistance
5
Defective CAN terminating resistor (internal open or short circuit)
Between battery (+) and M09 (female) (2)
Max. 1 Ω
Between M09 (female) (1) and F01(female) (2)
Max. 1 Ω
Between F01(female) (2) and FB1-11B
Max. 1 Ω
Between FB1-13 and CP01 (female) (1)
Max. 1 Ω
Between FB1-13 and CP01 (female) (4)
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01, and F15, and connect T-adapter to male side.
Resistance
Between CP01 (male) (7) and (14)
120±12 Ω
Between F15 (male) (11) and (12)
120±12 Ω
CAN communication line
REMARK CAN terminating resistor of 120 Ω are located in machine monitor and machine controller. That is, CAN terminating resistors of 120 Ω are connected in parallel. When circuit resistance is measured at connector of controller other than machine monitor and machine controller, if combined resistance is 60 Ω, wiring harness does not have open circuit. 1. Turn the starting switch to OFF position.
6
Open or short circuit in wiring harness
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect related connectors, and connect T-adapter to connector to be measured.
REMARK If short circuit is found (resistance between 2 terminals is 1 Ω or less), disconnect all CAN communication connectors of every controller and check whether short circuit occurs between wiring harnesses or inside controller.
Resistance
40-156
Between F15 (female) (11) and (12)
Approx. 120 Ω
Between CK01 (female) (10) and (11)
Approx. 60 Ω
Between CP01 (female) (7) and (26)
Approx. 120 Ω
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Failure Code [DBHQKR]
Cause
Procedure, measuring location, criteria and remarks ACC signal of starting switch (start of CAN communication is not recognized) 1. Turn the starting switch to OFF position. 2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connectors to be measured and insert T-adapters.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn the starting switch to ON position.
Voltage
7
Open circuit in wiring harness REMARK
Between F15 (3) and (2)
10 to 15 V
Between CK02 (3) and (1)
10 to 15 V
Between CP01 (17) and (2)
10 to 15 V
(Wire breakage or defec- If failure code is still displayed after above checks on cause 6, this check is not tive contact of connector) required. 1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect related connectors, and connect T-adapter to each female side connector to be measured.
Resistance
Between F15 (female) (11) and CP01 (female) (7)
Max. 1 Ω
Between F15 (female) (12) and CP01 (female) (26)
Max. 1 Ω
Between F15 (female) (11) and CK01 (female) (10)
Max. 1 Ω
Between F15 (female) (12) and CK01 (female) (11)
Max. 1 Ω
Between CP01 (female) (14) and CP01 (female) (33)
Max. 1 Ω
If no failure (no open circuit) is found by check on cause 6, measure resistance at any one place in each case. 1. Turn the starting switch to OFF position.
8
Ground fault in wiring harness (Contact with ground circuit)
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect related connectors, and connect T-adapter to each female side connector to be measured.
Resistance
PC45MR-5, PC55MR-5
Between ground and any point in CP01 (female) (7), or Min. 1 MΩ F15 (female) (11) Between ground and any point in CP01 (female) (26), or F15 (female) (12)
Min. 1 MΩ
40-157
Failure Code [DBHQKR]
No.
40 Troubleshooting
Cause
Procedure, measuring location, criteria and remarks If no failure (no open circuit) is found by check on cause 6, measure resistance at any one place in each case. 1. Turn the starting switch to OFF position.
9
Short circuit or hot short circuit in wiring harness (Contact with 12 V circuit)
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Insert T-adapter into connector to measure.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn starting switch to ON position.
Voltage
Between ground and any of F15 (11), and CK01 (10)
1 to 4 V
Between ground and any of F15 (12), and CK01 (11)
1 to 4 V
If all four failure codes [DBHQKR], and [D8AQKR] are displayed: To identify defective controller, repeat following steps 1. to 3. to disconnect controllers one by one from CAN communication line. 1. Turn the starting switch to OFF position.
10
Defective machine controller, or KOMTRAX terminal
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect CAN communication connector of machine controller (connector CP01), and KOMTRAX terminal (connector CK01) one by one in turn.
4.
Connect the battery ground, or turn the battery disconnect switch to ON position.
5.
Turn starting switch to ON position.
6.
Return to step 1 to check next controller.
Has the number of displayed failure codes decreased from 2?
If YES, the disconnected controller is defective.
11
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
12
Defective machine monitor
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-158
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DBHQKR]
Circuit Diagram Related to CAN2 Communication
PC45MR-5, PC55MR-5
40-159
Failure Code [DDNRKA]
40 Troubleshooting
Failure Code [DDNRKA] Action level
Failure code
L03
DDNRKA
Failure
Work Equipment Lever Lock Switch Open Circuit (Machine controller system)
• Detail of failure
No current flows on the PPC lock lever relay side when the work equipment lock lever is in RELEASE position, so the open circuit is detected.
•
No current flows on the controller side when the work equipment lock lever is in LOCK position, so the open circuit is detected.
Action of
•
None in particular (Lock lever automatic lock control may operate wrongly.)
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon
•
Starting motor does not start.
on machine
•
All work equipment, swing and travel does not work.
•
State of lock lever can be checked with monitoring function. (Code: 02203)
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position, and lock and unlock work equipment lock lever.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective fuse
If fuse No.3 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
2
Defective work equipment lever lock switch
Perform troubleshooting for failure code [DDNRKY].
3
Open circuit in wiring harness
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and F09, and connect T-adapter to female side of CP01 and male side of F09.
Resistance
4
Defective machine controller
40-160
Between F09 (male) (A) and FB1 (3)
Max. 1 Ω
Between CP01 (female) (41) and F09 (male) (C)
Max. 1 Ω
Between CP01 (female) (22) and F09 (male) (B)
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DDNRKA]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-161
Failure Code [DDNRKY]
40 Troubleshooting
Failure Code [DDNRKY] Action level
Failure code
L03
DDNRKY
Failure
Work Equipment Lever Lock Switch Hot Short Circuit (Machine controller system)
• Detail of failure
When the work equipment lock lever is in RELEASE position, PPC lock signal voltage of controller side circuit is 5.2 V and above.
•
When the work equipment lock lever is in LOCK position, signal voltage of PPC lock lever relay side circuit is 5.2 V and above.
Action of
•
Stops driving PPC lock relay.
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related information
No. 1
2
None of work equipment, swing or travel works. •
State of lock lever can be checked with monitoring function. (Code: 02203)
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position, and operate the work equipment lock lever to lock or release.
Cause Defective work equipment lever lock switch
Hot short circuit in wiring harness
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DDNRKY]. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F09, and connect T-adapter to male side.
Voltage 3
Defective machine controller
40-162
Between F09 (male) (B) and ground
Max. 1 V
Between F09 (male) (C) and ground
Max. 1 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DDNRKY]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-163
Failure Code [DDNS00]
40 Troubleshooting
Failure Code [DDNS00] Action level
Failure code
-
DDNS00
Details of
Failure
Lock Lever Auto Lock Release Switch Operation (Machine controller system)
failure
Lock lever automatic lock release switch operation is detected when lock lever is locked automatically.
Action of
•
None in particular
controller
•
Lock lever automatic lock does not operate.
Phenomenon
•
Lock lever automatic lock function does not operate.
on machine
•
Automatic lock release switch monitor is displayed in red on machine monitor.
•
Connectors CP01 and S25 do not provide T-adapter for measuring voltage, and use connector D01 for troubleshooting.
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.
Related information
No. 1
2
Cause
Procedure, measuring location, criteria and remarks
Lock lever automatic lock If lock lever automatic lock function operates normally, turn lock lever automatic cancel switch ON lock cancel switch OFF.
Hot short circuit in wiring harness
1.
Turn the starting switch to OFF position.
2.
Disconnect connector D01, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage 3
Defective machine controller
40-164
Between D01 (female) (5) and ground
Max. 1 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DDNS00]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-165
Failure Code [DDWLKA]
40 Troubleshooting
Failure Code [DDWLKA] Action level
Failure code
-
DDWLKA
Detail of failure
Breaker Switch Open Circuit or Ground Fault (Machine controller system)
Since there is open circuit or ground fault in breaker switch signal system, both main signal and sub signal of breaker switch become open.
Action of
•
Stops driving attachment flow rate adjustment EPC2 solenoid.
controller
•
Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon on machine
Related
Breaker does not function. •
This failure code is displayed only when attachment 1 (with Attachment) or attachment 2 (with Attachment) is set.
•
By releasing the breaker switch, main signal of breaker switch becomes OPEN, and sub signal becomes CLOSE.
•
By pushing the breaker switch, main signal of breaker switch becomes CLOSE, and sub signal becomes OPEN.
information
No. 1
Failure
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse FB1 (No.5) is blown out, circuit probably has ground fault, etc. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F26, and connect T-adapter to male side.
3.
Breaker switch OFF
REMARK
2
Defective breaker switch (internal open circuit or short circuit)
Switch OFF: Release Switch ON: Push
Resistance
3
4
Open circuit in wiring harness
40-166
Switch OFF
Max. 1 Ω
Between F26 (male) (6) and (8)
Switch ON
Min. 1 MΩ
Between F26 (male) (6) and (1)
Switch OFF
Min. 1 MΩ
Between F26 (male) (6) and (1)
Switch ON
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and F26, and connect T-adapters to each female side.
(Wire breakage or defective contact of connector) Resistance
Defective machine controller
Between F26 (male) (6) and (8)
Between CP01 (female) (36) and F26 (female) (1)
Max. 1 Ω
Between CP01 (female) (55) and F26 (female) (8)
Max. 1 Ω
Between FB1 (5) and F26 (female) (6)
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DDWLKA]
Circuit Diagram Related to Breaker Switch
PC45MR-5, PC55MR-5
40-167
Failure Code [DDWLKB]
40 Troubleshooting
Failure Code [DDWLKB] Action level
Failure code
-
DDWLKB
Detail of failure
Breaker Switch Hot Short Circuit (Machine controller system)
Since there is hot short circuit in breaker switch signal system, both main signal and sub signal of breaker switch become CLOSE.
Action of
•
Stops driving attachment flow rate adjustment EPC2 solenoid.
controller
•
Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon on machine
Related
Breaker does not function. •
This failure code is displayed only when attachment 1 (with Attachment) or attachment 2 (with Attachment) is set.
•
By releasing the breaker switch, main signal of breaker switch becomes OPEN, and sub signal becomes CLOSE.
•
By pushing the breaker switch, main signal of breaker switch becomes CLOSE, and sub signal of breaker switch becomes OPEN.
information
No. 1
Failure
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse FB1 (No.5) is blown out, circuit probably has ground fault, etc. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F26, and connect T-adapter to male side.
3.
Breaker switch OFF
REMARK
2
Defective breaker switch (internal open circuit or short circuit)
Switch OFF: Release Switch ON: Push
Resistance
3
Hot short circuit in wiring harness
Defective machine controller
40-168
Switch OFF
Max. 1 Ω
Between F26 (male) (6) and (8)
Switch ON
Min. 1 MΩ
Between F26 (male) (6) and (1)
Switch OFF
Min. 1 MΩ
Between F26 (male) (6) and (1)
Switch ON
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and F26, and connect T-adapter to either female side.
Voltage 4
Between F26 (male) (6) and (8)
Between F26 (female) (1) and ground
Max. 1 V
Between F26 (female) (6) and ground
Max. 1 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DDWLKB]
Circuit Diagram Related to Breaker Switch
PC45MR-5, PC55MR-5
40-169
Failure Code [DFB1KZ]
40 Troubleshooting
Failure Code [DFB1KZ] Action level
Failure code
L01
DFB1KZ
Detail of failure
When attachment proportional switch of service lever 1 (right lever) was used, abnormality was detected in circuit.
Stops driving attachment flow rate adjustment EPC2 solenoid.
controller
•
Stops driving attachment flow rate adjustment EPC5 solenoid.
Related information
Attachment does not operate. •
This failure code is displayed only when attachment 1 (with Attachment) or attachment 2 (with Attachment) is set.
•
Service lever 1 (right lever) potentiometer 1 signal voltage can be checked with the monitoring function (code: 42008).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
No.
Cause
1
Defective 5 V sensor 1 power supply system
Defective service lever 1 (right iever) potentiometer (internal defect)
Procedure, measuring location, criteria and remarks If failure code [DBH5KP] is also displayed, perform troubleshooting these first. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F26, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage
5
(Contact with ground circuit)
4.3±0.2 V
NEUTRAL
2.5 V
LOWER
0.7±0.2 V
Turn starting switch to OFF position. Disconnect connector CP01 and F26, and connect T-adapters to each female side. Between CP01 (female) (68) and F26 (5)
Max. 1 Ω
Between CP01 (female) (8) and F26 (2)
Max. 1 Ω
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Resistance
Between CP01 (female) (68) and ground
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Defective machine controller Resistance
40-170
RAISE
2. Open circuit in wiring harness
Ground fault in wiring harness
Between F26 (female) (5) and (4)
1.
Resistance
4
(Machine controller system)
•
on machine
3
Service Lever Potentio 1 Open or Short Circuit
Action of Phenomenon
2
Failure
Between CP01 (female) (13) and (8)
4.0 to 6.0 kΩ
Between CP01 (female) (68) and (13)
0.25 to 5.0 kΩ
Between CP01 (female) (68) and (8)
0.25 to 5.0 kΩ
Between CP01 (female) (68) and ground
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DFB1KZ]
Circuit Diagram of Service Lever Potentiometer 1
PC45MR-5, PC55MR-5
40-171
Failure Code [DFB3L8]
40 Troubleshooting
Failure Code [DFB3L8] Action level
Failure code
-
DFB3L8
Detail of failure
Service Lever 1 Potentio Signal Incompatibility (Machine controller system)
When attachment proportional switch of service lever 1 (right lever) was used, abnormality was detected in circuit.
Action of
•
Stops driving attachment flow rate adjustment EPC2 solenoid.
controller
•
Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon on machine
Related information
Attachment does not operate. •
This failure code is displayed only when attachment 1 (with Attachment) or attachment 2 (with Attachment) is set.
•
Service lever 1 (right lever) potentiometer 1 signal voltage can be checked with the monitoring function (code: 42008).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
No.
Cause
1
Defective 5 V sensor 1 power supply system
2
Failure
Procedure, measuring location, criteria and remarks If failure code [DBH5KP] is also displayed, perform troubleshooting these first. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F26, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Defective service lever 1 (right iever) potentiometer (internal defect)
Between F26 (female) (5) and (4) Voltage Between F26 (female) (3) and (4)
3
(Contact with ground circuit)
40-172
NEUTRAL
2.5 V
LOWER
0.7±0.2 V
RAISE
0.7±0.2 V
NEUTRAL
2.5 V
LOWER
4.3±0.2 V
Turn starting switch to OFF position.
2.
Disconnect connector CP01 and F26, and connect T-adapters to each female side.
Resistance
4
4.3±0.2 V
1.
Open circuit in wiring harness
Ground fault in wiring harness
RAISE
Between CP01 (female) (68) and F26 (5)
Max. 1 Ω
Between CP01 (female) (30) and F26 (3)
Max. 1 Ω
Between CP01 (female) (8) and F26 (2)
Max. 1 Ω
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Resistance
Between CP01 (female) (68) and ground
Min. 1 MΩ
Between CP01 (female) (30) and ground
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
5
Failure Code [DFB3L8]
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Defective machine controller Resistance
Between CP01 (female) (13) and (8)
4.0 to 6.0 kΩ
Between CP01 (female) (68) and (13)
0.25 to 5.0 kΩ
Between CP01 (female) (68) and (8)
0.25 to 5.0 kΩ
Between CP01 (female) (30) and (13)
0.25 to 5.0 kΩ
Between CP01 (female) (30) and (8)
0.25 to 5.0 kΩ
Between CP01 (female) (68) and ground
Min. 1 MΩ
Circuit Diagram of Service Lever Potentiometer 1
PC45MR-5, PC55MR-5
40-173
Failure Code [DFB5KZ]
40 Troubleshooting
Failure Code [DFB5KZ] Action level
Failure code
-
DFB5KZ
Detail of failure
When attachment proportional switch of service lever 1 (right lever) was used, abnormality was detected in circuit.
Stops driving attachment flow rate adjustment EPC2 solenoid.
controller
•
Stops driving attachment flow rate adjustment EPC5 solenoid.
Related information
Attachment does not operate. •
This failure code is displayed by only machine equipped with attachment proportional switch.
•
Service lever 1 (right lever) potentiometer 2 signal voltage can be checked with the monitoring function (code: 42009).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
No.
Cause
1
Defective 5 V sensor 1 power supply system
Defective service lever 1 (right iever) potentiometer (internal defect)
Procedure, measuring location, criteria and remarks If failure code [DBH5KP] is also displayed, perform troubleshooting these first. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F26, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage
5
(Contact with ground circuit)
0.7±0.2 V
NEUTRAL
2.5 V
LOWER
4.3±0.2 V
Turn starting switch to OFF position. Disconnect connector CP01 and F26, and connect T-adapters to each female side. Between CP01 (female) (30) and F26 (3)
Max. 1 Ω
Between CP01 (female) (8) and F26 (2)
Max. 1 Ω
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Resistance
Between CP01 (female) (30) and ground
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Defective machine controller Resistance
40-174
RAISE
2. Open circuit in wiring harness
Ground fault in wiring harness
Between F26 (female) (3) and (4)
1.
Resistance
4
(Machine controller system)
•
on machine
3
Service Lever sub-Potentio 1 Open or Short Circuit
Action of Phenomenon
2
Failure
Between CP01 (female) (13) and (8)
4.0 to 6.0 kΩ
Between CP01 (female) (30) and (13)
0.25 to 5.0 kΩ
Between CP01 (female) (30) and (8)
0.25 to 5.0 kΩ
Between CP01 (female) (68) and ground
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DFB5KZ]
Circuit Diagram of Service Lever Potentiometer 1
PC45MR-5, PC55MR-5
40-175
Failure Code [DHS1MA]
40 Troubleshooting
Failure Code [DHS1MA] Action level
Failure code
L01
DHS1MA
Detail of failure Action of controller
Failure
Swing PPC Pressure Sensor Abnormality (Machine controller system)
Signal voltage of swing parking cancel PPC pressure sensor circuit is 0.3 V or less or 4.5 V or above. •
Controls machine by regarding swing parking brake cancel PPC pressure sensor as 0 MPa {0 kgf/cm2} .
•
If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
•
Auto-deceleration function cannot be reset.
on machine
•
Poor operability of swing
REMARK If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will break. Accordingly, take extreme care when checking. Related information
No.
•
As T-adapter for machine controller connector is “socket-type box”, operating voltage cannot be measured at machine controller connector.
•
Swing parking brake cancel PPC pressure can be checked with monitoring function. (Code: 09000)
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position or start the engine.
Cause
Procedure, measuring location, criteria and remarks If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1
Defective 5 V sensor power supply 1 system
1.
Turn starting switch to OFF position.
2.
Disconnect connector P03, and connect T-adapter to female side.
3.
Turn starting switch to ON position.
If power supply voltage is abnormal, proceed to check on cause 3. Voltage
Between P03 (female) (3) and (1)
Power supply
4.5 to 5.5 V
If no failure is found by check on cause 1, checks of resistance 1 and 3 on cause 3 are not required. 1. Turn starting switch to OFF position.
2
Open circuit in wiring har2. ness (Wire breakage or defective contact of connector)
Disconnect connector CP01 and P03, and connect T-adapters to each female side.
Resistance
3
4
Ground fault in wiring harness (Contact with ground circuit) Hot short circuit in wiring harness (Contact with 5V / 12V circuit)
40-176
Between CP01 (female) (8) and P03 (female) (3)
Max. 1 Ω
Between CP01 (female) (47) and P03 (female) (1)
Max. 1 Ω
Between CP01 (female) (48) and P03 (female) (2)
Max. 1 Ω
1.
Turn starting switch to OFF position.
2.
Disconnect connectors CP01 and P03, and connect T-adapter to either female side.
Resistance
Between ground and CP01 (female) (48) or P03 (female) (2)
Min. 1 MΩ
1.
Turn starting switch to OFF position.
2.
Disconnect connector P03, and connect T-adapter to female side.
3.
Turn starting switch to ON position.
Voltage
Between P03 (female) (2) and ground
Max. 1 V
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Failure Code [DHS1MA]
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Insert the T-adapter into connector P03.
3.
Turn the starting switch to ON position.
Voltage
Between P03 (2) and (1)
0.5 to 4.5 V
REMARK
5
Defective PPC pressure sensor for swing parking brake release
If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to determine the failure between ground fault and hot short circuit in wiring harness. Check as follows. 1.
Turn the starting switch to OFF position.
2.
Replace connector P03 with connector of another PPC pressure sensor.
3.
Turn the starting switch to ON position and display the Electrical Sys Abnormality Record screen of machine monitor.
4.
If E mark is not displayed again in this failure code column, swing parking brake release PPC pressure sensor is defective.
REMARK After the troubleshooting, always restore the connector. 6
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit Diagram Related to Swing PPC Pressure Sensor
PC45MR-5, PC55MR-5
40-177
Failure Code [DHS5MA]
40 Troubleshooting
Failure Code [DHS5MA] Action level
Failure code
L01
DHS5MA
Detail of failure
Failure
Travel PPC Pressure Sensor Error (Machine controller system)
Signal voltage of travel PPC pressure sensor circuit is 0.3 V or less or 4.5 V or above.
Action of
•
Controls machine by regarding travel PPC pressure sensor as 0 MPa {0 kgf/cm2} .
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon
•
Auto-deceleration function cannot be reset.
on machine
•
Poor operability of travel.
•
As T-adapter for machine controller connector is “socket-type box”, operating voltage cannot be measured at machine controller connector.
•
Travel PPC pressure can be checked with monitoring. (Code: 07101)
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position or start the engine.
Related information
k If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pres-
sure sensor will break. Accordingly, take extreme care when checking.
No.
Cause
Procedure, measuring location, criteria and remarks If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1
Defective 5 V sensor power supply 1 system
1.
Turn starting switch to OFF position.
2.
Disconnect connector P02, and connect T-adapter to female side.
3.
Turn starting switch to ON position.
If power supply voltage is abnormal, proceed to check on cause 3. Voltage
Between P02 (female) (3) and (1)
Power supply
1.
Turn the starting switch to OFF position.
2.
Insert the T-adapter into connector P02.
3.
Turn the starting switch to ON position.
Voltage
4.5 to 5.5 V
Between P02 (2) and (1)
0.5 to 4.5 V
REMARK
2
If power supply voltage is normal and sensor output voltage is not normal, it is difficult to judge whether cause of failure is ground fault or hot short circuit in wiring harness. Check as below.
Defective travel PPC pressure sensor (internal 1. defect) 2.
Turn the starting switch to OFF position. Exchange connector P02 with connector of another PPC pressure sensor.
3.
Turn the starting switch to ON position, and display “Electrical Sys Abnormality Record” screen on machine monitor.
4.
If E mark is not displayed again in this failure code column, travel PPC pressure sensor is defective.
NOTICE After the troubleshooting, always restore the connector.
40-178
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
3
Failure Code [DHS5MA]
Cause
Open circuit in wiring harness (wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and P02, and connect T-adapters to each female side. If power supply voltage in check on cause 1 is normal, this check is not required.
Max. 1 Ω
Between CP01 (female) (47) and P02 (female) (1) Resistance
Between CP01 (female) (29) and P02 (female) (2)
Max. 1 Ω
If power supply voltage in check on cause 1 is normal, this check is not required.
Max. 1 Ω
Between CP01 (female) (8) and P02 (female) (3)
4
Ground fault in wiring harness (contact with ground circuit)
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and P02, and connect T-adapter to either female side.
Resistance
5
Hot short circuit in wiring harness (contact with 5V / 12V circuit)
1.
Turn the starting switch to OFF position.
2.
Disconnect connector P02.
3.
Connect T-adapter to female side of connector P02.
4.
Turn the starting switch to ON position.
Voltage 6
Defective machine controller
Between ground and CP01 (female) (29) or P02 (female) (2)
Between P02 (female) (2) and ground
Min. 1 MΩ
Max. 1 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit Diagram Related to Travel PPC Pressure Sensor
PC45MR-5, PC55MR-5
40-179
Failure Code [DKULKA]
40 Troubleshooting
Failure Code [DKULKA] Action level
Failure code
L03
DKULKA
Detail of failure
Failure
PPC Lock Relay Open Circuit (Machine controller system)
Open circuit is detected in the circuit when output to PPC lock relay (coil side) is stopped (during lock lever automatic lock control operation).
Action of
•
None in particular (Since no current flows, relay is not operated.)
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related
All work equipment, swing, and travel are not operated even when lock lever is in FREE position. After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position, and release the lock lever while performing boom RAISE.
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector R02, and connect T-adapter to male side.
Resistance 1
Defective PPC lock relay
Between R02 (male) (1) and (2)
1.
Turn the starting switch to OFF position.
2.
Replace relay R02 with another one.
3.
Turn the starting switch to ON position.
80 to 200 Ω
If this failure code is cleared, the original PPC lock relay is defective.
2
Open circuit in wiring harness
1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP02 and relay R02, and connect T-adapter to each female side.
Resistance 3
Defective machine controller
40-180
Between CP02 (female) (109) and R02 (female) (1)
Max. 1 Ω
Between R02 (female) (2) and ground
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DKULKA]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-181
Failure Code [DKULKB]
40 Troubleshooting
Failure Code [DKULKB] Action level
Failure code
L03
DKULKB
Detail of failure Action of controller Phenomenon on machine
Failure
PPC Lock Relay Short Circuit (Machine controller system)
Short circuit is detected when output to PPC lock relay (coil side) is ON. •
Stops output to PPC lock relay.
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
•
All work equipment, swing, and travel are not operated even when lock lever is in FREE position.
Related
After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector R02, and connect T-adapter to male side.
Resistance 1
Defective PPC lock relay
Between R02 (male) (1) and (2)
1.
Turn the starting switch to OFF position.
2.
Replace relay R02 with another one.
3.
Turn the starting switch to ON position.
80 to 200 Ω
If this failure code is cleared, the original PPC lock relay is defective.
2
Ground fault in wiring harness
1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP02 and relay R02, and connect T-adapter to either female side.
Resistance 3
Defective machine controller
40-182
Between ground and CP02 (female) (109) or R02 (female) (1)
Min. 1 MΩ
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DKULKB]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-183
Failure Code [DKULKY]
40 Troubleshooting
Failure Code [DKULKY] Action level
Failure code
L03
DKULKY
Detail of failure
Failure
Proportional Pressure Control Lock Relay Hot Short Circuit (Machine controller system)
Hot short circuit is detected in the circuit when output to PPC lock relay (coil side) is stopped (during lock lever automatic lock control).
Action of
•
None in particular.
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related
When the lock lever is unlocked while the work equipment control lever or the travel lever is operated, the lock lever automatic lock system does not function. After completion of repair, check if the failure code is cleared by the following procedure.
information
Procedure: Start the engine, and lock the lock lever.
No.
Cause
1
Hot short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect relay R02, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage 2
Defective machine controller
40-184
Between R02 (female) (1) and ground
Max. 4.5 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DKULKY]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-185
Failure Code [DV00KB]
40 Troubleshooting
Failure Code [DV00KB] Action level
Failure code
L01
DV00KB
Detail of failure Action of controller Phenomenon on machine Related information
Failure
Buzzer Output Short Circuit (Machine monitor system)
Unusual current flows when power is output to alarm buzzer circuit. •
Stops outputting power to alarm buzzer circuit.
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Alarm buzzer does not sound. No
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective machine monitor
Defective machine monitor (Because this is an internal defect, troubleshooting cannot be performed.)
40-186
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DV20KB]
Failure Code [DV20KB] Action level
Failure code
L01
DV20KB
Detail of failure Action of controller Phenomenon on machine Related
Failure
Travel Alarm Short Circuit (Machine controller system)
Abnormal current flows when driving the travel alarm circuit. •
Stops driving the travel alarm circuit.
•
Even if cause of failure disappears, machine does not become normal until starting switch is set to OFF position.
Travel alarm does not sound.
information
As T-adapter for machine controller connector is “socket-type box”, operating voltage cannot be measured at machine controller connector.
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector M08, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Perform troubleshooting by control of travel lever.
k When driving machine, do not measure under the machine.
1
Defective travel alarm
REMARK
(Internal defect)
• When travel lever is set to the travel position, voltage is applied usually to
the travel alarm connector before machine moves off. • If the following voltage is normal but travel alarm does not sound, travel
alarm is defective. Voltage
2
3
Ground fault in wiring harness (Contact with ground circuit)
Defective machine controller
Max. 1 V 10 to 15 V
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP02 and M08, and connect T-adapter to either female side.
Resistance
Between CP02 (female) (86) and ground, or M08 (female) (1) and ground
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M08, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Perform troubleshooting by control of travel lever.
k When driving machine, do not measure under the machine.
Voltage
PC45MR-5, PC55MR-5
Between M08 (female) (1) Travel lever: Neutral and (2) Travel lever: Operated
Between M08 (female) (1) Travel lever: Neutral and (2) Travel lever: Operated
Max. 1 V 10 to 15 V
40-187
Failure Code [DV20KB]
40 Troubleshooting
Circuit Diagram of Travel Alarm
40-188
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DW43KA]
Failure Code [DW43KA] Action level
Failure code
L01
DW43KA
Detail of failure
When controller does not drive travel speed selector solenoid, output terminal voltage of controller is higher than specified value.
None in particular (Since no current flows, solenoid is not energized.)
controller
•
If cause of failure disappears, machine becomes normal by itself.
Machine travels slow in Hi travel speed setting (machine monitor shows Hi setting but the speed is kept at around Lo). •
Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (As long as controller's command to solenoid is ON, indication on monitoring is ON even if solenoid is not energized due to open circuit.) (Code: 02300)
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
Defective travel speed selector solenoid
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M17, and connect T-adapter to male side.
(Internal open circuit)
Resistance
Between M17 (male) (1) and (2)
8 to 15 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M17, and connect T-adapter to female side.
Open circuit, short circuit, 3. Turn the starting switch to ON position. ground fault, hot short circuit of wiring harness, REMARK or defective machine Shake the wiring harness by hand while measuring the voltage. If the voltage becontroller comes 0 V while shaking, wiring harness has open circuit. Voltage
3
(Machine controller system)
•
on machine
2
Travel Speed Solenoid Open Circuit
Action of Phenomenon
1
Failure
Open circuit or short circuit in wiring harness
Between M17 (female) (1) and (2)
1.9 to 7 V
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect connector CP02 and connect T-adapter to female side.
Resistance
Between CP02 (female) (107) and each of (114), (115), 8 to 15 Ω (117), and (120)
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position.
4
Open circuit in wiring har- 2. ness (Wire breakage or defective contact of connector)
Disconnect connectors CP02 and M17, and connect T-adapters to each female side.
Resistance
5
Defective machine controller
PC45MR-5, PC55MR-5
Between CP02 (female) (107) and M17 (female) (1)
Max. 1 Ω
Between M17 (female) (2) and each of CP02 (female) (114), (115), (117), and (120)
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-189
Failure Code [DW43KA]
40 Troubleshooting
Circuit Diagram of Travel Speed Hi/Lo Solenoid
40-190
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DW43KB]
Failure Code [DW43KB] Action level
Failure code
L01
DW43KB
Detail of failure Action of controller Phenomenon on machine
No.
1
2
Travel Speed Solenoid Short Circuit (Machine controller system)
Abnormal current flows when pump controller drives travel speed solenoid, so pump controller determines that short circuit exists in travel speed solenoid circuit. •
Stops driving travel speed solenoid.
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Machine travels slow in Hi travel speed setting (machine monitor shows Hi setting but the speed is kept at around Lo). •
Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (As long as controller's command to solenoid is ON, indication on monitoring is ON even if solenoid is not energized due to short circuit.) (Code: 02300)
•
After completion of repair, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position.
Related information
Failure
Cause
Procedure, measuring location, criteria and remarks
Defective travel speed selector solenoid
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M17, and connect T-adapter to male side.
(Internal short circuit or ground fault)
Resistance
Between M17 (male) (1) and (2)
8 to 15 Ω
Between M17 (male) (1) and ground
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP02 and connect T-adapter to female side.
Short circuit or ground fault in wiring harness
Resistance
Between CP02 (female) (107) and each of (114), (115), 8 to 15 Ω (117), and (120) Between CP02 (female) (107) and ground
3
Ground fault in wiring harness (Contact with ground circuit)
If no failure is found by check on cause 2, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect connectors CP02 and M17, and connect T-adapter to either female side.
Resistance 4
Defective machine controller
PC45MR-5, PC55MR-5
Min. 1 MΩ
Between ground and CP02 (female) (107) or M17 (female) (1)
Min. 1 MΩ
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-191
Failure Code [DW43KB]
40 Troubleshooting
Circuit Diagram of Travel Speed Hi/Lo Solenoid
40-192
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DW43KY]
Failure Code [DW43KY] Action level
Failure code
L01
DW43KY
Detail of failure
(Machine controller system)
When controller does not drive travel speed selector solenoid, output terminal voltage of controller is higher than specified value, and hot short circuit is detected. •
None in particular
controller
•
If cause of failure disappears, machine becomes normal by itself.
on machine
Machine travels fast in Lo travel speed setting (machine monitor shows Lo setting but the speed is kept at around Hi). •
Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (As long as controller's command to solenoid is OFF, sensor state displayed on monitoring screen is OFF even if solenoid is not energized due to hot short circuit.) (Code: 02300)
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
Related information
No.
Cause
Hot short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector M17, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage 2
Travel Speed Solenoid Hot Short Circuit
Action of Phenomenon
1
Failure
Defective machine controller
Between M17 (female) (1) and ground
Max. 4.5 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit Diagram of Travel Speed Hi/Lo Solenoid
PC45MR-5, PC55MR-5
40-193
Failure Code [DW4CKY]
40 Troubleshooting
Failure Code [DW4CKY] Action level
Failure code
L03
DW4CKY
Details of failure
Failure
PPC Lock Solenoid Hot Short Circuit (Machine controller system)
Voltage of 5.2 V or more is detected in PPC lock solenoid circuit during lock lever automatic lock.
Action of
•
None in particular
controller
•
If cause of failure disappears, machine becomes normal by itself.
Phenomenon on machine Related
Lock cannot be engaged by using lock lever.
information
After repairing, check if the failure code is cleared by the following procedure. Procedure: Start the engine and lock the lock lever.
No.
Cause
1
Hot short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector M18, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage 2
Defective machine controller
40-194
Between M18 (female) (1) and ground
Max.1 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DW4CKY]
Circuit Diagram of PPC Lock Switch
PC45MR-5, PC55MR-5
40-195
Failure Code [DXA8KA]
40 Troubleshooting
Failure Code [DXA8KA] Action level
Failure code
L03
DXA8KA
Detail of failure
No current flows when pump controller drives pump PC-EPC solenoid, so pump controller determines that open circuit exists in pump PC-EPC solenoid circuit.
None in particular (Since no current flows, solenoid is not energized.)
controller
•
If cause of failure disappears, machine becomes normal by itself.
Related
If pump load increases, engine speed decreases largely and engine may stop. •
When solenoid and wiring harness are normal, engine can be prevented from stopping by setting pump drive secondary switch to ON position.
•
Drive current of pump PC-EPC solenoid can be checked with monitoring function. (Code: 01300)
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
information
No.
Cause
Procedure, measuring location, criteria and remarks
Wrong operation of pump Toggle the pump drive secondary switch to normal (lower) position. secondary drive switch Defective PC-EPC solenoid
1.
Turn starting switch to OFF position.
2.
Disconnect connector M11, and connect T-adapter to male side.
(Internal open circuit)
Resistance 1.
3
Open circuit, short circuit, 2. ground fault, hot short 3. circuit of wiring harness, 4. or defective machine controller
5
Open or short circuit in wiring harness
Turn starting switch to ON position. Shake the wiring harness by hand while measuring the voltage. If the voltage becomes 0 V while shaking, wiring harness is open. Between M11 (female) (1) and (2)
Min. 10 V
1.
Turn starting switch to OFF position.
2.
Disconnect connector S25 and connect T-adapter to male side. Between S25 (male) (3) and (2)
Switch position: Normal
Max. 1 Ω
Switch position: Drive
Min. 1 MΩ
Between S25 (male) (6) and (5)
Switch position: Normal
Max. 1 Ω
Switch position: Drive
Min. 1 MΩ
Resistance
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP02 and connect T-adapter to female side.
Check that pump drive secondary switch is in the normal position (lower). Resistance
40-196
3 to 14 Ω
Disconnect connector M11, and connect T-adapter to female side.
Defective pump secondary drive switch (Internal open circuit)
Between M11 (male) (1) and (2)
Turn starting switch to OFF position.
Voltage
4
(Machine controller system)
•
on machine
2
Pump PC-EPC Solenoid Open Circuit
Action of Phenomenon
1
Failure
Between CP02 (female) (102) and each of (114), (115), 3 to 14 Ω (117), and (120)
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Failure Code [DXA8KA]
Cause
Procedure, measuring location, criteria and remarks If failure code is still displayed after above checks on cause 3, this check is not required. 1. Turn starting switch to OFF position.
6
Open circuit in wiring harness
2.
Disconnect connectors CP02, S25 and M11, and connect T-adapters to each female side.
(Wire breakage or defective contact of connector) Resistance
7
Defective machine controller
Between CP02 (female) (102) and S25 (female) (3)
Max. 1 Ω
Between S25 (female) (2) and M11 (female) (1)
Max. 1 Ω
Between S25 (female) (6) and each of CP02 (female) (114), (115), (117), (120)
Max. 1 Ω
Between S25 (female) (5) and M11 (female) (2)
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit Diagram of PC-EPC Solenoid System
PC45MR-5, PC55MR-5
40-197
Failure Code [DXA8KB]
40 Troubleshooting
Failure Code [DXA8KB] Action level
Failure code
L03
DXA8KB
Detail of failure Action of controller Phenomenon on machine
Related
1
2
3
Pump PC-EPC Solenoid Short Circuit (Machine controller system)
Abnormal current flows when pump controller drives pump PC-EPC solenoid, so pump controller determines that short circuit exists in pump PC-EPC solenoid circuit. Stops output to pump PC-EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. If pump load increases, engine speed decreases largely and engine may stop. •
When solenoid and wiring harness are normal, engine can be prevented from stopping by setting pump drive secondary switch to ON position.
•
Drive current of pump PC-EPC solenoid can be checked with monitoring function. (Code: 01300)
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn starting switch to ON position.
information
No.
Failure
Cause Defective PC-EPC solenoid (Internal short circuit or ground fault)
Defective pump secondary drive switch (internal short circuit, ground fault)
Short circuit or ground fault in wiring harness
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to OFF position.
2.
Disconnect connector M11, and connect T-adapter to male side.
Resistance
Between M11 (male) (1) and (2)
3 to 14 Ω
Between M11 (male) (1) and ground
Min. 1 MΩ
1.
Turn starting switch to OFF position.
2.
Disconnect connector S25 and connect T-adapter to male side.
Resistance
Between S25 (male) (2) and (5), or between S25 (male) (3) and (5)
Switch position: Normal
Min. 1 MΩ
Between S25 (male) (2) and ground, or between Switch position: Normal S25 (male) (3) and ground
Min. 1 MΩ
1.
Turn starting switch to OFF position.
2.
Disconnect connector CP02 and connect T-adapter to female side.
Check that pump drive secondary switch is in the normal position (lower). Resistance
Between CP02 (female) (102) and each of (114), (115), 3 to 14 Ω (117), and (120) Between CP02 (female) (102) and ground
4
Ground fault in wiring harness (Contact with ground circuit)
If failure code is still displayed after above checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2.
Disconnect connectors CP02, S25 and M11, and connect T-adapter to any female side.
Resistance
40-198
Min. 1 MΩ
Between ground and CP02 (female) (102) or S25 (female) (3)
Min. 1 MΩ
Between ground and S25 (female) (2) or M11 (female) (1)
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXA8KB]
No.
Cause
Procedure, measuring location, criteria and remarks
5
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit Diagram of PC-EPC Solenoid System
PC45MR-5, PC55MR-5
40-199
Failure Code [DXE7KA]
40 Troubleshooting
Failure Code [DXE7KA] Action level
Failure code
-
DXE7KA
Detail of failure
When attachment flow rate adjustment EPC2 solenoid is driven, no current flows in the circuit, so the open circuit is detected.
Stops driving attachment flow rate adjustment EPC2 solenoids.
•
Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
No.
Attachment does not move. •
Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with monitoring function (code: 01702).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment flow rate adjustment EPC 2. Disconnect connector V02, and connect T-adapter to male side. 2 (internal open circuit) Resistance Between V02 (male) (1) and (2) 3 to 15 Ω
Open circuit in wiring harness
1.
Turn starting switch to OFF position.
2.
Disconnect connectors CP02 and V02, and connect T-adapters to each female side.
Resistance
3
(Machine controller system)
•
on machine
2
Attachment Flow Regulating EPC 2 Solenoid Open Circuit
Action of
Phenomenon
1
Failure
Defective machine controller
40-200
Between CP02 (female) (103) and V02 (female) (2)
Max. 1 Ω
Between each of CP02 (female) (114), (115), (117), (120) and V02 (female) (1)
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXE7KA]
Circuit Diagram Related to ATT Flow Rate Adjustment EPC
PC45MR-5, PC55MR-5
40-201
Failure Code [DXE7KB]
40 Troubleshooting
Failure Code [DXE7KB] Action level
Failure code
-
DXE7KB
Detail of failure
Abnormal current flows when pump controller drives attachment flow rate (service current) EPC2 solenoid, so pump controller determines that short circuit exists in attachment flow rate adjustment (service current) EPC2 solenoid circuit.
Stops driving attachment flow rate adjustment EPC2 solenoids.
•
Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
No.
Attachment does not move. •
Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with monitoring function (code: 01702).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment 2. Disconnect connector V02, and connect T-adapter to male side. flow rate adjustment EPC 2 (internal short circuit or Between V02 (male) (1) and (2) 3 to 15 Ω Resistance ground fault) Between V02 (male) (2) and ground Min. 1 MΩ
Ground fault in wiring harness (contact with ground circuit)
1.
Turn starting switch to OFF position.
2.
Disconnect connectors CP02 and V02, and connect T-adapters to each female side.
Resistance 3
(Machine controller system)
•
on machine
2
Attachment Flow Regulating EPC 2 Solenoid Short Circuit
Action of
Phenomenon
1
Failure
Defective machine controller
40-202
Between ground and CP02 (female) (103) or V02 (female) (2)
Min. 1 MΩ
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXE7KB]
Circuit Diagram Related to ATT Flow Rate Adjustment EPC
PC45MR-5, PC55MR-5
40-203
Failure Code [DXE7KY]
40 Troubleshooting
Failure Code [DXE7KY] Action level
Failure code
-
DXE7KY
Detail of failure
Current flows when driving attachment flow rate adjustment EPC2 solenoid circuit stops.
Stops driving attachment flow rate adjustment EPC2 solenoids.
•
Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
No.
Attachment does not move. •
Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with monitoring function (code: 01702).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment 2. Disconnect connector V02, and connect T-adapter to male side. flow rate adjustment EPC 2 (internal short circuit or Between V02 (male) (1) and (2) 3 to 15 Ω Resistance ground fault) Between V02 (male) (2) and ground Min. 1 MΩ
Hot short circuit in wiring harness
1.
Turn starting switch to OFF position.
2.
Disconnect connector V02, and connect T-adapter to female side.
3.
Turn starting switch to ON position.
Voltage 3
(Machine controller system)
•
on machine
2
Attachment Flow Regulating EPC 2 Hot Short Circuit
Action of
Phenomenon
1
Failure
Defective machine controller
40-204
Between V02 (female) (2) and ground
Max. 4.5 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXE7KY]
Circuit Diagram Related to ATT Flow Rate Adjustment EPC
PC45MR-5, PC55MR-5
40-205
Failure Code [DXEAKA]
40 Troubleshooting
Failure Code [DXEAKA] Action level
Failure code
-
DXEAKA
Detail of failure
When attachment flow rate adjustment EPC5 solenoid is driven, no current flows in the circuit, so the open circuit is detected.
Stops driving attachment flow rate adjustment EPC5 solenoids.
•
Also sets output command to attachment flow rate adjustment EPC2 solenoid to 0 mA.
controller
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
No.
Attachment does not move. •
Drive current of attachment flow rate adjustment EPC5 solenoid can be checked with monitoring function (code: 01701).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment flow rate adjustment EPC 2. Disconnect connector V01, and connect T-adapter to male side. 5 (internal open circuit) Resistance Between V01 (male) (1) and (2) 3 to 15 Ω
Open circuit in wiring harness
1.
Turn starting switch to OFF position.
2.
Disconnect connectors CP02 and V01, and connect T-adapters to each female side.
Resistance
3
(Machine controller system)
•
on machine
2
Attachment Flow Regulating EPC 5 Solenoid Open Circuit
Action of
Phenomenon
1
Failure
Defective machine controller
40-206
Between CP02 (female) (111) and V01 (female) (2)
Max. 1 Ω
Between each of CP02 (female) (114), (115), (117), (120) and V01 (female) (1)
Max. 1 Ω
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXEAKA]
Circuit Diagram Related to ATT Flow Rate Adjustment EPC
PC45MR-5, PC55MR-5
40-207
Failure Code [DXEAKB]
40 Troubleshooting
Failure Code [DXEAKB] Action level
Failure code
-
DXEAKB
Detail of failure
Abnormal current flows when driving attachment flow rate (service current) EPC5 solenoid, so short circuit is detected.
Stops driving attachment flow rate adjustment EPC5 solenoids.
•
Also sets output command to attachment flow rate adjustment EPC2 solenoid to 0 mA.
controller
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
No.
Attachment does not move. •
Drive current of attachment flow rate adjustment EPC5 solenoid can be checked with monitoring function (code: 01701).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment 2. Disconnect connector V01, and connect T-adapter to male side. flow rate adjustment EPC 5 (internal short circuit or Between V01 (male) (1) and (2) 3 to 15 Ω Resistance ground fault) Between V01 (male) (2) and ground Min. 1 MΩ
Ground fault in wiring harness (contact with ground circuit)
1.
Turn starting switch to OFF position.
2.
Disconnect connectors CP02 and V01, and connect T-adapters to each female side.
Resistance 3
(Machine controller system)
•
on machine
2
Attachment Flow Regulating EPC 5 Solenoid Short Circuit
Action of
Phenomenon
1
Failure
Defective machine controller
40-208
Between ground and CP02 (female) (111) or V01 (female) (2)
Min. 1 MΩ
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXEAKB]
Circuit Diagram Related to ATT Flow Rate Adjustment EPC
PC45MR-5, PC55MR-5
40-209
Failure Code [DXEAKY]
40 Troubleshooting
Failure Code [DXEAKY] Action level
Failure code
-
DXEAKY
Detail of failure
Current flows when driving attachment flow rate adjustment EPC5 solenoid circuit stops.
Stops driving attachment flow rate adjustment EPC5 solenoids.
•
Also sets output command to attachment flow rate adjustment EPC2 solenoid to 0 mA.
controller
•
Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
No.
Attachment does not move. •
Drive current of attachment flow rate adjustment EPC5 solenoid can be checked with monitoring function (code: 01701).
•
After repairing, check if the failure code is cleared by the following procedure. Procedure: Turn the starting switch to ON position and set machine in attachment mode (ATT).
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment 2. Disconnect connector V01, and connect T-adapter to male side. flow rate adjustment EPC 5 (internal short circuit or Between V01 (male) (1) and (2) 3 to 15 Ω Resistance ground fault) Between V01 (male) (2) and ground Min. 1 MΩ
Hot short circuit in wiring harness
1.
Turn starting switch to OFF position.
2.
Disconnect connector V01, and connect T-adapter to female side.
3.
Turn starting switch to ON position.
Voltage 3
(Machine controller system)
•
on machine
2
Attachment Flow Regulating EPC 5 Hot Short Circuit
Action of
Phenomenon
1
Failure
Defective machine controller
40-210
Between V01 (female) (2) and ground
Max. 4.5 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
Failure Code [DXEAKY]
Circuit Diagram Related to ATT Flow Rate Adjustment EPC
PC45MR-5, PC55MR-5
40-211
E-1 Engine Does Not Start (Engine Does Not Crank)
40 Troubleshooting
Troubleshooting of Electrical System (E-Mode) E-1 Engine Does Not Start (Engine Does Not Crank) Failure
Engine does not start (engine does not crank) •
The engine start circuit is equipped with the start lock function of the following two systems.
1.
Start lock by password of machine monitor
Related infor- 2. mation •
Start lock by lock lever If failure symptom machine monitor does not light up is displayed while starting switch is turned to ON position, main power supply system may be defective. Perform troubleshooting for E-mode “WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING”.
No.
Cause
1
Loose terminal or open circuit in terminal
2
Insufficient battery capacity
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
Check terminals of starting motor, alternator, and ground terminals T01, T02, T03, etc. Check battery voltage and specific gravity of battery electrolyte. Battery voltage (per 1 cell)
Min. 12 V
Gravity of battery
Min. 1.26
3
Defective engine control- As for engine controller power supply and ACC signal, perform troubleshooting for ler system causes 1 and 2 of failure code [DB2QKR] first.
4
Defective fuse
If fuse No.3 in fuse box FB1 is blown out, circuit probably has ground fault. (See ground fault (contact to ground circuit) of wiring harness.) •
If fusible link M09 is burnt out, circuit probably has ground fault. In this case, perform troubleshooting for ground fault of wiring harness in cause 13 first. Fusible link M09 is connected to fuses No.1 to 10 and has large scale of circuits connected. Accordingly, if no failure is found by check on cause 13, reproduce the phenomenon to locate the ground fault place by unusual noise and burnt smell so that the trouble can be resolved earlier.
5
Defective fusible link
•
6
Defective slow-blow fuse
If slow-blow fuse (TM15) is blown out, circuit probably has ground fault, etc. (See check on cause of wiring harness ground fault.)
7
1.
Turn the starting switch to OFF position.
2.
Remove fuse No.14 in fuse box FB1 (to prevent engine from starting during check).
3. Insert checker harness into connector CE1. Defective starting switch, lock lever switch, starting 4. Turn the starting switch to START position and hold it (2 persons required motor cut-off relay, perfor this work). sonal code relay, and wirREMARK ing harness
For checker harness, see Engine Shop Manual. Voltage
Between CE1 (35) and ground
10 to 15 V
If voltage is abnormal, go to check on cause 8.
40-212
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
E-1 Engine Does Not Start (Engine Does Not Crank)
Cause
Procedure, measuring location, criteria and remarks If check on cause 7 is normal, this check is not required. 1. Turn starting switch to OFF position. 2.
8
Turn battery disconnect switch to OFF position.
Between TF1 and TF3
Defective starting switch (internal open circuit) Resistance
Between TF1 and TF4
Turn starting switch to OFF position.
Min. 1 MΩ
Turn starting switch to ON position.
Max. 1 Ω
Turn starting switch to OFF position.
Min. 1 MΩ
Turn starting switch to START position.
Max. 1 Ω
If no failure is found on cause 7, this check is not required. 1. Turn starting switch to OFF position. 2. 9
Defective lock lever switch
Disconnect connector F09 and connect T-adapter to female side.
Resistance
Between F09 (female) (A) and (C)
Lock lever: FREE
Min. 1 MΩ
Between F09 (female) (A) and (C)
Lock lever: LOCK
Max. 1 Ω
If check on cause 7 is normal, this check is not required. 1. Turn starting switch to OFF position. 10
Defective starting motor cut-off relay
2.
Replace the starting motor cut-off relay R01 with the light relay R04.
3.
Turn starting switch to ON position.
If the engine can be started, the original starting motor cut-off relay R01 is defective. If no failure is found on cause 7, this check is not required. 1. Turn the starting switch to OFF position. 11
Defective personal code relay
2.
Replace personal code relay R06 with light relay R04.
3.
Turn the starting switch to ON position.
If the engine can start, the original personal code relay R06 is defective.
PC45MR-5, PC55MR-5
40-213
E-1 Engine Does Not Start (Engine Does Not Crank)
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 7, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position. (to avoid short circuit during check)
3.
Disconnect fusible link M09 and fuse FB1 (3).
4.
Connect T-adapter to male side of connector M09.
Resistance
Between battery (+) terminal and M09 (male) (2)
Max. 1 Ω
Between M09 (male) (1) and TF1
Max. 1 Ω
If no failure is found by check on cause 7, this check is not required. 1. Turn the starting switch to OFF position.
12
Open circuit in wiring har- 2. ness 1 (wire breakage or 3. defective contact of connector) 4.
Disconnect connectors F09, R01, R06, F15, and CE1. Connect T-adapter to each female sides of F09, R01, R06, F15, CE1, and male side of F09. Remove fuse FB1 (3).
Resistance
40-214
Between TF3 and FB1 (1A)
Max. 1 Ω
Between FB1 (3) and F09 (male) (A)
Max. 1 Ω
Between F09 (male) (C) and R01 (female) (1)
Max. 1 Ω
Between R01 (female) (2) and ground
Max. 1 Ω
Between FB1 (3) and R06 (female) (1)
Max. 1 Ω
Between R06 (female) (2) and F15 (female) (4)
Max. 1 Ω
Between TF4 and R01 (female) (3)
Max. 1 Ω
Between R01 (female) (5) and R06 (female) (3)
Max. 1 Ω
Between R06 (female) (4) and CE1 (female) (35)
Max. 1 Ω
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
E-1 Engine Does Not Start (Engine Does Not Crank)
Cause
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 7, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position. (to avoid short circuit during check)
3.
Disconnect fusible link M09 and fuse FB1 (3).
4.
Connect T-adapter to male side of connector M09.
Resistance
Between ground and battery (+) terminal or M09 (male) (2)
Min. 1 MΩ
Between ground and M09 (male) (1) or TF1
Min. 1 MΩ
Between ground and TF3 or FB1 (1A)
Min. 1 MΩ
If no failure is found by check on cause 7, this check is not required. 1. Turn the starting switch to OFF position. 13
Ground fault in wiring harness 1 (contact with ground circuit)
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connectors F09, R01, R06, F15, and CE1.
4.
Connect T-adapter to each female sides of F09, R01, R06, F15, CE1, and male side of F09.
5.
Remove fuse FB1 (3).
Resistance
Between ground and TF3 or FB1 (1A)
Min. 1 MΩ
Between ground and FB1 (3) or F09 (male) (A) or R06 (female) (1)
Min. 1 MΩ
Between ground and R06 (female) (2) or F15 (female) (4)
Min. 1 MΩ
Between ground and TF4 or R01 (female) (3)
Min. 1 MΩ
Between ground and R01 (female) (5) or R06 (female) (3)
Min. 1 MΩ
Between ground and R06 (female) (4) or CE1 (female) Min. 1 MΩ (35)
14
Defective starting motor relay
1.
Turn the starting switch to OFF position.
2.
Replace starter relay M16 with glow plug relay M13.
3.
Turn the starting switch to ON position.
If the engine can be started, the original starter relay M16 is defective.
15
Defective alternator (internal short circuit)
1.
Turn starting switch to OFF position.
2.
Turn starting switch to START position to perform troubleshooting.
Voltage
PC45MR-5, PC55MR-5
Between M10 (1) and ground
Max. 1 V
40-215
E-1 Engine Does Not Start (Engine Does Not Crank)
No.
16
Cause
Defective starting motor
40 Troubleshooting
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to OFF position.
2.
Turn starting switch to START position to perform troubleshooting.
Voltage
Between starting motor terminal B (TM16) and ground
Power supply
10 to 15 V
Between starting motor terminal S (TM6) and ground
Input for starting
10 to 15 V
If power supply and start input are normal but the starting motor does not rotate, the starting motor is defective.
REMARK If fuse or fusible link is burnt out, replace it.
17
Open circuit in wiring harness 2 (wire breakage or defective contact of connector)
1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connector M16.
4.
Connect T-adapter to female side of CE1. Between TM1 and starting motor B terminal (TM16)
Between starting motor B terminal (TM16) and alternaMax. 1 Ω tor B terminal (TM2) Resistance
18
Ground fault in wiring harness 2 (contact with ground circuit)
Max. 1 Ω
Between alternator B terminal (TM2) and M16 (female) Max. 1 Ω (1) Between M16 (female) (4) and starting motor S terminal (TM6)
Max. 1 Ω
Between CE1 (female) (73) and M16 (female) (2)
Max. 1 Ω
Between M16 (female) (3) and CE1 (female) (28)
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connectors F09, R01, R06, F15, and CE1.
4.
Connect T-adapter to each female sides of F09, R01, R06, F15, CE1, and male side of F09.
5.
Remove fuse FB1 (3).
Resistance
Between ground and starting motor B terminal (TM16) or alternator B terminal (TM2) or M16 (female) (1)
Min. 1 MΩ
Between ground and M16 (female) (4) or starting motor S terminal (TM6)
Min. 1 MΩ
Between ground and M16 (female) (2) or CE1 (female) Min. 1 MΩ (73)
40-216
PC45MR-5, PC55MR-5
40 Troubleshooting
E-1 Engine Does Not Start (Engine Does Not Crank)
Circuit Diagram of Engine Starting System
PC45MR-5, PC55MR-5
40-217
E-2 Engine Does Not Start (Fuel Feed Pump System)
40 Troubleshooting
E-2 Engine Does Not Start (Fuel Feed Pump System) Failure
Engine does not start (fuel feed pump system).
Related inforWhen engine cranks mation No. 1
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse No.5 in fuse box FB1 is blown out, circuit probably has ground fault, etc. 1.
Turn the starting switch to OFF position.
2.
Connect T-adapter to connector M14.
Resistance 2
Defective fuel feed pump
Approx. 140 Ω
Between M14 (male) (1) and (2)
1.
Turn the starting switch to OFF position.
2.
Disconnect fuel hose at outlet side.
3.
Turn the starting switch to ON position.
Fuel flows out.
3
1. Turn the starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors M14, and connect T-adapter to female side of M14. ness (wire breakage or defective contact of conBetween FB1(5) and M14 (female) (2) Max. 1 Ω Resistance nector) Between ground and M14 (female) (1) Max. 1 Ω
4
Ground fault in wiring harness (contact with ground circuit)
40-218
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors M14, and connect T-adapter to female side of M14.
Resistance
Between ground and FB1(5) or M14 (female) (2)
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
E-2 Engine Does Not Start (Fuel Feed Pump System)
Circuit Diagram of Fuel Feed Pump
PC45MR-5, PC55MR-5
40-219
E-3 Automatic Preheating System Does Not Operate
40 Troubleshooting
E-3 Automatic Preheating System Does Not Operate Failure
Automatic preheating system does not work. •
Automatic preheating starts when engine coolant temperature is below +5 °C. (Monitoring code: 04107)
Related information
•
Engine controller checks primary (coil) side of glow plug relay (connector M16) with failure code [#B0541] or [#B0543].
•
Engine controller checks engine coolant temperature sensor with failure code [#B0117] or [#B0118].
•
If machine monitor does not light up when starting switch is turned to ON position, main power supply system may be defective. Perform troubleshooting for “Engine does not start (engine does not crank)” and “When starting switch is turned to ON position, machine monitor displays nothing” in E mode.
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective slow-blow fuse
If slow-blow fuse TM14 is blown out, circuit probably has ground fault. In this case, perform troubleshooting for ground fault in wiring harness (contact to ground circuit) first.
2
3
4
1.
Turn the starting switch to OFF position.
2.
Replace glow plug relay (connector M13) with starter relay (connector
1.
Turn the starting switch to OFF position.
2.
Disconnect TM14, M13, and M23.
Defective glow plug relay M16). (internal open or short 3. Turn the starting switch to ON position. circuit) If automatic preheating starts when coolant temperature is below +5 °C, the original glow plug relay is defective.
Open circuit in wiring harness (Wire breakage or defective contact of connector) Resistance
Defective glow plug
5
(Contact with ground circuit)
40-220
Max. 1 Ω
Between M13 (female) (1) and TM14
Max. 1 Ω
Between TM13 and alternator B terminal (TM2)
Max. 1 Ω
Between alternator B terminal (TM2) and starting motor B terminal (TM16)
Max. 1 Ω
Between starting motor B terminal (TM16) and battery (+) terminal
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M23.
Continuity
Ground fault in wiring harness
Between M23 (female) (1) and M13 (female) (4)
Between M23 (male) (1) and ground
Continuity
If slow-blow fuse is not blown out, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect TM14 and M23. Between ground and TM14 or M13 (female) (1)
Resistance
Min. 1 MΩ
Between ground and M13 (female) (4) or M23 (female) Min. 1 MΩ (1)
PC45MR-5, PC55MR-5
40 Troubleshooting
E-3 Automatic Preheating System Does Not Operate
Circuit Diagram of Engine Preheating
PC45MR-5, PC55MR-5
40-221
E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing
40 Troubleshooting
E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing Failure
When starting switch is turned to ON position, machine monitor displays nothing. •
When starting switch is turned to ON position, machine monitor displays KOMATSU logo, password input screen (if set), working mode and travel speed check screen, and standard screen in order.
•
Battery voltage may drop sharply when engine is started, depending on ambient temperature and battery condition. In this case, machine monitor display may disappear for a while. This phenomenon is not abnormal.
Related information
No.
Cause
1
Omission of turning battery disconnect switch ON
Procedure, measuring location, criteria and remarks Turn starting switch to OFF position, and check that battery disconnect switch is turned ON. Check battery voltage and specific gravity of battery electrolyte.
2
Insufficient battery capacity
Battery voltage (per 1 cell)
Min. 12 V
Battery voltage (2cells in-line)
Min. 24 V
Gravity of battery
Min. 1.26
3
Defective fusible link
If fusible link M05 or M09 is burnt out, circuit probably has ground fault. (See ground fault (contact to ground circuit) of wiring harness.)
4
Defective fuse
If fuse No.10 or No.13 in fuse box FB1 is blown out, circuit probably has ground fault. (See ground fault (contact to ground circuit) of wiring harness.)
5
1.
Turn the starting switch to OFF position.
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect connector F15, and connect T-adapter.
Defective wiring harness, 4. starting switch, or machine monitor 5.
Connect the battery ground, or turn the battery disconnect switch to ON position. Turn the starting switch to ON position (connect ACC).
Voltage
6
Between F15 (1) and (2)
10 to 15 V
Between F15 (6) and (7)
10 to 15 V
Between F15 (3) and (7)
10 to 15 V
1.
Turn starting switch to OFF position.
2.
Turn battery disconnect switch to OFF position.
Defective starting switch (internal open circuit) Resistance
40-222
Between TF1 and TF3
Turn starting switch to OFF position.
Min. 1 MΩ
Turn starting switch to HEAT position.
Max. 1 Ω
PC45MR-5, PC55MR-5
E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing
40 Troubleshooting
No.
Cause
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 5, this check is not required. 1. Turn the starting switch to OFF position.
7
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect fusible links M05 and M09, fuses FB1 (10) and (13), and connector F15.
4.
Connect T-adapter to connectors M05 (male), M09 (male), and F15 (female).
Open circuit in wiring harness (Internal open circuit)
Resistance
Between battery (-) terminal and ground
Max. 1 Ω
Between battery (+) terminal and M09 (male) (2)
Max. 1 Ω
Between M09 (male) (1) and FB1 (11A)
Max. 1 Ω
Between FB1 (13) and each of F15 (female) (1) and (6)
Max. 1 Ω
Between battery (+) terminal and M05 (male) (2)
Max. 1 Ω
Between M05 (male) (1) and TF1
Max. 1 Ω
Between TF3 and FB1 (1A)
Max. 1 Ω
Between FB1 (10) and F15 (female) (3)
Max. 1 Ω
If no failure is found by checks on causes 3, 4, and 5, this check is not required. 1. Turn the starting switch to OFF position.
8
Ground fault in wiring harness
2.
Disconnect the battery ground, or turn the battery disconnect switch to OFF position.
3.
Disconnect fusible links M05 and M09, fuses FB1 (10) and (13), and connectors F15 and CP01.
4.
Connect T-adapter to connectors M05 (male), M09 (male), and F15 (female).
(Contact with ground circuit)
Resistance
9
Defective machine monitor
PC45MR-5, PC55MR-5
Between ground and battery (+) terminal or M09 (male) (2)
Min. 1 MΩ
Between ground and M09 (male) (1) or FB1 (11A)
Min. 1 MΩ
Between ground and each of FB1 (13), F15 (female) (1) and (6)
Min. 1 MΩ
Between ground and M05 (male) (1) or TF1
Min. 1 MΩ
Between ground and TF3 or FB1 (1A)
Min. 1 MΩ
Between ground and FB1 (10) or F15 (female) (3)
Min. 1 MΩ
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-223
E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing
40 Troubleshooting
Circuit Diagram Related to Machine Monitor Power Supply
40-224
PC45MR-5, PC55MR-5
E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs
40 Troubleshooting
E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs Failure
Engine coolant temperature monitor lights up in white while engine is running. •
Signal of engine coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor via machine controller through CAN communication system.
•
Engine coolant temperature can be checked with monitoring function. (Code: 04107)
Related information
No.
1
2
Cause Insufficient warm-up operation of machine (When system works properly)
Defective engine coolant temperature gauge system
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks If monitor is lit in white, engine coolant temperature may be low (approximately 59°C and below). Warm up engine. • Lights up in white: Engine coolant temperature is low. •
Lights up in blue: Coolant temperature is proper.
If no failure is found by preceding checks, engine coolant temperature gauge system may be defective. Perform following troubleshooting. • E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
NOT MOVE FROM MINIMUM OR MAXIMUM” •
E-mode “DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE”(indicates neither full nor empty)
40-225
E-6 Charge Level Monitor Comes On in Red While Engine is in Operation
40 Troubleshooting
E-6 Charge Level Monitor Comes On in Red While Engine is in Operation Failure Related information No.
1
Charge level monitor lights up in red while engine is running. Generated signal condition of alternator can be checked with monitoring function (Code: 04300) Cause
Defective alternator
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Start the engine
Voltage
2
Ground fault in wiring harness (contact with ground circuit)
Between M10 (1) and ground
Immediately after starting the engine
13.5 to 14.5 V
Perform troubleshooting for failure code [#B1568].
Circuit Diagram Related to Battery Charge
40-226
PC45MR-5, PC55MR-5
40 Troubleshooting
E-7 Fuel Level Monitor Comes On in Red While Engine Runs
E-7 Fuel Level Monitor Comes On in Red While Engine Runs Failure
Fuel level monitor lights up in red while engine is running.
Related
•
information No.
Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200)
Cause Fuel level reduction
1
2
Procedure, measuring location, criteria and remarks Because fuel level may be lowered, check and refill with fuel if level is lowered.
(When system works properly) If no failure is found by preceding checks, fuel gauge system may be defective. Perform following troubleshooting: Defective fuel gauge sys- • E-mode “FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM” tem • E-mode “DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL
LEVEL” (indicates neither full nor empty).
PC45MR-5, PC55MR-5
40-227
E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
40 Troubleshooting
E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation Failure
Engine coolant temperature monitor lights up in red while engine is running. •
Signal voltage of engine coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor via machine controller through CAN communication system.
•
Engine coolant temperature can be checked with monitoring function. (Code: 04107)
Related information
No.
1
2
Cause
Overheat of engine coolant (when system works properly)
Defective engine coolant temperature gauge system
40-228
Procedure, measuring location, criteria and remarks If monitor is lit in red, coolant temperature may be high (above approximately 107 °C). Cool down coolant. (Run engine at low idle speed.) • Lights up in red: Coolant temperature is high (overheating). •
Lights up in blue: Coolant temperature is proper.
•
Perform troubleshooting S-mode “COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING).”
If no failure is found by preceding checks, engine coolant temperature gauge system may be defective. Perform following troubleshooting. • E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
NOT MOVE FROM MINIMUM OR MAXIMUM” •
E-mode “DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE”(indicates neither full nor empty)
PC45MR-5, PC55MR-5
E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation
40 Troubleshooting
E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation Failure
Engine oil pressure monitor lights up in red while engine is running •
Engine oil pressure switch signals are input to engine controller.
Related
•
If engine oil pressure switch is turned on while engine is running, engine controller sends the failure code [#B1198] to machine monitor through machine controller by CAN communication.
information
No.
Cause
1
Low engine oil pressure (when system works properly)
2
If failure code still displays after above checks on cause 1, engine oil pressure Defective engine oil presswitch system may be defective. Perform troubleshooting for failure codes sure system [#B1198].
3
Defective machine monitor
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks Since engine oil pressure low is sensed, check engine oil pressure. • Perform troubleshooting S-mode “OIL PRESSURE DROPS.”
If no failure can be found in causes 1 and 2, machine monitor is defective. (Because this is an internal defect, troubleshooting cannot be performed.)
40-229
E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum
40 Troubleshooting
E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum Failure
Fuel gauge display does not move from minimum or maximum.
Related
•
information No.
1
2
Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200)
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
Defective fuel level sensor
2.
Disconnect connector M06, and connect T-adapter to male side.
(Internal open or short circuit)
Resistance
Between M06 (male) (2) and (3)
Fuel level FULL
0 to 2 Ω
Fuel level EMPTY
140 to 160 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector CP01, and connect T-adapter to female side.
Open or short circuit in wiring harness
Resistance
Between CP01 (female) (69) and (51)
Fuel level FULL
0 to 2 Ω
Fuel level EMPTY
140 to 160 Ω
REMARK If no failure is found by check on cause 2, this check is not required. 3
Open circuit in wiring har- 1. ness 2. (Wire breakage or defective contact of connector)
Turn the starting switch to OFF position. Disconnect connectors CP01 and M06, and connect T-adapter to each female side.
Resistance
Between CP01 (female) (69) and M06 (female) (2)
Max. 1 Ω
Between CP01 (female) (51) and M06 (female) (3)
Max. 1 Ω
REMARK
4
Ground fault in wiring harness (Contact with ground circuit)
If no failure is found by check on cause 2, this check is not required. 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and M06, and connect T-adapter to either female side.
Resistance
5
Hot short circuit in wiring harness
Between ground and CP01 (female) (69) or M06 (female) (2)
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M06.
3.
Insert T-adapter into connector CP01, or connect T-adapter to female side of M06.
4.
Turn starting switch to ON position.
REMARK • If voltage is 0 V, wiring harness has open circuit, ground fault, or short cir-
cuit, and if voltage is 12 V, wiring harness has hot short circuit. • Voltage of approximately 5 V is applied to fuel level sensor signal circuits
through resistor in machine controller. Voltage 6
Defective machine controller
40-230
Between ground and CP01 (69) or M06 (female) (2)
Approx. 5 V
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum
Circuit Diagram of Fuel Level Sensor
PC45MR-5, PC55MR-5
40-231
E-11 Display of Fuel Gauge is Different from Actual Fuel Level
40 Troubleshooting
E-11 Display of Fuel Gauge is Different from Actual Fuel Level Failure
Display of fuel gauge differs from actual fuel level.
Related
•
information
Signal voltage of fuel sensor can be checked with monitoring function (Code: 04200)
No.
Cause
1
Defective fuel level sensor
40-232
Procedure, measuring location, criteria and remarks Perform the check on cause 1 of “The pointer of fuel gauge does not move from minimum or maximum”
PC45MR-5, PC55MR-5
E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
40 Troubleshooting
E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum Failure
Engine coolant temperature gauge indication does not move from minimum or maximum. •
Signal of engine coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor via machine controller through CAN communication system.
•
Engine coolant temperature can be checked with monitoring function. (Code: 04107)
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective engine coolant temperature sensor system
Coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [#B0117] and [#B0118].
2
Defective machine monitor
PC45MR-5, PC55MR-5
If failure code still displays after above checks on Cause 1, machine monitor may be defective. (In case of an internal defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
40-233
E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature
40 Troubleshooting
E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature Failure
Engine coolant temperature gauge does not indicate correct temperature •
Signal of engine coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor via machine controller through CAN communication system.
•
Engine coolant temperature can be checked with monitoring function. (Code: 04107)
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective engine coolant temperature sensor system
Coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [#B0117] and [#B0118].
40-234
PC45MR-5, PC55MR-5
40 Troubleshooting
E-14 Some Areas of Machine Monitor Screen are Not Shown
E-14 Some Areas of Machine Monitor Screen are Not Shown Failure
•
Some areas of machine monitor screen are not displayed.
Related information No.
1
2
Cause Defective machine monitor (Liquid crystal display panel part)
Defective machine monitor
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks Perform troubleshooting when starting switch is in ON position. When all the lights of liquid crystal display panel is on (entirely white) by the following switch operation, machine monitor is normal. •
Switch operation: While pressing [F8], press [F6] and then release [F6] only.
If failure code still displays after above checks on Cause 1, machine monitor may be defective. (In case of an internal defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
40-235
E-15 Function Switch Does Not Operate
40 Troubleshooting
E-15 Function Switch Does Not Operate Failure
Function switch does not work.
Related
•
information
Signal state of function switch can be checked with monitoring function. (Code: 04507, 04508)
No.
Cause
1
Defective machine monitor
40-236
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Because this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40 Troubleshooting
E-16 Auto-Decelerator is Not Operated or Canceled with Lever
E-16 Auto-Decelerator is Not Operated or Canceled with Lever Failure Related information No.
1
Auto-deceleration function does not operate or is not canceled while lever is operated. •
Since set engine speed for auto-deceleration is 1225 min-1 {1225 rpm}, auto-deceleration is not actuated or canceled if engine speed set with fuel control dial is below this speed.
•
Pressure switch signal can be checked with monitoring function.(Code:01900)
Cause
Procedure, measuring location, criteria and remarks 1.
Start the engine and perform troubleshooting (with monitoring function).
2.
If display of monitoring is incorrect, perform troubleshooting for “MONITORING FUNCTION DOES NOT INDICATE *** CORRECTLY” in E mode.
Defective PPC oil pressure signal Monitoring display
Travel (when lever is operated)
ON
Travel (when lever is in NEUTRAL)
OFF
Swing or arm IN (when lever is operated)
ON
Swing or arm IN (when lever is in NEUTRAL)
OFF
Work equipment (when any lever of boom, arm, bucket, blade, boom swing, and service is operated)
ON
Work equipment (when any lever of boom, arm, bucket, blade, boom swing, and service is in NEUTRAL)
OFF
2
Defective machine monitor
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
4
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is ler an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
40-237
E-17 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
40 Troubleshooting
E-17 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed Failure
Setting of engine and hydraulic pump is not changed when working mode is changed.
Related information No.
Cause
1
Defective machine monitor
Machine monitor may be defective. (Because this is an internal defect, troubleshooting cannot be performed.)
2
Defective machine controller
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-238
Procedure, measuring location, criteria and remarks
PC45MR-5, PC55MR-5
E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change
40 Troubleshooting
E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change Failure Related information
No. 1
2
Travel speed does not change after the travel speed is changed. •
As T-adapter for machine controller connector is “socket-type box”, operating voltage cannot be measured at machine controller connector.
•
If failure code [DW43KA], [DW43KB], or [DW43KY] is displayed, perform troubleshooting for these failure codes first.
Cause Defective fuse
Defective selector switch for 2nd travel speed (internal open circuit or short circuit)
Procedure, measuring location, criteria and remarks If fuse No.5 in fuse box FB1 is blown out, circuit probably has ground fault. (See ground fault (contact to ground circuit) of wiring harness.) 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F38, and connect T-adapter to male side.
REMARK Switch ON: Push Switch OFF: Release
Resistance
1. 3
Open circuit in wiring har- 2. ness
Between F38 (male) (1) and (2)
Turn the starting switch to OFF position.
Min. 1 MΩ
Turn the starting switch to ON position.
Max. 1 Ω
Turn the starting switch to OFF position. Disconnect connectors F38 and CP01, and connect T-adapter to each female side.
(Wire breakage or defective contact of connector) Resistance
Between FB1 (5) and F38 (female) (1)
Max. 1 Ω
Between F38 (female) (2) and CP01 (female) (61)
Max. 1 Ω
If fuse is not blown out, this check is not required. 1. Turn the starting switch to OFF position. 4
Ground fault in wiring harness (Contact with ground circuit)
2.
Remove fuse FB1 (5).
3.
Disconnect connectors F38 and CP02, and connect T-adapter to each female side.
Resistance 5
Defective machine controller
PC45MR-5, PC55MR-5
Between ground and FB1 (5) or F38 (female) (1)
Min. 1 MΩ
Between F38 (female) (2) and ground
Min. 1 MΩ
If no failure is found by preceding checks, work equipment controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-239
E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change
40 Troubleshooting
Circuit Diagram Related to Travel Speed Solenoid
40-240
PC45MR-5, PC55MR-5
40 Troubleshooting
E-19 Alarm Buzzer Does Not Sound
E-19 Alarm Buzzer Does Not Sound Failure
Related information
No.
1
2
Alarm buzzer does not sound. •
When turning the starting switch from OFF to ON position, buzzer sound by self check is not heard (for 2 seconds).
•
When travel speed increasing switch and function switch are pressed while starting switch is in ON position, no switching sound is heard (short sound).
•
Check that fuse FB1 (5) is not blown out before performing troubleshooting.
Cause
Defective alarm buzzer
Open circuit in wiring harness (wire breakage or defective contact)
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Insert T-adapter in connector F28, and connect T-adapter box to it.
3.
Turn the starting switch to ON position.
4.
Connect No.1 of T-adapter box to the ground.
Buzzer sound
It sounds only when connected,
Voltage
Between F28 (2) and ground
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors F15 and F28, and connect T-adapter to each female side.
Resistance
3
Defective machine monitor
10 to 15 V
Between F15 (female) (5) and F28 (female) (1)
Max. 1 Ω
Between FB1 (5) and F28 (female) (2)
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector F15, and connect T-adapter and T-adapter box to female side.
3.
Turn the starting switch to ON position.
4.
Connect No.5 of T-adapter box to the ground.
Buzzer sound
It sounds only when connected,
Circuit Diagram Related to Alarm Buzzer
PC45MR-5, PC55MR-5
40-241
E-20 Alarm Buzzer Cannot be Canceled
40 Troubleshooting
E-20 Alarm Buzzer Cannot be Canceled Failure Related information No.
1
2
Alarm buzzer does not stop sounding. Check that fuse FB1 (5) is not blown out before performing troubleshooting. Cause
Defective machine monitor
Ground fault in wiring harness (contact with ground circuit)
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector F15.
Buzzer sound
It stops sounding.
Turn the starting switch to ON position.
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors F15 and F28, and connect T-adapter to either female side.
Resistance
Between ground and F15 (female) (5) or F28 (female) (1)
Min. 1 MΩ
Circuit Diagram Related to Alarm Buzzer
40-242
PC45MR-5, PC55MR-5
E-21 Service Meter is Not Shown, While Starting Switch is in OFF Position
40 Troubleshooting
E-21 Service Meter is Not Shown, While Starting Switch is in OFF Position Failure
Service meter is not displayed while starting switch is in OFF position.
Related
•
information No.
1
The following switch operation with the starting switch set to OFF position displays a service meter in the middle of the screen. Operation of switches: [F2]+[F3] (pressed simultaneously)
Cause
Defective backup power supply system
Procedure, measuring location, criteria and remarks When starting switch is turned to ON position and machine monitor displays nothing, backup power supply system may be defective and perform the following troubleshooting: • E-mode “WHEN STARTING SWITCH IS TURNED TO ON POSITION,
MACHINE MONITOR DISPLAYS NOTHING”
2
Defective machine monitor
PC45MR-5, PC55MR-5
If failure code still displays after above checks on Cause 1, machine monitor may be defective. (In case of an internal defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
40-243
E-22 Service Mode Cannot be Selected
40 Troubleshooting
E-22 Service Mode Cannot be Selected Failure Related information
Service mode cannot be selected. See “TESTING AND ADJUSTING”, “SERVICE MODE”
No.
Cause
1
Defective machine monitor
40-244
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Because this is an internal defect, troubleshooting cannot be performed.)
PC45MR-5, PC55MR-5
E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move
40 Troubleshooting
E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move Failure Related information No.
None of work equipment, swing or travel works. •
As for PPC lock lever relay system, troubleshooting is performed by failure codes [DKULKA] and [DKULKB].
•
As for PPC lock switch system, troubleshooting is performed by failure code [DDNRKA].
Cause
Procedure, measuring location, criteria and remarks If fuse No.3 in fuse box FB1 is blown out, circuit probably has ground fault. (See ground fault (contact to ground circuit) of wiring harness.)
1
Defective fuse
2
Defective PPC lock switch (internal open)
Perform troubleshooting for failure code [DDNRKA].
Defective PPC lock relay (internal open or short circuit)
Perform troubleshooting for failure codes [DKULKA] and [DKULKB].
3
4
5
Defective PPC lock solenoid
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M18, and connect T-adapter to male side.
(Internal open, short circuit, or ground fault)
Resistance
Defective diode array D01
Between M18 (male) (1) and ground
Min. 1 MΩ
Turn starting switch to OFF position.
2.
Disconnect connector D01 and connect T-adapter to male side.
REMARK Measure it with diode range of multimeter. Continuity
6
8 to 15 Ω
1.
(Internal ground fault)
Open or short circuit in wiring harness
Between M18 (male) (1) and (2)
Between D01 (male) (5) (+) and (1) (-)
Continuity
Between D01 (male) (1) (+) and (5) (-)
No continuity
1.
Turn the starting switch to OFF position.
2.
Disconnect connector R02, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Set the lock lever to FREE position.
Resistance Voltage
Between R02 (female) (5) and ground (Resistance of PPC lock solenoid) Between R02 (female) (3) and ground
8 to 15 Ω Min. 10 V
If no failure is found by check on cause 6, this check is not required. 1. Turn the starting switch to OFF position.
7
Open circuit in wiring harness
2.
Remove fuse No.3.
3.
Disconnect connectors F09, M18, and R02, and connect T-adapter to each female side.
Resistance
PC45MR-5, PC55MR-5
Between M18 (female) (2) and ground
Max. 1 Ω
Between M18 (female) (1) and R02 (female) (5)
Max. 1 Ω
Between R02 (female) (3) and F09 (male) (B)
Max. 1 Ω
Between FB1 (3) and F09 (male) (A)
Max. 1 Ω
40-245
E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 1, this check is not required. 1. Turn the starting switch to OFF position.
8
Ground fault in wiring harness
2.
Remove fuse No.3.
3.
Disconnect connectors F09, D01, and M18, and then connect T-adapter to male side of F09 or female side of M18.
(Contact with ground circuit)
Between ground and M18 (female) (1) or R02 (female) Min. 1 MΩ (5) Resistance
Between ground and R02 (female) (3) or F09 (male) (B)
Min. 1 MΩ
Between F09 (male) (A) and ground
Min. 1 MΩ
Circuit Diagram of PPC Lock Switch
40-246
PC45MR-5, PC55MR-5
E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock
40 Troubleshooting
E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock Failure Related information
Any of work equipment, swing, and travel cannot be locked. •
As for PPC lock lever relay system, troubleshooting is performed by failure code [DKULKY].
•
As for PPC lock switch system, troubleshooting is performed by failure code [DDNRKY].
No.
Cause Defective PPC lock switch (internal short circuit)
Perform troubleshooting for failure code [DDNRKY].
1
Defective PPC lock lever relay (internal short circuit)
Perform troubleshooting for failure code [DKULKY].
2
3
Procedure, measuring location, criteria and remarks
1.
Turn the starting switch to OFF position.
Hot short circuit in wiring harness
2.
Disconnect connector M18, and connect T-adapter to female side.
(Contact with 12 V circuit)
3.
Turn the starting switch to ON position.
4.
Turn the lock lever to LOCK position.
Voltage
PC45MR-5, PC55MR-5
Between M18 (female) (2) and (1)
Max.1 V
40-247
E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock
40 Troubleshooting
Circuit Diagram of PPC Lock Switch
40-248
PC45MR-5, PC55MR-5
40 Troubleshooting
E-25 Alarm Does Not Sound During Travel
E-25 Alarm Does Not Sound During Travel Failure Related information No.
Alarm does not sound during travel. Work in pairs. Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting when starting switch is at OFF position and engine is running.
1
Defective travel signal
If monitoring data is not displayed normally, perform troubleshooting for ““Travel” is not displayed correctly with monitoring function” in E mode. Monitoring display
2
Defective travel alarm (Internal defect)
01900: Pressure switch 1
Travel signal
ON
Travel signal (when lever is in NEUTRAL)
OFF
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M08, and connect T-adapter to female side.
3.
Start the engine, and operate the travel lever.
k When driving machine, do not measure under the machine.
REMARK If the voltage is normal but the alarm does not sound, travel alarm is defective. Voltage 1.
3
4
Open circuit in wiring har- 2. ness
(Contact with ground circuit)
PC45MR-5, PC55MR-5
10 to 15 V
Turn the starting switch to OFF position. Disconnect connectors M08 and CP02, and connect T-adapters to each female side.
(Wire breakage or defective contact of connector) Resistance
Ground fault in wiring harness
Between M08 (female) (1) and (2)
Between CP02 (female) (86) and M08(female) (1)
Max. 1 Ω
Between M08 (female) (2) and ground
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP02 and M08, and connect T-adapter to either female side.
Resistance
Between CP02 (female) (86) and ground, or M08 (female) (1) and ground
Min. 1 MΩ
40-249
E-25 Alarm Does Not Sound During Travel
40 Troubleshooting
Circuit Diagram of Travel Alarm
40-250
PC45MR-5, PC55MR-5
40 Troubleshooting
E-26 Travel Alarm Does Not Stop When Machine Stops
E-26 Travel Alarm Does Not Stop When Machine Stops Failure
Alarm does not stop sounding while machine is stopped.
Related information No.
Cause
1
Defective travel PPC oil pressure sensor system (internal open or short circuit)
2
Hot short circuit in wiring harness (Contact with 12 V circuit)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DHS5MA].
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M08, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage
Between M08 (female) (1) and ground
Max. 1 V
Circuit Diagram of Travel Alarm
PC45MR-5, PC55MR-5
40-251
E-27 Horn Does Not Sound
40 Troubleshooting
E-27 Horn Does Not Sound Failure
Horn does not sound.
Related information No. 1
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse FB1-5 is blown out, the circuit probably has ground fault. In this case, perform check on cause 7 first. 1.
2
Turn starting switch to OFF position.
Defective horn relay
2.
Replace horn relay (connector: R03) with another relay.
(Internal open or short circuit)
3.
Turn starting switch to ON position.
4.
Press R.H. knob switch.
If horn sounds, original horn relay is defective.
3
4
1.
Turn starting switch to OFF position.
Defective horn switch
2.
Disconnect connector F13 and connect T-adapter to male side.
(Internal open or short circuit)
Resistance
Defective horn (internal open or short circuit)
Defective wiring harness
Switch: OFF
Min. 1 MΩ
Switch: ON
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M01 and connect T-adapters to each male side.
Continuity
5
Between F13 (male) (1) and (2)
Between M01 (male) (1) and (2)
Continuity
1.
Turn the starting switch to OFF position.
2.
Disconnect connector R03, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Press R.H. knob switch.
Voltage
Between R03 (female) (1) and (2)
10 to 15 V
Between R03 (female) (3) and (2)
10 to 15 V
1.
Turn the starting switch to OFF position.
2.
Disconnect connector R03, and connect T-adapter to female side.
Continuity
Between R03 (female) (2) and ground
Continuity
Between R03 (female) (5) and ground
Continuity
If no failure is found by check on cause 5 or preceding check, this check is not required. 1. Turn the starting switch to OFF position. 6
Open circuit in wiring har- 2. ness (wire breakage or 3. defective contact)
Remove fuse FB1-5. Disconnect connectors F13, R03, and M01, and connect T-adapter to each connector.
Resistance
40-252
Between FB1 (5) and F13 (female) (2)
Max. 1 Ω
Between F13 (female) (1) and R03 (female) (1)
Max. 1 Ω
Between R03 (female) (2) and ground
Max. 1 Ω
Between FB1 (5) and R03 (female) (3)
Max. 1 Ω
Between R03 (female) (5) and M01 (female) (1)
Max. 1 Ω
Between M01 (female) (2) and ground
Max. 1 Ω
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
E-27 Horn Does Not Sound
Cause
Procedure, measuring location, criteria and remarks If fuse is not blown out, this check is not required. 1. Turn the starting switch to OFF position.
7
2.
Remove fuse FB1-5.
3.
Disconnect connectors F13, R03, and M01, and connect T-adapter to each female side.
Ground fault in wiring harness (contact with ground circuit)
Resistance
Between ground and F13 (female) (2) or R03 (female) (3)
Min. 1 MΩ
Between ground and F13 (female) (1) or R03 (female) (1)
Min. 1 MΩ
Between ground and R03 (female) (5) or M01 (female) Min. 1 MΩ (1) 8
Defective horn (internal defect)
If no failure is found by above checks, horn may be defective.
Circuit Diagram of Horn
PC45MR-5, PC55MR-5
40-253
E-28 Horn Does Not Sound (For Proportional Lever Spec)
40 Troubleshooting
E-28 Horn Does Not Sound (For Proportional Lever Spec) Failure
Horn does not sound (for proportional lever spec).
Related information No. 1
Cause Defective fuse
Procedure, measuring location, criteria and remarks If fuse FB1-5 is blown out, the circuit probably has ground fault. In this case, perform check on cause 7 first. 1.
2
Turn starting switch to OFF position.
Defective horn relay
2.
Replace horn relay (connector: R03) with another relay.
(Internal open or short circuit)
3.
Turn starting switch to ON position.
4.
Press R.H. knob switch.
If horn sounds, original horn relay is defective.
3
4
1.
Turn starting switch to OFF position.
Defective horn switch
2.
Disconnect connector F26 and connect T-adapter to male side.
(Internal open or short circuit)
Resistance
Defective horn (internal open or short circuit)
Defective wiring harness
Switch: OFF
Min. 1 MΩ
Switch: ON
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M01 and connect T-adapters to each male side.
Continuity
5
Between F26 (male) (7) and (6)
Between M01 (male) (1) and (2)
Continuity
1.
Turn the starting switch to OFF position.
2.
Disconnect connector R03, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Press R.H. knob switch.
Voltage
Between R03 (female) (1) and (2)
10 to 15 V
Between R03 (female) (3) and (2)
10 to 15 V
1.
Turn the starting switch to OFF position.
2.
Disconnect connector R03, and connect T-adapter to female side.
Continuity
Between R03 (female) (2) and ground
Continuity
Between R03 (female) (5) and ground
Continuity
If no failure is found by check on cause 5 or preceding check, this check is not required. 1. Turn the starting switch to OFF position. 6
Open circuit in wiring har- 2. ness (wire breakage or 3. defective contact)
Remove fuse FB1-5. Disconnect connectors F26, R03, and M01, and connect T-adapter to each connector.
Resistance
40-254
Between FB1 (5) and F26 (female) (6)
Max. 1 Ω
Between F26 (female) (7) and R03 (female) (1)
Max. 1 Ω
Between R03 (female) (2) and ground
Max. 1 Ω
Between FB1 (5) and R03 (female) (3)
Max. 1 Ω
Between R03 (female) (5) and M01 (female) (1)
Max. 1 Ω
Between M01 (female) (2) and ground
Max. 1 Ω
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
E-28 Horn Does Not Sound (For Proportional Lever Spec)
Cause
Procedure, measuring location, criteria and remarks If fuse is not blown out, this check is not required. 1. Turn the starting switch to OFF position.
7
Ground fault in wiring harness
2.
Remove fuse FB1-5.
3.
Disconnect connectors F26, R03, and M01, and connect T-adapter to each female side.
(Contact with ground circuit) Resistance
Between ground and F26 (female) (6) or R03 (female) (3)
Min. 1 MΩ
Between ground and F26 (female) (7) or R03 (female) (1)
Min. 1 MΩ
Between ground and R03 (female) (5) or M01 (female) Min. 1 MΩ (1) 8
Defective horn (internal defect)
If no failure is found by above checks, horn may be defective.
Circuit Diagram Related to Horn (For Proportional Lever Spec)
PC45MR-5, PC55MR-5
40-255
E-29 Horn Does Not Stop
40 Troubleshooting
E-29 Horn Does Not Stop Failure
Horn does not stop sounding.
Related information No.
1
Cause
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to OFF position.
2.
Disconnect connector F13 and connect T-adapter to male side.
Defective horn switch
Resistance
2
Between F13 (male) (1) and (2)
Switch: OFF
Min. 1 MΩ
Switch: ON
Max. 1 Ω
1.
Turn starting switch to OFF position.
Defective horn relay
2.
(Internal open or short circuit)
Remove horn relay (connector R03).
3.
Turn starting switch to ON position.
If horn stops sounding, the original horn relay is defective.
3
Hot short circuit in wiring harness (Contact with 12 V circuit)
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors M01 and R03, and connect T-adapter to each female side.
3.
Turn the starting switch to ON position.
Voltage
40-256
Between M01 (female) (2) and (1)
Max. 1 V
Between R03 (female) (1) and (2)
Max. 1 V
PC45MR-5, PC55MR-5
40 Troubleshooting
E-29 Horn Does Not Stop
Circuit Diagram of Horn
PC45MR-5, PC55MR-5
40-257
E-30 Horn Does Not Stop (For Proportional Lever Spec)
40 Troubleshooting
E-30 Horn Does Not Stop (For Proportional Lever Spec) Failure
Horn does not stop sounding (for proportional lever spec).
Related information No.
1
2
Cause
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to OFF position.
Defective horn switch
2.
Disconnect connector F26 and connect T-adapter to male side.
(Internal open or short circuit)
Resistance
Between F26 (male) (7) and (6)
Switch: OFF
Min. 1 MΩ
Switch: ON
Max. 1 Ω
1.
Turn starting switch to OFF position.
Defective horn relay
2.
(Internal open or short circuit)
Remove horn relay (connector R03).
3.
Turn starting switch to ON position.
If horn stops sounding, the original horn relay is defective.
3
Hot short circuit in wiring harness (Contact with 12 V circuit)
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors F26, R03, and M01, and connect T-adapter to each female side.
3.
Turn the starting switch to ON position.
Voltage
40-258
Between R03 (female) (1) and (2)
Max. 1 V
Between M01 (female) (2) and (1)
Max. 1 V
PC45MR-5, PC55MR-5
40 Troubleshooting
E-30 Horn Does Not Stop (For Proportional Lever Spec)
Circuit Diagram Related to Horn (For Proportional Lever Spec)
PC45MR-5, PC55MR-5
40-259
E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec)
40 Troubleshooting
E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec) Failure
Working lamp or travel lamp does not light up (canopy spec).
Related information
If working lamp relay or working lamp switch or diode or common wiring harness of working lamp and travel lamp is defective, neither working lamp nor travel lamp does not light up. (If either of them lights up, check the cause on these failures is not required.)
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective working lamp or travel lamp
Since working lamp and travel lamp may be defective, check their bulbs for burnedout.
2
Defective fuse
If fuse No.1 and No.11 in fuse box FB1 are blown out, circuit probably has ground fault, etc. Accordingly, perform troubleshooting for “Ground fault of wiring harness” first. 1.
3
Defective working lamp relay (Internal open or short circuit)
Turn the starting switch to OFF position.
2.
Replace working lamp relay R04 with another one.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
If working lamp lights up, original working lamp relay is defective.
4
1.
Turn the starting switch to OFF position.
2.
Disconnect connector S02, and connect T-adapter to male side.
3.
Turn the working lamp switch to ON/OFF position to perform troubleshooting. (ON is available for both directions.)
Defective working lamp switch
Between S02 (male) (5) and (6)
OFF
Min. 1 MΩ
ON
Max. 1 Ω
Between S02 (male) (5) and (4)
OFF
Min. 1 MΩ
ON
Max. 1 Ω
Resistance
1.
Turn the starting switch to OFF position.
2.
Disconnect connector D01, and connect T-adapter to male side.
REMARK Defective diode 5
Measure it with diode range of multimeter.
(internal open or short circuit) Continuity
40-260
Between D01 (male) (3) (+) and (7) (-)
No continuity
Between D01 (male) (7) (+) and (3) (-)
Continuity
Between D01 (male) (4) (+) and (8) (-)
No continuity
Between D01 (male) (8) (+) and (4) (-)
Continuity
PC45MR-5, PC55MR-5
E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec)
40 Troubleshooting
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors W02 and W03, and connect T-adapter to each female side.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
Voltage
Between W02 (female) (A) and (B)
10 to 15 V
Between W03 (female) (1) and (2)
10 to 15 V
If no failure is found by preceding checks, this check is not required. 1. Turn the starting switch to OFF position.
6
Open or short circuit in wiring harness
2.
Disconnect connector W01, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
Voltage
Between W01 (female) (1) and (2)
10 to 15 V
If no failure is found by preceding checks, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect connector R04, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
Voltage
Between R04 (female) (1) and (2)
10 to 15 V
Between R04 (female) (3) and (2)
10 to 15 V
If no failure is found by preceding checks, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect connector S02, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage
PC45MR-5, PC55MR-5
Between S02 (female) (5) and (2)
10 to 15 V
40-261
E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec)
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 6, this check is not required. 1. Turn the starting switch to OFF position.
7
2.
Remove fuses FB1 (1) and FB1 (11).
3.
Disconnect connectors S02, D01, R04, F03, W02, and W03, and connect T-adapter to each female side.
Open circuit in wiring harness (wire breakage or defective contact of connector) Resistance
Between W02 (female) (B) and ground
Max. 1 Ω
Between W03 (female) (2) and ground
Max. 1 Ω
Between W02 (female) (A) and R04 (female) (5)
Max. 1 Ω
Between W03 (female) (2) and R04 (female) (5)
Max. 1 Ω
Between R04 (female) (1) and D01 (female) (3)
Max. 1 Ω
Between R04 (female) (1) and D01 (female) (4)
Max. 1 Ω
Between R04 (female) (2) and ground
Max. 1 Ω
Between R04 (female) (3) and FB1 (11)
Max. 1 Ω
Between D01 (female) (7) and each of S02 (female) (1) and (6)
Max. 1 Ω
Between S02 (female) (2) and ground
Max. 1 Ω
Between D01 (female) (8) and each of S02 (female) (3) and (4)
Max. 1 Ω
Between S02 (female) (5) and FB1 (1)
Max. 1 Ω
If no failure is found by check on cause 6, this check is not required. 1. Turn the starting switch to OFF position.
8
Ground fault in wiring harness
2.
Remove fuses FB1 (1) and FB1 (11).
3.
Disconnect connectors S02, D01, R04, W02, and W03, and connect Tadapter to female side of S02 and R04.
(contact with ground circuit) Resistance
40-262
Between R04 (female) (1) and ground
Min. 1 MΩ
Between R04 (female) (3) and ground
Min. 1 MΩ
Between R04 (female) (5) and ground
Min. 1 MΩ
Between S02 (female) (5) and ground
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec)
Circuit Diagram Related to Working Lamp and Travel Lamp
PC45MR-5, PC55MR-5
40-263
E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec)
40 Troubleshooting
E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec) Failure
None of working lamp, travel lamp, or additional lamp lights up (cab spec).
Related
If working lamp switch or diode or common wiring harness of working lamp, travel lamp, and additional lamp is defective, none of working lamp, travel lamp, or additional lamp lights up. (If any of them lights up, check the cause on these failures is not required.)
information
REMARK Additional lamp is optional for cab spec.
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective working lamp, travel lamp, or additional lamp
Since working lamp, travel lamp, or additional lamp may be defective, check their bulbs for burned-out.
2
Defective fuse
3
Defective working lamp relay (Internal open or short circuit)
If fuse No.1 and No.11 in fuse box FB1 are blown out, circuit probably has ground fault, etc. Accordingly, perform troubleshooting for “Ground fault of wiring harness” first. 1.
Turn the starting switch to OFF position.
2.
Replace working lamp relay R04 with another one.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
If working lamp lights up, original working lamp relay is defective. 1.
4
5
Turn the starting switch to OFF position.
2. Replace additional lamp relay R05 with another one. Defective additional lamp 3. Turn the starting switch to ON position. relay (Internal open or short 4. Turn on the working lamp switch. circuit) If travel lamp and additional lamp light up, original additional lamp relay is defective. 1.
Turn the starting switch to OFF position.
2.
Disconnect connector S02, and connect T-adapter to male side.
3.
Turn the working lamp switch to ON/OFF position to perform troubleshooting. (ON is available for both directions.)
Defective working lamp switch
Between S02 (male) (5) and (6)
OFF
Min. 1 MΩ
ON
Max. 1 Ω
Between S02 (male) (5) and (4)
OFF
Min. 1 MΩ
ON
Max. 1 Ω
Resistance
1.
Turn the starting switch to OFF position.
2.
Disconnect connector D01, and connect T-adapter to male side.
REMARK Defective diode 6
Measure it with diode range of multimeter.
(internal open or short circuit) Continuity
40-264
Between D01 (male) (3) (+) and (7) (-)
No continuity
Between D01 (male) (7) (+) and (3) (-)
Continuity
Between D01 (male) (4) (+) and (8) (-)
No continuity
Between D01 (male) (8) (+) and (4) (-)
Continuity
PC45MR-5, PC55MR-5
E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec)
40 Troubleshooting
No.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connectors W02, F22A, and F22B, and connect T-adapter to each female side.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
Voltage
Between W02 (female) (A) and (B)
10 to 15 V
Between F22A (female) (1) and (2)
10 to 15 V
Between F22B (female) (1) and (2)
10 to 15 V
If no failure is found by preceding checks, this check is not required. 1. Turn the starting switch to OFF position.
7
Open or short circuit in wiring harness
2.
Disconnect connector W01, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
Voltage
Between W01 (female) (1) and (2)
10 to 15 V
Between F22 (female) (1) and (2)
10 to 15 V
If no failure is found by preceding checks, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect connectors R04 and R05, and connect T-adapter to each female side.
3.
Turn the starting switch to ON position.
4.
Turn on the working lamp switch.
Voltage
Between R04 (female) (1) and (2)
10 to 15 V
Between R04 (female) (3) and (2)
10 to 15 V
Between R05 (female) (1) and (2)
10 to 15 V
Between R05 (female) (3) and (2)
10 to 15 V
If no failure is found by preceding checks, this check is not required. 1. Turn the starting switch to OFF position. 2.
Disconnect connector S02, and connect T-adapter to female side.
3.
Turn the starting switch to ON position.
Voltage
PC45MR-5, PC55MR-5
Between S02 (female) (5) and (2)
10 to 15 V
40-265
E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec)
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks If no failure is found by check on cause 7, this check is not required. 1. Turn the starting switch to OFF position.
8
2.
Remove fuses FB1 (1) and FB1 (11).
3.
Disconnect connectors S02, D01, R04, R05, F03, W02, F22A, and F22B, and connect T-adapter to each female side.
Open circuit in wiring harness (wire breakage or defective contact of connector) Resistance
Between W02 (female) (B) and ground
Max. 1 Ω
Between F22A (female) (1) and ground
Max. 1 Ω
Between F22B (female) (1) and ground
Max. 1 Ω
Between W02 (female) (A) and R04 (female) (5)
Max. 1 Ω
Between F22A (female) (2) and R05 (female) (5)
Max. 1 Ω
Between F22B (female) (2) and R05 (female) (5)
Max. 1 Ω
Between R04 (female) (1) and D01 (female) (3)
Max. 1 Ω
Between R04 (female) (1) and D01 (female) (4)
Max. 1 Ω
Between R05 (female) (1) and D01 (female) (3)
Max. 1 Ω
Between R05 (female) (1) and D01 (female) (4)
Max. 1 Ω
Between R04 (female) (2) and ground
Max. 1 Ω
Between R05 (female) (2) and ground
Max. 1 Ω
Between R04 (female) (3) and FB1 (11)
Max. 1 Ω
Between R05 (female) (3) and FB1 (11)
Max. 1 Ω
Between D01 (female) (7) and each of S02 (female) (1) and (6)
Max. 1 Ω
Between S02 (female) (2) and ground
Max. 1 Ω
Between D01 (female) (8) and each of S02 (female) (3) and (4)
Max. 1 Ω
Between S02 (female) (5) and FB1 (1)
Max. 1 Ω
If no failure is found by check on cause 7, this check is not required. 1. Turn the starting switch to OFF position.
9
Ground fault in wiring harness
2.
Remove fuses FB1 (1) and FB1 (11).
3.
Disconnect connectors S02, D01, R04, R05, F03, W02, F22A, and F22B, and connect T-adapter to female side of S02 and R04.
(contact with ground circuit) Resistance
40-266
Between ground and R04 (female) (1) or R05 (1)
Min. 1 MΩ
Between ground and R04 (female) (3) or R05 (3)
Min. 1 MΩ
Between ground and R04 (female) (5) or R05 (5)
Min. 1 MΩ
Between S02 (female) (5) and ground
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec)
Circuit Diagram Related to Working Lamp, Travel Lamp, and Additional Lamp
PC45MR-5, PC55MR-5
40-267
E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate
40 Troubleshooting
E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate Failure
Wiper does not operate even if wiper switch is operated.
Related information
When engine starts (If engine does not start, perform troubleshooting for “Engine does not start (Engine does not crank)” in E mode first.
No.
Cause
1
2
Defective fuse
Defective wiper switch (internal open circuit or defective contact)
Procedure, measuring location, criteria and remarks If fuse FB1 (No.4) is blown out, circuit probably has ground fault, etc. 1.
Turn the starting switch to OFF position.
2.
Disconnect terminal of wiper switch.
Resistance
1.
4
OFF: (No operation)
Max. 1 Ω
Between terminal (2) and (3)
ON: (First stage)
Max. 1 Ω
Between terminal (3) and (4)
WASH: (2nd stage)
Max. 1 Ω
Install terminal wiring, and perform troubleshooting when starting switch is in ON position.
Voltage
3
Between terminal (1) and (2)
Between terminal (2) and ground
ON: (First stage)
1.
Turn the starting switch to OFF position.
2.
Disconnect terminal of wiper switch.
10 to 15 V
Open circuit in wiring harness
Between FB1 (4) and F24 (1), between F24 (1) and F27 (4), between F27 (4) and wiper switch terminal (3)
Max. 1 Ω
(Wire breakage or defective contact of connector) Resistance
Between wiper switch terminal (2) and wiper motor (+)
Max. 1 Ω
Between wiper motor (-) and F27 (1), between F27 (1) and F24 (2), between F24 (2) and F02 (2), between F02 (2) and ground
Max. 1 Ω
Ground fault in wiring harness (Contact with ground circuit)
40-268
1.
Turn the starting switch to OFF position.
2.
Disconnect terminal of wiper switch.
Resistance
Between ground and FB1 (4) or wiper switch terminal (3)
Min. 1 MΩ
Between ground and wiper switch terminal (2) or wiper Min. 1 MΩ motor (+)
PC45MR-5, PC55MR-5
40 Troubleshooting
E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate
Circuit Diagram of Windshield Wiper
PC45MR-5, PC55MR-5
40-269
E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate
40 Troubleshooting
E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate Failure Related information No.
1
Window washer does not operate even if window washer switch is operated. •
Before troubleshooting, check the fluid level inside of window washer tank.
•
When wiper operates. (If wiper does not operate, perform troubleshooting for “Wiper does not operate even if wiper switch is operated” in E mode first.)
Cause
Defective washer motor (internal defective contact)
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector M02, and connect T-adapter.
Resistance 1.
Turn the starting switch to OFF position.
2.
Connect T-adapter to connector M02.
3.
Turn the starting switch to ON position.
Voltage
2
Defective wiper switch (Internal defective contact)
Turn the starting switch to OFF position.
2.
Disconnect terminal of wiper switch.
Resistance 1.
Min. 1 MΩ
Between M02 (female) (2) and ground
1.
Between terminal (3) and (4)
10 to 15 V
WASH: (2nd stage)
Between terminal (4) and ground
WASH: (2nd stage)
Turn the starting switch to OFF position.
2.
Disconnect connector M02 and wiper switch terminal, and connect Tadapter to female side of M02.
Open circuit in wiring harness (wire breakage or defective contact)
Between M02 (female) (2) and F03 (4), between F03 (4) and F24 (3), between F24 (3) and F27 (3), between Max. 1 Ω F27 (3) and wiper switch terminal (4) Between M02 (female) (1) and ground
Ground fault in wiring harness (contact with ground circuit)
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M02 and wiper switch terminal, and connect Tadapter to female side of M02.
Resistance
40-270
10 to 15 V
1.
Resistance
4
Max. 1 Ω
Install terminal wiring, and perform troubleshooting when starting switch is in ON position.
Voltage
3
Between M02 (male) (1) and ground
Between ground and M02 (2) or wiper switch terminal (4)
Min. 1 MΩ
PC45MR-5, PC55MR-5
40 Troubleshooting
E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate
Circuit Diagram of Windshield Washer
PC45MR-5, PC55MR-5
40-271
E-35 Travel Indicator is Not Shown Correctly with Monitoring Function
40 Troubleshooting
E-35 Travel Indicator is Not Shown Correctly with Monitoring Function Failure Related information
“Travel” is not displayed correctly with monitoring function. Monitoring code: 01900
No.
Cause
1
Defective travel PPC oil pressure sensor system (internal open or short circuit)
40-272
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DHS5MA].
PC45MR-5, PC55MR-5
40 Troubleshooting
E-36 Swing or Arm IN is Not Shown Normally in Monitoring Function
E-36 Swing or Arm IN is Not Shown Normally in Monitoring Function Failure Related information No.
1
“Swing or Arm IN” is not displayed normally in monitoring function. Monitoring code: 01900 Cause
Defective swing PPC oil pressure sensor system
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DHS1MA].
(Internal open or short circuit)
PC45MR-5, PC55MR-5
40-273
E-37 Work Equipment is Not Shown Normally in Monitoring Function
40 Troubleshooting
E-37 Work Equipment is Not Shown Normally in Monitoring Function Failure Related information No.
“Work Equipment” is not displayed normally in monitoring function. Monitoring code: 01900 Cause
Procedure, measuring location, criteria and remarks Be ready with starting switch in OFF position, then start the engine to perform troubleshooting.
1
2
3
4
Defective work equipment PPC oil pressure switch (Internal open or short circuit)
Resistance
1. Open circuit in wiring har- 2. ness
(contact with ground circuit)
Short circuit or hot short circuit in wiring harness (contact with 12 V circuit)
Min. 1 MΩ
R.H. and L.H. work equipment control lever: Operate any of boom, arm, bucket, service, blade control lever, and boom swing control pedal.
Max. 1 Ω
Turn the starting switch to OFF position. Disconnect connectors CP01 and P01, and connect T-adapter to each female side.
(wire breakage or defective contact of connector) Resistance
Ground fault in wiring harness
Between P01 (male) (1) and (2)
R.H. and L.H. work equipment control lever: NEUTRAL
Between CP01 (female) (21) and P01 (female) (1)
Max. 1 Ω
Between P01 (female) (2) and ground (T02)
Max. 1 Ω
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and P01, and connect T-adapters to female side or P01.
Resistance
Between ground and CP01 (female) (21) or P01 (female) (1)
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connectors CP01 and P01, and connect T-adapter to either female side.
3.
Turn the starting switch to ON position.
Voltage
Between ground and CP01 (female) (21) or P01 (female) (1)
Max. 9 V
Be ready with starting switch in OFF position, then start the engine to perform troubleshooting.
5
Defective machine controller
40-274
Resistance
Between CP01 (female) (21) and ground
R.H. and L.H. work equipment control lever: NEUTRAL
Min. 1 MΩ
R.H. and L.H. work equipment control lever: Operate any of boom, arm, bucket, service, blade control lever, and boom swing control pedal.
Max. 1 Ω
PC45MR-5, PC55MR-5
40 Troubleshooting
E-37 Work Equipment is Not Shown Normally in Monitoring Function
Circuit Diagram Related to Work Equipment PPC Oil Pressure Switch
PC45MR-5, PC55MR-5
40-275
E-38 KOMTRAX System Does Not Operate Normally
40 Troubleshooting
E-38 KOMTRAX System Does Not Operate Normally Failure
KOMTRAX system does not operate normally. •
Perform following troubleshooting if administrator of KOMTRAX system requests to check whether failure occurs in system on machine.
•
Even when KOMTRAX system is defective, no problem is displayed on machine.
Related
•
All troubleshooting can be checked on the service menu of the machine monitor.
information
•
For checking of Terminal Status, see Testing and Adjusting, “Examine KOMTRAX Settings (Terminal State)”.
•
For checking of GPS & Communication State, see Testing and Adjusting, “Examine KOMTRAX Settings (GPS & Communication State)”.
No.
1
Cause
Transmitting error 1
Procedure, measuring location, criteria and remarks 1.
Turn starting switch to ON position.
2.
Display Terminal Status screen.
Monitoring display
2
Check item: KOMTRAX Communication
1.
Turn starting switch to ON position.
2.
Display GPS & Communication Status screen.
State of radio station establishment
N ###.##.## (Latitude)
Defective GPS positioning
Monitoring display
Check item: Positioning
E ###.##.## (Longitude) Positioning in Progress
If the latitude and longitude are not displayed within 5 minutes in an open-sky area, call the KOMTRAX service hot-line for advice.
3
1.
Turn starting switch to ON position.
2.
Display GPS & Communication Status screen.
Defective communication Monitoring display environment
Check item: Communication
Communication reception range level 1 to 3
Contact KOMTRAX service hot-line if communication reception range is not within level 1 to 3.
4
Transmitting error 2
1.
Turn starting switch to ON position.
2.
Display GPS & Communication Status screen.
Monitoring display
40-276
Check item: Number of message(s) not yet sent
0 to 100 (normally 0)
PC45MR-5, PC55MR-5
40 Troubleshooting
Information Shown in Troubleshooting Table (H-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) Information Shown in Troubleshooting Table (H-Mode) The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Failure
Failure symptom that appears on machine
Related inforInformation on occurred failure or troubleshooting mation No .
Cause
Procedure, measuring location, criteria, and remarks
1 2 3 4
Probable cause of failure (Each number is serial number, not priority sequence.)
<Contents of description> •
Criteria to determine probable causes
•
Remarks for determination of probable cause
5
PC45MR-5, PC55MR-5
40-277
H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate
40 Troubleshooting
H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate Failure
All work equipment, travel, swing or blade do not operate •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Before performing troubleshooting, check that electrical system (solenoid circuit) is normal.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of PPC lock solenoid valve
Solenoid valve outlet pressure
Lock lever: LOCK
0 MPa {0 kgf/cm2}
Lock lever: FREE
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Relief presIncorrect adjustment or malfunction of relief valve sure of con- All control levers: NEUTRAL trol circuit in control circuit
4.90 (+0.59/-0.1) MPa {50 (+6/-1) kgf/cm2}
When pressure cannot be adjusted to normal level, control relief valve may malfunction or may have internal defect. Check it. 3
Clogged suction strainer or return filter
If no failure is found by preceding checks, the strainer or return filter may be clogged. Check it.
4
Defective control pump
If no failure is found by preceding checks, control pump may be defective.
5
Defective main pump, drive shaft or damper
40-278
Disconnect the discharge hose of main pump and crank the engine with starting motor, and check if the oil flows out from the discharge port.
REMARK No-Injection cranking is required. For details of procedure, see Testing and Adjusting, “Examine Compression Pressure”.
PC45MR-5, PC55MR-5
40 Troubleshooting
H-2 All Work Equipment or Travel Does Not Operate
H-2 All Work Equipment or Travel Does Not Operate Failure
Related information
No.
All work equipments or travel does not operate •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that swing and blade operations are normal.
Cause
Procedure, measuring location, criteria and remarks When pressure cannot be adjusted to normal level, main relief valve may malfunction or may have internal defect. Check it.
1
Be ready with engine stopped, then perform troubleshooting with engine at high idle. Improper adjustment or malfunction of main relief 26.5 valve ± 0.98 MPa • Arm IN relief Main relief {270 pressure • Travel hydraulic relief ± 10 kgf/cm2 } Disconnect the discharge hose of main pump and crank the engine with starting motor, and check if the oil flows out from the discharge port.
2
Defective piston pump
REMARK No-Injection cranking is required. For details of procedure, see Testing and Adjusting, “Examine Compression Pressure”.
PC45MR-5, PC55MR-5
40-279
H-3 Travel or Blade Does Not Operate
40 Troubleshooting
H-3 Travel or Blade Does Not Operate Failure
Related information
No.
1
Travel or blade does not operate. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that all work equipments and swing operations are normal.
Cause
Defective center swivel joint
Procedure, measuring location, criteria and remarks 1.
Engine stopped
2.
Plug the hydraulic hose to travel or blade circuit at control valve side
3.
Engine at high idle
Main pump relief pressure
Swing and blade pump relief pressure
Travel lever circuit (at the side where hose is disconnected)
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
Blade lever circuit (at the side where hose is disconnected)
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If the oil pressure in all hydraulic circuits is low in all the preceding checks, center swivel joint may be defective. Check it.
40-280
PC45MR-5, PC55MR-5
40 Troubleshooting
H-4 Swing or Blade Does Not Operate
H-4 Swing or Blade Does Not Operate Failure
Related information
No.
Swing or blade does not operate. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that all work equipments and swing operations are normal.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Improper adjustment or malfunction of swing and blade pump relief valve
Swing and blade pump relief pressure
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade pump may malfunction or may have internal defect. Check it.
2
Defective swing and blade pump, drive shaft or coupling
PC45MR-5, PC55MR-5
Disconnect the discharge hose of swing and blade pump and crank the engine with starting motor, and check if the oil flows out from the discharge port.
REMARK No-Injection cranking is required. For details of procedure, see Testing and Adjusting, “Examine Compression Pressure”.
40-281
H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low
40 Troubleshooting
H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low Failure
Related information
No.
All work equipment, travel, swing and blade speed or power is low •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Before performing troubleshooting, check that electrical system (solenoid circuit) is normal.
•
If failure codes are displayed, perform troubleshooting of failure codes displayed first. (DXA8KA and DXA8KB)
•
It is not abnormal that the phenomenon disappears by increasing the engine speed.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of PPC lock solenoid valve
Solenoid valve outlet pressure
Lock lever: LOCK
0 MPa {0 kgf/cm2}
Lock lever: FREE
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Relief presIncorrect adjustment or malfunction of relief valve sure of con- All control levers: NEUTRAL trol circuit in control circuit
4.90 (+0.59/-0.1) MPa {50 (+6/-1) kgf/cm2}
When pressure cannot be adjusted to normal level, control relief valve may malfunction or may have internal defect. Check it. 3
Clogged suction strainer or return filter
If no failure is found by preceding checks, the strainer or return filter may be clogged. Check it.
4
Defective control pump
If no failure is found by preceding checks, control pump may be defective.
40-282
PC45MR-5, PC55MR-5
40 Troubleshooting
H-6 All Work Equipment and Travel Speed or Power is Low
H-6 All Work Equipment and Travel Speed or Power is Low Failure
All work equipment and travel speed or power is low •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that swing and blade operations are normal.
•
It is not abnormal that the phenomenon disappears by increasing the engine speed.
No.
Cause
Procedure, measuring location, criteria and remarks When pressure cannot be adjusted to normal level, main relief valve may malfunction or may have internal defect. Check it.
1
Be ready with engine stopped, then perform troubleshooting with engine at high idle. Improper adjustment or malfunction of main relief 26.5 valve ± 0.98 MPa • Arm IN relief Main relief {270 pressure • Travel hydraulic relief ± 10 kgf/cm2 } Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Malfunction of unload valve
Unload pressure
All control levers in NEUTRAL
2.9±0.49 MPa {30±5 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle. LS differenBucket CURL operated tial pressure 3
Defective adjustment and Lever opermalfunction of LS valve ation and oil All control levers in NEUpressure ra- TRAL tio
Differential pressure between pump discharged pressure and LS valve input pressure
1.57±0.1 MPa {16±1 kgf/cm2}
Differential pressure between pump discharged pressure and LS valve input pressure
2.9(+0.98/-0 ) MPa {30(+10/-0) kgf/cm2}
When pressure cannot be adjusted to normal level, the LS valve may have malfunction. Check for malfunction of the LS valve (fatigue of spring), internal defect (seized LS spool, stick), etc. 4
Defective adjustment and When pressure cannot be adjusted to normal level, check for malfunction of the PC malfunction of PC valve valve (fatigue of spring), internal defect (seized PC spool, stick), etc.
5
Clogged orifice or filter in Check if orifice and filter in pump servo device is not clogged. pump servo device
6
Defective piston pump
PC45MR-5, PC55MR-5
If failure code is still displayed after above checks, piston pump may have malfunction, internal defect, etc.
40-283
H-7 Travel and Blade Speed or Power is Low
40 Troubleshooting
H-7 Travel and Blade Speed or Power is Low Failure
Travel and blade speed or power is low •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that all work equipments and swing operations are normal.
•
It is not abnormal that the phenomenon disappears by increasing the engine speed.
No.
1
Cause
Defective center swivel joint
Procedure, measuring location, criteria and remarks 1.
Engine stopped
2.
Plug the hydraulic hose to travel or blade circuit at control valve side
3.
Engine at high idle
Main pump relief pressure
Swing and blade pump relief pressure
Travel lever circuit (at the side where hose is disconnected)
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
Blade lever circuit (at the side where hose is disconnected)
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If the oil pressure in all hydraulic circuits is low in all the preceding checks, center swivel joint may be defective. Check it.
40-284
PC45MR-5, PC55MR-5
40 Troubleshooting
H-8 Swing and Blade Speed or Power is Low
H-8 Swing and Blade Speed or Power is Low Failure
Swing and blade speed is low or power is low. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that all work equipments and travel operations are normal.
•
It is not abnormal that the phenomenon disappears by increasing the engine speed.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Improper adjustment or malfunction of swing and blade pump relief valve
Swing and blade pump relief pressure
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade pump may malfunction or may have internal defect. Check it. 2
Defective swing and blade pump
PC45MR-5, PC55MR-5
When oil pressure is not normal even after adjustment or replacement, performance deterioration of the swing and blade pump may be occurred.
40-285
H-9 Fine Control Performance or Response is Unsatisfactory
40 Troubleshooting
H-9 Fine Control Performance or Response is Unsatisfactory Failure
Fine control performance or response is poor.
Related
•
Perform all troubleshooting with working mode to be set to power mode (P).
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
No. 1
Cause
Procedure, measuring location, criteria and remarks
Clogging of LS circuit ori- LS circuit orifice may be clogged. Check it. fice Be ready with engine stopped, then perform troubleshooting with engine at high idle. LS differenBucket CURL operated tial pressure
2
Defective adjustment and Lever opermalfunction of LS valve ation and oil All control levers in NEUpressure ra- TRAL tio
Differential pressure between pump discharged pressure and LS valve input pressure
1.57±0.1 MPa {16±1 kgf/cm2}
Differential pressure between pump discharged pressure and LS valve input pressure
2.9(+0.98/-0 ) MPa {30(+10/-0) kgf/cm2}
When pressure cannot be adjusted to normal level, the LS valve may have malfunction. Check for malfunction of the LS valve (fatigue of spring), internal defect (seized LS spool, stick), etc. 3
Malfunction of servo piston
Check if orifice and filter in pump servo device is not clogged. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
5
Malfunction of unload valve
Clogged main pump orifice plug
40-286
Unload pressure
All control levers in NEUTRAL
2.9±0.49 MPa {30±5 kgf/cm2}
If no failure is found by above checks, main pump orifice plug may be clogged. Check it.
PC45MR-5, PC55MR-5
40 Troubleshooting
H-10 Unusual Noise is Heard from Around Hydraulic Pump
H-10 Unusual Noise is Heard from Around Hydraulic Pump Failure
Unusual noise is heard from around hydraulic pump.
Related
•
Perform all troubleshooting with working mode to be set to power mode (P).
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
No.
Cause
Procedure, measuring location, criteria and remarks Check the hydraulic oil level.
1
Lowered hydraulic oil lev- REMARK el
2
Defective hydraulic oil
Air may have entered into hydraulic oil and check for bubbles or milky oil, etc.
3
Clogged hydraulic tank breather
Hydraulic tank breather may be clogged and pressure inside the tank may become negative. Check it.
4
Clogged hydraulic oil tank strainer
Hydraulic tank strainer may be clogged and pressure of suction circuit may become negative. Check it.
5
Clogged hydraulic tank return filter
Hydraulic tank return filter may be clogged and pressure of suction circuit may become negative. Check it.
6
Defective piston pump
If any metallic matters are adhered in preceding check cause 4 and 5, piston pump may have internal defect.
If the oil level is low and there is no trace of external leakage, it is possible that it is flowing into the flywheel chamber due to pump shaft seal damage.
PC45MR-5, PC55MR-5
40-287
H-11 Engine Speed Drops Largely or Engine Stops
40 Troubleshooting
H-11 Engine Speed Drops Largely or Engine Stops Failure
Related information
No.
Engine speed drops largely or engine stops. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
If failure codes are displayed, perform troubleshooting of failure codes displayed first. (DXA8KA and DXA8KB)
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Incorrect adjustment or Main relief malfunction of main relief pressure valve
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
Arm IN relief
When pressure cannot be adjusted to normal level, main relief valve may malfunction or may have internal defect. Check it. 2
Defective adjustment and When pressure cannot be adjusted to normal level, check for malfunction of the PC malfunction of PC valve valve (fatigue of spring), internal defect (seized PC spool, stick), etc. Be ready with engine stopped, then perform troubleshooting with engine at high idle. LS differenBucket CURL operated tial pressure
3
Defective adjustment and Lever opermalfunction of LS valve ation and oil All control levers in NEUpressure ra- TRAL tio
Differential pressure between pump discharged pressure and LS valve input pressure
1.57±0.1 MPa {16±1 kgf/cm2}
Differential pressure between pump discharged pressure and LS valve input pressure
2.9(+0.98/-0 ) MPa {30(+10/-0) kgf/cm2}
When pressure cannot be adjusted to normal level, the LS valve may have malfunction. Check for malfunction of the LS valve (fatigue of spring), internal defect (seized LS spool, stick), etc. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Swing and Incorrect adjustment or blade pump malfunction of relief valve relief presfor gear pump sure
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
Blade LOWER relief
When pressure cannot be adjusted to normal level, relief valve for swing and blade pump may malfunction or may have internal defect. Check it. 5
Clogged orifice or filter in Check if orifice and filter in pump servo device is not clogged. pump servo device
6
Defective piston pump
If failure code is still displayed after above checks, piston pump may have malfunction, internal defect, etc.
7
Defective engine system
If failure code is still displayed after above checks, engine performance may lower. Perform troubleshooting by referring to “S mode” troubleshooting.
8
Clogged hydraulic oil tank strainer
Hydraulic tank strainer may be clogged and pressure of suction circuit may become negative. Check it.
40-288
PC45MR-5, PC55MR-5
40 Troubleshooting
H-11 Engine Speed Drops Largely or Engine Stops
No.
Cause
Procedure, measuring location, criteria and remarks
9
Clogged hydraulic tank return filter
Hydraulic tank return filter may be clogged and pressure of suction circuit may become negative. Check it.
PC45MR-5, PC55MR-5
40-289
H-12 All Work Equipment Speed or Power is Low
40 Troubleshooting
H-12 All Work Equipment Speed or Power is Low Failure
All work equipments speed or power is low •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that travel, swing, and blade operations are normal.
•
It is not abnormal that the phenomenon disappears by increasing the engine speed.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Defective sealing of logic valve and check valve for PPC valve control circuit pressure outlet prespilot sure
40-290
•
Right and left work equipment control lever: NEUTRAL
•
Boom swing control pedal: NEUTRAL
•
Right and left work equipment control lever: Both directions
•
Boom swing control pedal: Right swing
0 MPa {0 kgf/cm2} 2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
PC45MR-5, PC55MR-5
40 Troubleshooting
H-13 All Work Equipment and Blade Speed or Power is Low
H-13 All Work Equipment and Blade Speed or Power is Low Failure
All work equipments and blade speed or power is low •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that travel and swing operations are normal.
•
It is not abnormal that the phenomenon disappears by increasing the engine speed.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle. Main pump relief pressure
1
Swing and Malfunction of centralized blade pump safety valve relief pressure
•
Work equipment control lever: Both directions
•
Boom swing control pedal: Right swing
Blade control lever: LOWER
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 } 21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If the oil pressure in all hydraulic circuits is low in all the preceding checks, centralized safety valve may be defective. Check it.
REMARK Centralized safety valve works on both sides of head and bottom for boom, arm, and bucket, and it works on head side for swing, and bottom side for blade.
PC45MR-5, PC55MR-5
40-291
H-14 Blade Does Not Operate
40 Troubleshooting
H-14 Blade Does Not Operate Failure
Blade does not operate. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
Related
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information
•
If swing does not operate, perform troubleshooting for “SWING AND BLADE DO NOT OPERATE” in H mode first.
•
If travel does not operate, perform troubleshooting for “TRAVEL AND BLADE DO NOT OPERATE” in H mode first.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of PPC valve PPC valve outlet pressure
Blade control lever: NEUTRAL
0 MPa {0 kgf/cm2}
Blade control lever: RAISE and LOWER
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 2
Malfunction of blade control valve (spool)
•
Check if the bucket spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove the blade spool from valve body, and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high idle. 3
4
Defective blade cylinder
Defective blade cylinder or blade
40-292
Leakage of blade cylinder
Blade LOWER relief
10 cc/min
Blade cylinder or blade may be deformed. Check it.
PC45MR-5, PC55MR-5
40 Troubleshooting
H-15 All Work Equipment Do Not Operate
H-15 All Work Equipment Do Not Operate Failure
Related information
No.
All work equipments do not operate. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that travel, swing, and blade operations are normal.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Defective sealing of logic valve and check valve for PPC valve control circuit pressure outlet prespilot sure
PC45MR-5, PC55MR-5
•
Right and left work equipment control lever: NEUTRAL
•
Boom swing control pedal: NEUTRAL
•
Right and left work equipment control lever: Both directions
•
Boom swing control pedal: Right swing
0 MPa {0 kgf/cm2} 2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
40-293
H-16 All Work Equipment or Blade Do Not Operate
40 Troubleshooting
H-16 All Work Equipment or Blade Do Not Operate Failure
Related information
No.
All work equipments or blade do not operate •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that travel and swing operations are normal.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle. Main pump relief pressure
1
Swing and Malfunction of centralized blade pump safety valve relief pressure
•
Work equipment control lever: Both directions
•
Boom swing control pedal: Right swing
Blade control lever: LOWER
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 } 21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If the oil pressure in all hydraulic circuits is low in all the preceding checks, centralized safety valve may be defective. Check it.
REMARK Centralized safety valve works on both sides of head and bottom for boom, arm, and bucket, and it works on head side for swing, and bottom side for blade.
40-294
PC45MR-5, PC55MR-5
40 Troubleshooting
H-17 Speed or Power of Boom is Low
H-17 Speed or Power of Boom is Low Failure Related information No.
Boom speed or power is low. •
Perform all troubleshooting with working mode to be set to power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of R.H. PPC valve (boom circuit)
PPC valve outlet pressure
R.H. work equipment control lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. work equipment control lever: Boom RAISE and boom LOWER
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 2
Malfunction of merge-divider main spool
•
Check for stuck or seized main spool in merge-divider valve body (spool should move smoothly).
•
Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Release the remaining pressure from hydraulic tank and pipes, and then perform troubleshooting with engine stopped. 3
Malfunction of boom control valve (spool)
•
Check if boom spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove boom spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt to enter. 4
Malfunction of boom con- Pressure compensation valve of boom control valve may be defective. Check it. trol valve (pressure compensation valve)
5
Malfunction or defective sealing of boom control valve (suction valve)
PC45MR-5, PC55MR-5
Suction valve (bottom side) of boom control valve may malfunction or may have defective sealing. Check it.
40-295
H-17 Speed or Power of Boom is Low
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped.
6
•
Check if pilot spool is stuck or seized with valve body.
•
Remove pilot spool from valve body and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
Malfunction of boom lock Be ready with engine stopped, then perform troubleshooting with engine at high idle. valve Boom relief pressure •
26.5±1.5 MPa {270±15 kgf/cm2}
Boom RAISE relief
If only the relief pressure of anti-drop valve side is low among the work equipment relief pressures, safety valve may be defective. Replace safety valve assembly.
7
Malfunction or defective sealing of centralized safety valve and suction valve
Centralized safety valve and suction valve of control valve may malfunction or may have defective sealing. Check it.
8
Malfunction of boom con- Lock valve of boom control valve may be defective. Check it. trol valve (lock valve) Be ready with engine stopped, then perform troubleshooting with engine at high idle.
9
Defective boom cylinder
40-296
Leakage of boom cylinder
Boom RAISE relief
10 cc/min
PC45MR-5, PC55MR-5
40 Troubleshooting
H-18 Arm Speed or Power is Low
H-18 Arm Speed or Power is Low Failure Related information No.
Arm speed or power is low. •
Perform all troubleshooting with working mode to be set to power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of L.H. PPC valve (arm circuit)
PPC valve outlet pressure
L.H. work equipment control lever: NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: Arm IN and arm OUT
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 2
Malfunction of merge-divider main spool
•
Check for stuck or seized main spool in merge-divider valve body (spool should move smoothly).
•
Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of arm control valve (spool)
•
Check for stuck or seized arm spool in control valve body (spool should move smoothly).
•
Remove arm spool from valve body and check for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Malfunction of arm control valve (pressure compensation valve)
Pressure compensation valve of arm control valve may be defective. Check it.
4
5
Malfunction or defective sealing of arm control valve (suction valve)
Suction valve (bottom and head side) of arm control valve may malfunction or may have defective sealing. Check it.
6
Malfunction or defective sealing of centralized safety valve and suction valve
Centralized safety valve and suction valve of control valve may malfunction or may have defective sealing. Check it.
7
Defective arm cylinder
PC45MR-5, PC55MR-5
Be ready with engine stopped, then perform troubleshooting with engine at high idle. Leakage of Arm IN relief arm cylinder
10 cc/min
40-297
H-19 Bucket Speed or Power is Low
40 Troubleshooting
H-19 Bucket Speed or Power is Low Failure Related information No.
Bucket speed or power is low. •
Perform all troubleshooting with working mode to be set to power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of R.H. PPC valve (bucket circuit)
PPC valve outlet pressure
R.H. work equipment control lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. work equipment control lever: Arm IN and arm OUT
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 2
Malfunction of merge-divider main spool
•
Check for stuck or seized main spool in merge-divider valve body (spool should move smoothly).
•
Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of bucket control valve (spool)
•
Check for stuck or seized bucket spool in control valve body (spool should move smoothly).
•
Remove bucket spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Malfunction of bucket control valve (pressure compensation valve)
Pressure compensation valve of bucket control valve may be defective. Check it.
4
5
Malfunction or defective sealing of bucket control valve (suction valve)
Suction valve (bottom and head side) of bucket control valve may malfunction or may have defective sealing. Check it.
6
Malfunction or defective sealing of centralized safety valve and suction valve
Centralized safety valve and suction valve of control valve may malfunction or may have defective sealing. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high idle. 7
Defective bucket cylinder Leakage of bucket cylin- Bucket CURL relief der
40-298
10 cc/min
PC45MR-5, PC55MR-5
40 Troubleshooting
H-20 Blade Speed or Power is Low
H-20 Blade Speed or Power is Low Failure
Blade speed is low or power is low. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
Related
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information
•
If swing speed is slow, perform troubleshooting for “SWING AND BLADE SPEED IS LOW OR POWER IS LOW” in H mode first.
•
If travel speed is slow, perform troubleshooting for “TRAVEL AND BLADE SPEED IS LOW OR POWER IS LOW” in H mode first.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Swing and Incorrect adjustment or blade pump malfunction of relief valve relief presfor gear pump sure
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade pump may malfunction or may have internal defect. Check it. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Malfunction of blade PPC PPC valve valve (blade circuit) outlet pressure
Blade control lever: NEUTRAL
0 MPa {0 kgf/cm2}
Blade control lever: RAISE and LOWER
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of blade control valve (spool)
•
Check if blade spool is stuck or seized with valve body. (Spool should move smoothly.)
•
Remove blade spool from valve body, and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high idle. 4
5
Defective blade cylinder
Leakage of blade cylinder
Blade LOWER relief
10 cc/min
Malfunction of load check Load check valve in the spool of control valve may malfunction. Check it. valve in the spool of control valve
PC45MR-5, PC55MR-5
40-299
H-20 Blade Speed or Power is Low
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle. Blade relief pressure
6
Malfunction of blade RAISE (suction-safety valve)
Blade RAISE relief
21.6(+0.98/0.49) MPa {220(+10/-5) kgf/cm2}
•
If blade RAISE relief pressure is low, suction valve may be defective. Check it.
•
Check that check valve of suction safety valve is seated on valve body in position (it is not stuck halfway).
REMARK Since relief pressure of safety valve cannot be adjusted when it is installed on the machine, replace safety valve assembly if it is found to be defective. Be ready with engine stopped, then perform troubleshooting with engine at high idle. Blade relief pressure
7
8
Malfunction of blade LOWER (suction safety valve)
Defective gear pump
Blade LOWER relief
21.6(+0.98/0.49) MPa {220(+10/-5) kgf/cm2}
•
If only blade LOWER relief pressure is low between swing and blade LOWER relief pressure, suction valve may be defective. Check it.
•
Check that check valve of suction valve is seated on valve body in position (it is not stuck halfway).
•
Remove check valve from valve body, and check it for flaw and sticking of dirt.
•
Check spring for fatigue and deformation.
•
When restoring, be careful about the dirt to enter.
Performance deterioration, malfunction, and internal defect of the gear pump may be occurred. Check it. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
9
Blade relief Malfunction of centralized pressure safety valve
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If oil pressure does not become normal after adjustment, check safety valve for malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt), etc.
40-300
PC45MR-5, PC55MR-5
40 Troubleshooting
H-21 Boom Swing Speed or Power is Low
H-21 Boom Swing Speed or Power is Low Failure
Boom swing speed or power is low •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of swing PPC valve
PPC valve outlet pressure
Boom swing control pedal: NEUTRAL
0 MPa {0 kgf/cm2}
Boom swing control pedal: Left swing and right swing
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 2
Malfunction of swing control valve (spool)
•
Check if swing spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove swing spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter. 3
Malfunction of swing con- Pressure compensation valve of swing control valve may be defective. Check it. trol valve (pressure compensation valve)
4
Malfunction or defective sealing of swing control valve (suction valve) (swing RIGHT only)
Suction valve (head side) of swing control valve may malfunction or may have defective sealing. Check it.
5
Malfunction or defective sealing of centralized safety valve and suction valve
Centralized safety valve and suction valve of control valve may malfunction or may have defective sealing. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high idle. 6
Defective swing cylinder
PC45MR-5, PC55MR-5
Leakage of swing cylinder
Relief at the end of swing LEFT
10 cc/min
40-301
H-22 Work Equipment Does Not Move in Single Operation
40 Troubleshooting
H-22 Work Equipment Does Not Move in Single Operation Failure
Related information
No.
Work equipment does not move in single operation •
Perform all troubleshooting with working mode to be set to power mode (P).
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
REMARK While the work equipment is used in single operation, if pump pressure remains at (approximately4 MPa {Approx. 40 kgf/cm2 }), spool in the control valve probably stays at neutral position. (All the oil from pump is drained to the tank through unload valve.) Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of PPC valve PPC valve outlet pressure
Work equipment control lever: NEUTRAL
0 MPa {0 kgf/cm2}
Work equipment control lever: Operated
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
Release the remaining pressure from hydraulic tank and pipes, and then perform troubleshooting with engine stopped. 2
Malfunction of boom control valve (spool)
•
Check if boom spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove boom spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of arm control valve (spool)
•
Check for stuck or seized arm spool in control valve body (spool should move smoothly).
•
Remove arm spool from valve body and check for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 4
Malfunction of bucket control valve (spool)
•
Check for stuck or seized bucket spool in control valve body (spool should move smoothly).
•
Remove bucket spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 5
Malfunction of swing control valve (spool)
•
Check if swing spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove swing spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter.
40-302
PC45MR-5, PC55MR-5
40 Troubleshooting
H-23 Hydraulic Drift of Boom is Large
H-23 Hydraulic Drift of Boom is Large Failure Related information No.
Hydraulic drift of boom is large. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
2
Defective boom cylinder
Malfunction of boom control valve (lock valve)
Leakage of boom cylinder
Boom RAISE relief
10 cc/min
•
Check that pilot piston and puppet are seated on body in position (they should not be stuck halfway).
•
Check if pilot piston and puppet are stuck or seized with lock valve body (they should move smoothly).
•
Remove pilot piston and puppet from valve body, and check them for flaw and sticking of dirt.
•
Check puppet spring for fatigue and deformation.
•
When restoring, be careful about the dirt to enter.
Release the remaining pressure from hydraulic tank and pipes, and then perform troubleshooting with engine stopped. 3
Malfunction of boom control valve (spool)
•
Check if boom spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove boom spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt to enter. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Boom relief Malfunction of centralized pressure safety valve
•
Boom RAISE relief
•
Boom LOWER relief
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
If oil pressure does not become normal after adjustment, check safety valve for malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt), etc.
PC45MR-5, PC55MR-5
40-303
H-24 Hydraulic Drift of Arm is Large
40 Troubleshooting
H-24 Hydraulic Drift of Arm is Large Failure Related information No.
1
Hydraulic drift of arm is large. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Defective arm cylinder
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle. Leakage of Arm IN relief arm cylinder
10 cc/min
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
Arm relief pressure
2
Malfunction of arm control valve (suction valve) (arm IN side)
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
Arm IN relief
REMARK If only arm IN relief pressure is low among the work equipment relief pressures, suction valve may be defective. Check it. •
Check that check valve is seated on valve body in position (it is not stuck halfway).
•
Remove check valve from valve body, and check it for flaw and sticking of dirt.
•
Check spring for fatigue and deformation.
•
When restoring, take care to prevent the dirt from entering.
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of arm control valve (spool)
•
Check for stuck or seized arm spool in control valve body (spool should move smoothly).
•
Remove arm spool from valve body and check for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Arm relief Malfunction of centralized pressure safety valve
•
Arm IN relief
•
Arm OUT relief
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
If oil pressure does not become normal after adjustment, check safety valve for malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt), etc.
40-304
PC45MR-5, PC55MR-5
40 Troubleshooting
H-25 Hydraulic Drift of Bucket is Large
H-25 Hydraulic Drift of Bucket is Large Failure
Hydraulic drift of bucket is large.
Related
•
Perform all troubleshooting with working mode to be set to power mode (P).
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Defective bucket cylinder Leakage of bucket cylin- Bucket CURL relief der
10 cc/min
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
Bucket relief Bucket CURL or DUMP relief pressure
2
Malfunction of bucket control valve (suction valve)
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
If relief pressure is low, suction valve may be defective. • Remove check valve from valve body, and check it for flaw and sticking of
dirt. •
Check spring for fatigue and deformation.
•
When restoring, take care to prevent the dirt from entering.
•
Check that check valve is seated on valve body in position (it is not stuck halfway).
REMARK You can replace suction valve with other one and check whether failure symptom changes for judgment. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of bucket control valve (spool)
•
Check for stuck or seized bucket spool in control valve body (spool should move smoothly).
•
Remove bucket spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Bucket relief Malfunction of centralized pressure safety valve
•
Bucket CURL relief
•
Bucket DUMP relief
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
If oil pressure does not become normal after adjustment, check safety valve for malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt), etc.
PC45MR-5, PC55MR-5
40-305
H-26 Hydraulic Drift of Blade is Large
40 Troubleshooting
H-26 Hydraulic Drift of Blade is Large Failure
Hydraulic drift of blade is large (during blade RAISE or blade thrusting condition).
Related
•
Perform all troubleshooting with working mode to be set to power mode (P).
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Defective blade cylinder
Leakage of blade cylinder
Blade LOWER relief
10 cc/min
Be ready with engine stopped, then perform troubleshooting with engine at high idle. Blade relief pressure 2
Malfunction of blade RAISE (suction-safety valve)
Blade RAISE relief
21.6(+0.98/0.49) MPa {220(+10/-5) kgf/cm2}
•
If blade RAISE relief pressure is low, suction valve may be defective. Check it.
•
Check that check valve of suction safety valve is seated on valve body in position (it is not stuck halfway).
REMARK Since relief pressure of safety valve cannot be adjusted when it is installed on the machine, replace safety valve assembly if it is found to be defective. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of blade control valve (spool)
•
Check if the bucket spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove the blade spool from valve body, and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high idle. Blade relief pressure
4
Malfunction of blade LOWER (suction safety valve)
40-306
Blade LOWER relief
21.6(+0.98/0.49) MPa {220(+10/-5) kgf/cm2}
•
If only blade LOWER relief pressure is low between swing and blade LOWER relief pressure, suction valve may be defective. Check it.
•
Check that check valve of suction valve is seated on valve body in position (it is not stuck halfway).
•
Remove check valve from valve body, and check it for flaw and sticking of dirt.
•
Check spring for fatigue and deformation.
•
When restoring, be careful about the dirt to enter.
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
H-26 Hydraulic Drift of Blade is Large
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
5
Blade relief Malfunction of centralized pressure safety valve
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If oil pressure does not become normal after adjustment, check safety valve for malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt), etc. 6
Defective swivel joint
PC45MR-5, PC55MR-5
If no failure is found by above checks, seal of swivel joint may be defective.
40-307
H-27 Time Lag of Work Equipment is Large
40 Troubleshooting
H-27 Time Lag of Work Equipment is Large Failure
Time lag of work equipment is large. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks Check relief pressure of each work equipment. If only relief pressure at boom head side is abnormal, suction valve of boom control valve may malfunction.
1
Malfunction of boom con- REMARK trol valve (suction valve)
You can replace it with other suction valve and check whether failure symptom changes for judgment.
2
3
4
Malfunction of arm control valve (suction valve)
Malfunction of bucket control valve (suction valve)
Check the relief pressure of each work equipment. If only arm relief pressure is abnormal, suction valve of arm control valve may malfunction.
REMARK You can replace it with other suction valve and check whether failure symptom changes for judgment. Check relief pressure of each work equipment. If only bucket relief pressure is abnormal, suction valve of bucket control valve may malfunction.
REMARK You can replace it with other suction valve and check whether failure symptom changes for judgment.
Check relief pressure of each work equipment. If only blade relief pressure is abMalfunction of blade con- normal, suction valve and suction safety valve of blade control valve may malfunction. trol valve (Suction safety valve) REMARK (Suction valve)
You can replace it with other suction valve and check whether failure symptom changes for judgment.
5
Malfunction of centralized Check relief pressure of each work equipment. If relief pressure of all work equipsafety valve ment other than blade RAISE is unusual, centralized safety valve may malfunction.
6
Malfunction of rebuilt check valve in boom spool
7
Malfunction of rebuilt check valve in arm spool
40-308
Release the remaining pressure from hydraulic tank and pipes, and then perform troubleshooting with engine stopped. Check the surface and hole part of spool for flaw and sticking of dirt. Release the remaining pressure from hydraulic tank and pipes, and then perform troubleshooting with engine stopped. Check the surface and hole part of spool for flaw and sticking of dirt.
PC45MR-5, PC55MR-5
H-28 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower
40 Troubleshooting
H-28 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower Failure Related information No.
In combined operation of work equipment, equipment having heavier load moves slower. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Procedure, measuring location, criteria and remarks Pressure compensation valve of control valve with smaller load may be defective. Side with larger load: Boom
Arm pressure compensation valve
Combination of combined operations: Boom RAISE + Arm OUT
Side with larger load: Arm
Boom pressure compensation valve
Combination of combined operations: Boom RAISE + Bucket CURL
Side with larger load: Boom
Bucket pressure compensation valve
Side with larger load: Arm
Bucket pressure compensation valve
Combination of combined operations: Boom LOWER Side with larger load: Arm + Arm OUT
Boom pressure compensation valve
Combination of combined operations: Boom RAISE + Arm IN
1
Malfunction of control valve (pressure compen- Malfunction sation valve) with smaller of pressure compensaload tion valve
Combination of combined operations: Arm OUT + Bucket CURL
PC45MR-5, PC55MR-5
40-309
H-29 Machine Does Not Travel Straight
40 Troubleshooting
H-29 Machine Does Not Travel Straight Failure
Related information
Machine does not travel straight. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Travel PPC pressure can be checked on the monitor as well. Code: (07101)
No.
Cause
1
Defective center swivel joint
Procedure, measuring location, criteria and remarks Check whether the turn direction changes if the right and left hoses are switched between the swivel joint and travel motor. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
R.H. travel PPC valve outlet presMalfunction of R.H. travel sure PPC valve
R.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
3
Malfunction of L.H. travel PPC valve
L.H. PPC valve outlet pressure
L.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
L.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 4
Malfunction of travel Junction valve (spool)
•
Check travel Junction valve for stick (spool should move smoothly).
•
Remove spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter.
40-310
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
H-29 Machine Does Not Travel Straight
Cause
Procedure, measuring location, criteria and remarks Release the remaining pressure from hydraulic tank and pipes, and then perform troubleshooting with engine stopped.
5
Malfunction of pump merge-divider (spool)
•
Check if spool is stuck or seized with merge-divider valve body. (Spool should move smoothly.)
•
Remove the merge-divider valve spool from body, and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high idle. 6
7
Malfunction of unload valve
Unload pressure
All control levers in NEUTRAL
2.9±0.49 MPa {30±5 kgf/cm2}
Malfunction of logic valve Logic valve may malfunction. Check it. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped.
8
Malfunction of R.H. travel control valve (spool)
•
Check if travel spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove travel spool from valve body, and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 9
Malfunction of L.H. travel control valve (spool)
•
Check if travel spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove travel spool from valve body, and check it for flaw and sticking of dirt.
10
Defective travel motor
Travel motor may have an internal defect. Check it. (You can exchange right and left travel motors and final drive assemblies, and check whether the direction of travel deviation changes for judgment.)
11
Defective final drive
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment.
12
Defective adjustment of travel deviation adjustment plug
PC45MR-5, PC55MR-5
See Testing and Adjusting, “Examine and Adjust Travel Deviation” to adjust.
40-311
H-30 Machine Does Not Move Off Straight
40 Troubleshooting
H-30 Machine Does Not Move Off Straight Failure
Related information
No. 1
Machine deviates when moving off. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Travel PPC pressure can be checked on the monitor as well. Code: 07101)
Cause Defective travel motor (counterbalance valve and check valve)
Procedure, measuring location, criteria and remarks Counter balance valve and check valve of travel motor may malfunction. Check it. (You can exchange them between forward and reverse or right and left of the same motor, and check whether failure symptom changes for judgment.) Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
R.H. travel PPC valve outlet presMalfunction of R.H. travel sure PPC valve
R.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
3
Malfunction of L.H. travel PPC valve
L.H. PPC valve outlet pressure
L.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
L.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
4
Defective R.H. travel mo- If R.H. track does not move in relief pressure state when operating R.H. travel off tor (parking brake) ground, travel parking brake may malfunction.
5
Defective L.H. travel motor (parking brake)
40-312
If L.H. track does not move in relief pressure state when operating L.H. travel off ground, travel parking brake may malfunction.
PC45MR-5, PC55MR-5
40 Troubleshooting
H-31 Machine is Not Steered Correctly or Steering Power is Low
H-31 Machine is Not Steered Correctly or Steering Power is Low Failure
Machine is not steered well or steering power is low. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Travel PPC pressure can be checked on the monitor as well. Code: (07101)
Related information
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of R.H. travel R.H. travel PPC valve PPC valve outlet pressure
R.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
3
Malfunction of L.H. travel L.H. PPC PPC valve valve outlet pressure
L.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
L.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Malfunction of logic valve Logic valve may malfunction. Check it. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped.
4
Malfunction of travel Junction valve (spool)
•
Check travel Junction valve for stick (spool should move smoothly).
•
Remove spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 5
Malfunction of merge-divider main spool
•
Check for stuck or seized main spool in merge-divider valve body (spool should move smoothly).
•
Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 6
Malfunction of R.H. travel control valve (spool)
PC45MR-5, PC55MR-5
•
Check if travel spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove travel spool from valve body, and check it for flaw and sticking of dirt.
•
When restoring, be careful about the dirt to enter.
40-313
H-31 Machine is Not Steered Correctly or Steering Power is Low
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped.
7
Malfunction of L.H. travel control valve (spool)
•
Check if travel spool is stuck or seized with control valve body. (Spool should move smoothly.)
•
Remove travel spool from valve body, and check it for flaw and sticking of dirt.
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
8
Malfunction of R.H. travel control valve (pressure Travel relief compensation valve) pressure
R.H. travel FORWARD hydraulic relief
26.5±0.98 MPa {270±10 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
9
Malfunction of L.H. travel control valve (pressure Travel relief compensation valve) pressure
L.H. travel FORWARD hydraulic relief
26.5±0.98 MPa {270±10 kgf/cm2}
10
Defective operation of travel control valve (suction valve)
Even after the relief valve is adjusted, if the relief pressure is low at only 1 port, suction valve may malfunction. Check the check valve for damage and spring for fatigue.
11
Defective center swivel joint
Check whether the turn direction changes if the right and left hoses are switched between the swivel joint and travel motor.
12
In the check on cause (6) and (8), if “Right Travel” is abnormal on both forward and Defective R.H. travel mo- reverse, or “Left Travel” is abnormal on both forward and reverse, safety valve may tor (safety valve) malfunction. Exchange the safety valves of right and left travel motor and check whether the phenomenon changes.
13
Defective L.H. travel motor (safety valve)
14
In the check on cause (6) and (8), if the pressure compensation valve is normal, Defective R.H. travel mocheck valve may malfunction. Exchange the safety valves of right and left travel tor (check valve) motor and check whether the phenomenon changes.
15
Defective L.H. travel motor (check valve)
In the check on cause (7) and (9), if the pressure compensation valve is normal, check valve may malfunction. Exchange the forward and reverse check valves of the same motor and check whether the phenomenon changes.
16
Defective travel motor (counterbalance valve and check valve)
Counter balance valve and check valve of travel motor may malfunction. Check it. (You can exchange them between forward and reverse or right and left of the same motor, and check whether failure symptom changes for judgment.)
40-314
In the check on cause (7) and (9), if “Left Travel” is abnormal on both forward and reverse, safety valve may malfunction. Exchange the safety valves of right and left travel motor and check whether the phenomenon changes.
PC45MR-5, PC55MR-5
40 Troubleshooting
H-32 Travel Speed is Low
H-32 Travel Speed is Low Failure
Travel speed is slow. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Check that machine has no travel deviation.
•
Travel PPC pressure can be checked on the monitor as well. Code: 07101)
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
R.H. travel PPC valve outlet presMalfunction of R.H. travel sure PPC valve
R.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Malfunction of L.H. travel PPC valve
L.H. PPC valve outlet pressure
L.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
L.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 3
Malfunction of merge-divider main spool
•
Check for stuck or seized main spool in merge-divider valve body (spool should move smoothly).
•
Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter. Be ready with engine stopped, then perform troubleshooting with engine at high idle. 4
Malfunction of unload valve
PC45MR-5, PC55MR-5
Unload pressure
All control levers in NEUTRAL
2.9±0.49 MPa {30±5 kgf/cm2}
40-315
H-32 Travel Speed is Low
No.
40 Troubleshooting
Cause
Procedure, measuring location, criteria and remarks
5
Defective travel motor
Travel motor may have an internal defect. Check it. (You can exchange right and left travel motors and final drive assemblies, and check whether the direction of travel deviation changes for judgment.)
6
Defective final drive
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment.
7
Defective undercarriage
8
Malfunction of logic valve Logic valve may malfunction. Check it.
•
Check that track shoe tension is adjusted equally on right and left.
•
Check front idler and roller, etc. for defective rotation, deformation, damage.
Release remaining pressure from hydraulic tank and piping, and then perform troubleshooting with engine stopped. 9
Malfunction of travel Junction valve (spool)
•
Check travel Junction valve for stick (spool should move smoothly).
•
Remove spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
10
Malfunction of R.H. travel control valve (pressure Travel relief compensation valve) pressure
R.H. travel FORWARD hydraulic relief
26.5±0.98 MPa {270±10 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
11
Malfunction of L.H. travel control valve (pressure Travel relief compensation valve) pressure
L.H. travel FORWARD hydraulic relief
26.5±0.98 MPa {270±10 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle. 12
Improper adjustment or malfunction of main relief Main relief valve pressure
40-316
Travel hydraulic relief
26.5 ± 0.98 MPa {270 ± 10 kgf/cm2 }
PC45MR-5, PC55MR-5
40 Troubleshooting
H-33 Two Sides of Crawlers Do Not Move
H-33 Two Sides of Crawlers Do Not Move Failure
Travel do not operate (both sides of tracks). •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Travel PPC pressure can be checked on the monitor as well. Code: 07101) REMARK • Prepare PPC circuit check valves of A to D as shown in the figure below, and take out signal voltage for switching merge valve from travel PPC pressure.
Related information
• If back flow prevention function of check valves of A to D are damaged, travel may not operate. • (Ex.) When back flow prevention function of A is damaged • Operation by which travel operates normally: (L.H. track forward), (L.H. track forward and R.H. track forward), (L.H. track forward and R.H. track reverse) • Operation by which travel may not operate: (L.H. track reverse), (R.H. track forward), (R.H. track reverse), (L.H. track reverse and R.H. track forward), (L.H. track reverse and R.H. track reverse)
No.
Cause
Procedure, measuring location, criteria and remarks
1
Defective check valve in travel circuit (For merge-divider valve operating pressure)
If PPC circuit pressure is normal for only 1 circuit among left travel (forward and reverse) and right travel (forward and reverse), the PPC circuit check valve in normal circuit may be defective. Check it.
Related Diagram Between Defective PPC Circuit Check Valve and “Travel Does Not Operate”
PC45MR-5, PC55MR-5
40-317
H-34 One of Tracks Does Not Run
40 Troubleshooting
H-34 One of Tracks Does Not Run Failure
One of tracks does not run. •
Perform all troubleshooting with working mode to be set to power mode (P).
Related
•
Check that oil level in hydraulic tank is normal.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Travel PPC pressure can be checked on the monitor as well. Code: (07101)
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
R.H. travel PPC valve outlet presMalfunction of R.H. travel sure PPC valve
R.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
R.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Malfunction of L.H. travel PPC valve
L.H. PPC valve outlet pressure
L.H. travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
L.H. travel lever: FORWARD/REVERSE
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Difference between R.H. and Travel lever: FORWARD/REVERSE L.H. of PPC valve outlet pressure
Within. 0.4 MPa {Within. 4 kgf/cm2}
3
If no failure is found by check on R.H. travel PPC valve, and one track does not run Malfunction of R.H. travel when travel control lever is operated with pump pressure at approx. 4 MPa, check control valve (spool) whether spool is stuck near neutral position.
4
If no failure is found by check on L.H. travel PPC valve, and one track does not run Malfunction of L.H. travel when travel control lever is operated with pump pressure at approx. 4 MPa, check control valve (spool) whether spool is stuck near neutral position.
5
Malfunction of R.H. travel If one track does not run due to low pump pressure, when Right Travel is operated, control valve (suction check suction valve. valve)
6
Malfunction of L.H. travel If one track does not run due to low pump pressure, when Left Travel is operated, control valve (suction check suction valve. valve)
7
Defective travel motor
40-318
Travel motor may have an internal defect. Check it. (You can exchange right and left travel motors and final drive assemblies, and check whether the direction of travel deviation changes for judgment.)
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
Cause
H-34 One of Tracks Does Not Run
Procedure, measuring location, criteria and remarks
8
Defective final drive
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment.
9
Defective travel motor (counterbalance valve and check valve)
Counter balance valve and check valve of travel motor may malfunction. Check it. (You can exchange them between forward and reverse or right and left of the same motor, and check whether failure symptom changes for judgment.)
PC45MR-5, PC55MR-5
40-319
H-35 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast
40 Troubleshooting
H-35 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast Failure
Travel speed does not change, or travel speed is too slow or fast. •
Perform all troubleshooting with working mode to be set to power mode (P).
•
Check that oil level in hydraulic tank is normal.
Related
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information
•
If failure codes are displayed, troubleshoot displayed failure codes first. (DW43KA, DW43KB, and DW43KY)
•
Travel speed selector solenoid (ON/OFF) can also be checked on monitor. (Monitoring code: 02300)
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
2
Malfunction of travel speed solenoid valve
Travel speed: Lo Solenoid valve outlet pressure
Travel speed: Hi
Travel lever: NEUTRAL
0 MPa {0 kgf/cm2}
Travel lever: Fine control
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Defective travel motor If no failure is found by checks on preceding item, speed switching part of travel (speed switching section) motor may malfunction.
40-320
PC45MR-5, PC55MR-5
40 Troubleshooting
H-36 Upper Structure Does Not Swing to Right and Left
H-36 Upper Structure Does Not Swing to Right and Left Failure
Upper structure does not swing both to the right and left. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
If blade does not operate, perform troubleshooting for “SWING AND BLADE DO NOT OPERATE” in H mode first.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Swing motor parking L.H. work equipment control lever: Operate arm IN diMalfunction of swing mobrake rerection or swing RIGHT/LEFT direction tor (swing parking brake) lease pressure
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the swing parking brake may malfunction. Check it. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
3
Swing relief Malfunction of swing mo- pressure L.H. work equipment control lever: Swing LEFT relief, tor (safety valve) (pump pres- swing RIGHT relief sure)
19.6±0.98 MPa {200±10 kgf/cm2}
If the relief pressures are same at right and left swing and lower than specified value, sealing of safety valve may be defective. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Swing PPC Malfunction of swing concircuit prestrol valve (spool) sure
L.H. work equipment control lever: Operate swing RIGHT/LEFT direction
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the spool of swing control valve may malfunction. Check it.
PC45MR-5, PC55MR-5
40-321
H-36 Upper Structure Does Not Swing to Right and Left
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
5
Malfunction of check valve in the circuit for swing parking brake releasing pressure
Swing motor parking L.H. work equipment control lever: Operate arm IN dibrake rerection or swing RIGHT/LEFT direction lease pressure
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If there is a defective hydraulic circuit, the check valve of PPC circuit at swing RIGHT/LEFT and arm IN side may be defective. Check it. 6
Defective swing machinery
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment.
7
Defective gear pump
Performance deterioration, malfunction, and internal defect of the gear pump may be occurred. Check it. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
8
9
Incorrect adjustment or malfunction of relief valve Swing and for Swing and blade blade pump pump relief pressure Defective swing motor
40-322
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
If no failure is found by preceding checks, internal defect of the swing motor is suspected. Check it.
PC45MR-5, PC55MR-5
40 Troubleshooting
H-37 Upper Structure Swings Only to Right or Left
H-37 Upper Structure Swings Only to Right or Left Failure
Related information
No.
Upper structure swings either to the right or to the left. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Swing PPC pressure can be checked with monitoring function. (Code: 09000)
•
If blade does not operate, perform troubleshooting for “SWING AND BLADE DO NOT OPERATE” in H mode first.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Swing PPC Malfunction of swing concircuit prestrol valve (spool) sure
L.H. work equipment control lever: Operate swing RIGHT/LEFT direction
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the spool of swing control valve may malfunction. Check it. Replace the suction valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw. 3
Defective seal of swing motor (suction valve)
Be ready with engine stopped, then perform troubleshooting with engine at high idle. Swing relief pressure L.H. work equipment control lever: Swing LEFT relief, (pump pres- swing RIGHT relief sure)
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Defective sealing of swing motor (check valve)
5
Malfunction of load check Load check valve in the control valve may be defective. Check it. valve in the spool of control valve
PC45MR-5, PC55MR-5
19.6±0.98 MPa {200±10 kgf/cm2}
Swing relief pressure L.H. work equipment control lever: Swing LEFT relief, (pump pres- swing RIGHT relief sure)
19.6±0.98 MPa {200±10 kgf/cm2}
40-323
H-37 Upper Structure Swings Only to Right or Left
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
6
Malfunction of check valve in the circuit for swing parking brake releasing pressure
Swing motor parking L.H. work equipment control lever: Operate arm IN dibrake rerection or swing RIGHT/LEFT direction lease pressure
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If there is a defective hydraulic circuit, the check valve of PPC circuit at swing RIGHT/LEFT and arm IN side may be defective. Check it.
40-324
PC45MR-5, PC55MR-5
H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions
40 Troubleshooting
H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions Failure
Swing acceleration or swing speed is low in both directions of right and left. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
If blade speed is slow, perform troubleshooting for “SWING AND BLADE SPEED IS LOW OR POWER IS LOW” in H mode first.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Swing relief L.H. work equipment control lever: Swing LEFT relief, Malfunction of swing mo- pressure (pump pres- swing RIGHT relief tor (safety valve) sure)
19.6±0.98 MPa {200±10 kgf/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be defective. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Swing motor Malfunction of swing mo- parking L.H. work equipment control lever: Operate arm IN dibrake retor parking brake rection or swing RIGHT/LEFT direction lease pressure
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the brake may malfunction. Check it. 3
Defective swing machinery
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
4
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
5
Swing PPC Malfunction of swing concircuit prestrol valve (spool) sure
L.H. work equipment control lever: Operate swing RIGHT/LEFT direction
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the spool of swing control valve may malfunction. Check it.
PC45MR-5, PC55MR-5
40-325
H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions
No.
Cause
40 Troubleshooting
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
6
Incorrect adjustment or malfunction of relief valve Swing and for Swing and blade blade pump pump relief pressure
7
Clogging of swing PPC line throttle, slow return valve
8
Defective swing motor
40-326
Blade LOWER relief
21.6 (+0.98/-0.49 ) MPa {220 (+10/-5) kgf/cm2}
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment. If no failure is found by preceding checks, internal defect of the swing motor is suspected. Check it.
PC45MR-5, PC55MR-5
H-39 Swing Acceleration or Swing Speed is Low in Only One Direction
40 Troubleshooting
H-39 Swing Acceleration or Swing Speed is Low in Only One Direction Failure
Related information
No.
Swing acceleration performance is poor or swing speed is slow in only one direction. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that the oil level in hydraulic tank is correct.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Swing PPC pressure can be checked with monitoring function. (Code: 09000)
•
If blade speed is slow, perform troubleshooting for “SWING AND BLADE SPEED IS LOW OR POWER IS LOW” in H mode first.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Swing PPC Malfunction of swing concircuit prestrol valve (spool) sure
L.H. work equipment control lever: Operate swing RIGHT/LEFT direction
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the spool of swing control valve may malfunction. Check it. 3
Defective seat of swing motor (suction valve)
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
4
Defective sealing of swing motor (check valve)
Replace the check valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
5
Malfunction of load check Load check valve in the control valve may be defective. Check it. valve in the spool of control valve
PC45MR-5, PC55MR-5
40-327
H-40 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)
40 Troubleshooting
H-40 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) Failure Related information No.
Upper structure overruns excessively when it stops swinging (both right and left). •
Perform all troubleshooting with working mode to be set to power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Swing relief Malfunction of swing mo- pressure L.H. work equipment control lever: Swing LEFT relief, tor (safety valve) (pump pres- swing RIGHT relief sure)
19.6±0.98 MPa {200±10 kgf/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be defective. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
3
If no failure is found by above checks and upper structure does not swing when Malfunction of swing conswing control lever is operated with pump pressure at approximately 4 MPa, spool trol valve (spool) may be stuck near NEUTRAL position.
4
Defective swing motor
40-328
If no failure is found by preceding checks, internal defect of the swing motor is suspected. Check it.
PC45MR-5, PC55MR-5
H-41 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)
40 Troubleshooting
H-41 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) Failure
Upper structure overruns excessively when it stops swinging (either right or left). •
Perform all troubleshooting with working mode set in power mode (P).
Related
•
Check that oil level in hydraulic tank is normal.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Swing PPC pressure can be checked with monitoring function. (Code: 09000)
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
2
R.H. swing PPC line throttle slow return valve may malfunction. Replace R.H. and Clogging of R.H. swing L.H. of swing line throttle slow return valve, and check whether failure symptom PPC line throttle, slow re- changes to make judgment. turn valve When removing the line throttle slow return valve, check its strainer for clogging.
3
L.H. swing PPC line throttle slow return valve may malfunction. Replace R.H. and Clogging of L.H. swing L.H. of swing line throttle slow return valve, and check whether failure symptom PPC line throttle, slow re- changes to make judgment. turn valve When removing the line throttle slow return valve, check its strainer for clogging.
4
Malfunction of control valve (spool)
Spool of swing control valve may malfunction. Check that spool moves smoothly and has no defects. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
5
Swing relief L.H. work equipment control lever: Swing LEFT relief, Malfunction of swing mo- pressure tor (safety valve) (pump pres- swing RIGHT relief sure)
19.6±0.98 MPa {200±10 kgf/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be defective. 6
Defective seal of swing motor (suction valve)
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
7
Defective sealing of swing motor (check valve)
Replace the check valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
PC45MR-5, PC55MR-5
40-329
H-42 Shock is Large When Upper Structure Stops Swing Operation
40 Troubleshooting
H-42 Shock is Large When Upper Structure Stops Swing Operation Failure
Shock is large when upper structure stops swinging. •
Perform all troubleshooting with working mode to be set to power mode (P).
Related
•
Check that oil level in hydraulic tank is normal.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
Swing PPC pressure can be checked with monitoring function. (Code: 09000)
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Malfunction of swing PPC valve
Swing PPC valve outlet pressure
L.H. work equipment control lever: In NEUTRAL
0 MPa {0 kgf/cm2}
L.H. work equipment control lever: In swing RIGHT/ LEFT direction
2.94(+0.49/0.1) MPa {30(+5/-1) kgf/cm2}
2
Malfunction of R.H. swing R.H. swing PPC slow return valve may malfunction. Replace R.H. and L.H. swing PPC slow return valve slow return valve, and check whether failure symptom changes to make judgment.
3
Malfunction of L.H. swing L.H. swing PPC slow return valve may malfunction. Replace R.H. and L.H. swing PPC slow return valve slow return valve, and check whether failure symptom changes to make judgment.
4
Malfunction of swing mo- Safety valve of swing motor malfunctions. Check the spool for sticking or seizure, tor (safety valve) and spring for fatigue.
5
Malfunction of control valve (spool)
40-330
Spool of swing control valve may malfunction. Check that spool moves smoothly and has no defects.
PC45MR-5, PC55MR-5
H-43 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation
40 Troubleshooting
H-43 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation Failure
Large unusual noise is heard when upper structure stops swinging. •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
•
Check that oil level in hydraulic tank is normal.
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Related information
No.
Cause
Procedure, measuring location, criteria and remarks
1
Malfunction of back pres- Back pressure check valve in control valve may malfunctions. Check for stuck, sure check valve seized, and damaged spool and loose spring. Defective swing motor (safety valve)
•
Malfunction of the safety valve of the swing motor is a possibility.
2
•
If normal pressure is not obtained after adjustment, internal defect of safety valve may be defective.
3
Defective seal of swing motor (suction valve)
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
4
Defective swing machinery
Check for unusual noise, unusual heat, and metallic powders in drained oil to make judgment.
PC45MR-5, PC55MR-5
40-331
H-44 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)
40 Troubleshooting
H-44 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) Failure
Swing drift on a slope is large (while swing parking brake is applied). •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
When the control lever for swing and arm IN is in NEUTRAL, the swing brake is applied and swing is fixed by disc brake.
No.
Cause
Procedure, measuring location, criteria and remarks Be ready with engine stopped, then perform troubleshooting with engine at high idle.
1
Swing motor Malfunction of swing mo- parking L.H. work equipment control lever: Operate arm IN dibrake retor parking brake rection or swing RIGHT/LEFT direction lease pressure
2.94 (+0.49/-0.1) MPa {30 (+5/-1) kgf/cm2}
If no failure is found by preceding checks, the brake may malfunction. Check it.
40-332
PC45MR-5, PC55MR-5
H-45 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)
40 Troubleshooting
H-45 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) Failure
Swing drift on a slope is large (while swing parking brake is released). •
Set working mode to power mode (P), and perform all troubleshooting with power mode (P).
Related
•
Check that the oil level in hydraulic tank is correct.
information
•
Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
•
While operating arm IN, swing brake is released and swing is hold by hydraulic pressure only.
No. 1
Cause Malfunction of control valve (spool)
Procedure, measuring location, criteria and remarks Spool of swing control valve may malfunction. Check that spool moves smoothly and has no defects. Be ready with engine stopped, then perform troubleshooting with engine at high idle.
2
Swing relief L.H. work equipment control lever: Swing LEFT relief, Malfunction of swing mo- pressure (pump pres- swing RIGHT relief tor (safety valve) sure)
19.6±0.98 MPa {200±10 kgf/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be defective. 3
Defective seal of swing motor (suction valve)
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
4
Defective sealing of swing motor (check valve)
Replace the check valves of R.H. and L.H. swing motor, and check whether failure symptom changes to make judgment. When taking out the valve, check it for sticking and flaw.
PC45MR-5, PC55MR-5
40-333
Information Shown in Troubleshooting Table (S-Mode)
40 Troubleshooting
Troubleshooting of Engine (S-Mode) Information Shown in Troubleshooting Table (S-Mode) The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Failure
Failure symptom that appears on engine
Related inforInformation on occurred failure or troubleshooting mation Cause 1 2 3 4
Point to check, remarks
Remedy
<Contents of description> Probable cause of failure (Each number is serial number, not priority sequence.)
5
40-334
•
Contents of check to determine probable causes
•
Remarks for determination of probable cause
•
Actions to eliminate probable cause of failure
PC45MR-5, PC55MR-5
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position
40 Troubleshooting
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position Failure Related information No.
1
Engine does not crank when starting switch is turned to “START” position •
See E-mode in “ENGINE DOES NOT START (ENGINE DOES NOT CRANK)” for electrical system troubleshooting
•
If any failure code is displayed, perform troubleshooting for that code first.
Cause
Defective starting circuit wiring system
Point to check, remarks
Remedy
When starting switch is turned to START, starting motor pinion does not pop out.
Perform troubleshooting of “ENGINE DOES NOT START (ENGINE DOES NOT CRANK)” in E mode, and take corrective action.
•
Starting motor pinion makes grating noise (When starting switch is turned to START position, starting motor pinion pops out).
•
Starting motor pinion comes off halfway (When starting switch is turned to START position, starting motor pinion pops out).
•
Starting motor makes flapping sound and does not turn (When starting switch is turned to START position, starting motor pinion protrudes) (Reference: “Flapping sound” means sound made when starting motor pinion pops in and out)
2
Defective starting motor (safety relay portion)
3
If starting motor pinion makes grating noise and the Breakage of flywheel ring starting motor does not turn, visually check the flygear wheel ring gear. Disconnect the inlet and outlet gas piping of EGR cooler to check if water containing coolant is draining.
4
A crack on the EGR cooler (Reference: coolant REMARK contained in exhaust)
Moisture in exhaust gas may be condensed, but this is not a failure. Check if it is coolant or not.
PC45MR-5, PC55MR-5
Perform troubleshooting of “ENGINE DOES NOT START (ENGINE DOES NOT CRANK)” in E mode, and take corrective action.
Replace if the item is broken
After EGR cooler replacement, drain the water in the engine cylinder.
40-335
S-2 Engine Cranks but No Exhaust Smoke Comes Out
40 Troubleshooting
S-2 Engine Cranks but No Exhaust Smoke Comes Out Failure Related information
Engine cranks but no exhaust gas comes out. If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
Remedy
1
Fuel level is low.
2
Clogging fuel tank cap air bleeding hole
3
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
4
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
If fuel tank is checked, it is empty.
Refueling
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
5
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
6
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
Correct or replace fuel piping related parts
7
Defective common rail
Check leakage from common rail pressure limiter. For details, see Testing and adjusting, “Testing fuel delivery, return rate, and leakage”.
Common rail replacement
NOTICE Be sure to check for above “Defective common rail”. 8
Defective supply pump
Check common rail pressure with machine monitor. If it does not increase even during cranking, supply pump Supply pump replacement is defective.
REMARK Common rail pressure can be checked with monitoring function (Code: 36400 (MPa)). 9
Defective air bleeding from common rail or injection pipe
40-336
When common rail pressure (code: 36400 “Common rail pressure”) is checked on monitor, pressure does not drop after stopping (Pressure does not drop, if air is left).
Loosen common rail side of injection pipe and highpressure pipe mounting nuts to bleed air.
PC45MR-5, PC55MR-5
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
40 Troubleshooting
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) Failure Related information
Fuel is being injected but engine does not start (misfiring: engine cranks but does not start). If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
1
Defective battery
2
Fuel level is low.
3
Clogging fuel tank cap air bleeding hole
4
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
5
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
6
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
7
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
Correct or replace fuel piping related parts
8
Clogged air cleaner element
Air cleaner dust indicator is at caution level.
Air cleaner element check and cleaning
9
10
Defective intake air heater
Worn valve, rocker arm, etc.
Point to check, remarks
Remedy
Gravity of electrolyte and voltage of battery are low.
Filling of battery electrolyte
If fuel tank is checked, it is empty.
Refueling
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
•
Installation part of intake air heater is not warmed during preheat operation.
•
Engine preheating monitor does not operate normally during preheat operation or when it is low temperature.
•
Check valve clearance (Reference: See Testing and adjusting, “Testing and adjusting valve Valve or rocker arm reclearance”).
•
When engine is operated, unusual noise is heard from around cylinder head.
Intake air heater replacement
placement
11
Defective piston ring
Check compression pressure (Reference: See “Testing Piston ring and piston reand Adjusting”, “Testing compression pressure”). placement
12
Defective injector (clogged injector, defective spray)
Perform cylinder cutout mode operation to identify cylinder that does not change in speed (see “TESTING Replace injector. AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
13
Defective engine control- In case of an internal defect, troubleshooting is imposler sible as an assembly. Replace whole assembly.
PC45MR-5, PC55MR-5
Engine controller replacement
40-337
S-4 Engine Startability is Unsatisfactory
40 Troubleshooting
S-4 Engine Startability is Unsatisfactory Failure Related information
Engine startability is poor. •
If any failure code is displayed, perform troubleshooting for that code first.
•
Common rail fuel injection system (CRI) controls fuel injection timing electronically. Even when start operation is performed, engine does not start until crankshaft is rotated at least twice. This is not abnormal.
No.
Cause
Point to check, remarks
Remedy
1
Defective battery
2
Fuel level is low.
3
Unspecified fuel is used.
4
Clogging fuel tank cap air bleeding hole
5
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
6
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
7
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
8
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
Correct or replace fuel piping related parts
9
Defective common rail
Check leakage from common rail pressure limiter. For details, see Testing and adjusting, “Testing fuel delivery, return rate, and leakage”.
Common rail replacement
Gravity of electrolyte and voltage of battery are low.
Filling of battery electrolyte
If fuel tank is checked, it is empty.
Refueling
Unspecified fuel is used.
Use recommended fuel described in Operation and Maintenance Manual.
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
NOTICE Be sure to check for above “Defective common rail”. 10
Defective supply pump
Check common rail pressure with machine monitor. If it does not increase even during cranking, supply pump Supply pump replacement is defective.
REMARK Common rail pressure can be checked with monitoring function (Code: 36400 (MPa)). 11
12
Clogged air cleaner element
Defective intake air heater
40-338
Air cleaner dust indicator is at caution level. •
Installation part of intake air heater is not warmed during preheat operation.
•
Engine preheating monitor does not operate normally during preheat operation or when it is low temperature.
Air cleaner element check and cleaning
Intake air heater replacement
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
S-4 Engine Startability is Unsatisfactory
Cause
Point to check, remarks Disconnect the inlet and outlet gas piping of EGR cooler to check if water containing coolant is draining.
13
A crack on the EGR cooler (Reference: coolant REMARK contained in exhaust)
Moisture in exhaust gas may be condensed, but this is not a failure. Check if it is coolant or not. Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started.
•
Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
Defective injector
15
Defective engine control- In case of an internal defect, troubleshooting is imposler sible as an assembly. Replace whole assembly. • Defective contact of valve and valve seat
After EGR cooler replacement, drain the water in the engine cylinder.
•
14
16
Remedy
•
Engine controller replacement
Measure compression pressure (See Standard value table). (Reference: See Testing and adjusting, “Testing compression pressure”.)
Valve or valve seat repair Check valve clearance (Reference: See Testing or replacement
and adjusting, “Testing and adjusting valve clearance”).
17
Defective piston ring
PC45MR-5, PC55MR-5
•
Check exhaust gas color.(Reference: See “Testing and Adjusting”, “Checking exhaust gas color”).
•
Measure compression pressure (See standard value table). (Reference: See “Testing and Adjusting”, “Testing compression pressure”.)
•
Check piston ring and piston ring groove.
Piston ring and piston replacement
40-339
S-5 Engine Does Not Pick Up Smoothly
40 Troubleshooting
S-5 Engine Does Not Pick Up Smoothly Failure Related information
Engine does not pick-up smoothly. If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
Remedy
1
Fuel level is low.
2
Clogging fuel tank cap air bleeding hole
3
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
4
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
If fuel tank is checked, it is empty.
Refueling
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
5
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
6
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
Correct or replace fuel piping related parts
7
Defective common rail
Check leakage from common rail pressure limiter. For details, see Testing and adjusting, “Testing fuel delivery, return rate, and leakage”.
Common rail replacement
NOTICE Be sure to check for above “Defective common rail”. 8
Defective supply pump
Check common rail pressure with machine monitor. If it does not increase even during cranking, supply pump Supply pump replacement is defective.
REMARK Common rail pressure can be checked with monitoring function (Code: 36400 (MPa)).
9
10
Defective injector
Defective valve clearance
40-340
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started.
•
Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
•
When engine is operated, unusual noise is heard from around cylinder head.
•
Check valve clearance (Reference: See Testing ment and adjusting, “Testing and adjusting valve clearance”).
Valve clearance adjust-
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
11
12
13
S-5 Engine Does Not Pick Up Smoothly
Cause
Defective contact of valve and valve seat
Defective piston ring
Point to check, remarks •
Measure compression pressure (See Standard value table). (Reference: See Testing and adjusting, “Testing compression pressure”.)
•
Check valve clearance (Reference: See Testing or replacement and adjusting, “Testing and adjusting valve clearance”).
•
Check exhaust gas color.(Reference: See “Testing and Adjusting”, “Checking exhaust gas color”).
•
Measure compression pressure (See standard value table). (Reference: See “Testing and Adjusting”, “Testing compression pressure”.)
•
Check piston ring and piston ring groove.
Defective engine control- In case of an internal defect, troubleshooting is imposler sible as an assembly. Replace whole assembly.
PC45MR-5, PC55MR-5
Remedy
Valve or valve seat repair
Piston ring and piston replacement
Engine controller replacement
40-341
S-6 Engine Stops During Operation
40 Troubleshooting
S-6 Engine Stops During Operation Failure Related information
Engine stops during operation. If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
Remedy
1
Fuel level is low.
2
Clogging fuel tank cap air bleeding hole
3
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
4
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
If fuel tank is checked, it is empty.
Refueling
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
5
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
6
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
7
Defective supply pump
See Testing and adjusting, “Testing fuel discharge rate, Supply pump and presreturn rate, and leakage” sure limiter replacement
8
Defective air intake hose.
9
Defective air intake mani- Check for internal damages of air intake manifold. fold
10
Defective exhaust pipe.
Check exhaust pipes for damage and exhaust gas Exhaust piping replaceleakage (Check heat insulation cover and soot on heat ment insulation plate)
11
Broken valve or rocker arm
Check valve and rocker arm (when stops with unusual noise).
Visually check for damages of air intake hose.
Remove oil pan and check piston and connecting rod (Reference: Stopping with unusual noise or stopping caused by overheating)
•
Metal particles are contained in oil drained from oil pan. Crankshaft main bearing replacement Remove oil pan and check crankshaft main bearing.
13
14
Defective engine control- Check power supply wiring of engine controller. ler power supply wiring
•
Check starting switch wiring.
Malfunction of hydraulic system
40-342
Valve or rocker arm replacement
•
Breakage or seizure of crankshaft main bearing
16
Air intake manifold replacement
Oil drained from oil pan contains metallic powder.
Breakage or seizure of piston and connecting rod
Defective starting switch wiring
Air intake hose replacement
• 12
15
Correct or replace fuel piping related parts
Piston and connecting rod replacement
Correct engine controller power supply wiring Perform troubleshooting of “ENGINE DOES NOT START (ENGINE DOES NOT CRANK)” in E mode, and take corrective action.
See H mode, “Engine speed lowers significantly or en- Diagnose and take remgine stalls”. edies for H mode
PC45MR-5, PC55MR-5
40 Troubleshooting
S-7 Engine Runs Rough or is Not Stable
S-7 Engine Runs Rough or is Not Stable Failure Related information
Engine runs rough or is unstable. If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
Remedy
1
Fuel level is low.
2
Clogging fuel tank cap air bleeding hole
3
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
4
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
If fuel tank is checked, it is empty.
Refueling
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
5
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
6
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
Correct or replace fuel piping related parts
7
Clogged feed pump gauze filter
Clogged gauze filter
Gauze filter cleaning or replacement
8
Defective mass air flow and temperature sensor
PC45MR-5, PC55MR-5
Replace a sensor, and check if it operates normally (failure code may be displayed due to dust attached to sensor).
Mass air flow and temperature sensor replacement
40-343
S-8 Engine Lacks Power
40 Troubleshooting
S-8 Engine Lacks Power Failure Related information
Engine lacks power. If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
Remedy
1
Fuel level is low.
2
Clogging fuel tank cap air bleeding hole
3
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
4
Foreign materials are mixed into fuel.
If drain fuel from fuel tank, rust or water comes out.
If fuel tank is checked, it is empty.
Refueling
Fuel tank cap air bleeding hole is clogged.
Flush air breather hole in fuel tank cap surrounding area.
Fuel replacement •
Perform air bleeding operation
•
Correct or replace fuel piping
5
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
6
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
7
Defective supply pump
See Testing and adjusting, “Testing fuel discharge rate, Supply pump and presreturn rate, and leakage” sure limiter replacement
8
Clogged air cleaner element
9
Defective air cleaner
10
Defective air intake hose.
11
Defective air intake mani- Check for internal damages of air intake manifold. fold
12
Air intake pipe and joint part failures.
13
Correct or replace fuel piping related parts
Air cleaner dust indicator is at caution level.
Air cleaner element check and cleaning
Check air cleaner and rectifying wire net for deformation.
Air cleaner repair or replacement
Visually check for damages of air intake hose.
Air intake hose replacement Air intake manifold replacement
Air suction from the air intake pipe.
Repair or replacement of air intake pipe and joint part.
Defective installation of charge pressure sensor
Air leakage through mounting portion of charge pressure sensor
Repair installation of charge pressure sensor
14
Defective exhaust pipe.
Check exhaust pipes for damage and exhaust gas Exhaust piping replaceleakage (Check heat insulation cover and soot on heat ment insulation plate)
15
Gas leakage from EGR piping
16
Defective valve clearance
40-344
Gas leaking from EGR piping.
Replace EGR piping
•
When engine is operated, unusual noise is heard from around cylinder head.
•
Check valve clearance (Reference: See Testing ment and adjusting, “Testing and adjusting valve clearance”).
Valve clearance adjust-
PC45MR-5, PC55MR-5
40 Troubleshooting
No.
S-8 Engine Lacks Power
Cause
Point to check, remarks
Remedy
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started.
•
Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
17
Defective injector
18
Defective engine control- In case of an internal defect, troubleshooting is imposler sible as an assembly. Replace whole assembly.
Engine controller replacement
•
Measure compression pressure (See Standard value table). (Reference: See Testing and adjusting, “Testing compression pressure”.)
Valve or valve seat repair
•
Check valve clearance (Reference: See Testing or replacement and adjusting, “Testing and adjusting valve clearance”).
•
Check exhaust gas color.(Reference: See “TESTING AND ADJUSTING”, “Checking exhaust gas color”).
•
Measure compression pressure (See standard placement value table). (Reference: See “TESTING AND ADJUSTING”, “Testing compression pressure”.)
•
Check piston ring and piston ring groove.
19
20
Defective contact of valve and valve seat
Defective piston ring
PC45MR-5, PC55MR-5
Piston ring and piston re-
40-345
S-9 KDPF Becomes Clogged in a Short Time
40 Troubleshooting
S-9 KDPF Becomes Clogged in a Short Time No.
Cause
Point to check, remarks
1
Unspecified fuel is used.
2
Foreign materials are mixed into fuel.
3
Defective air cleaner
Check air cleaner and rectifying wire net for deformation.
4
Defective exhaust pipe.
Check exhaust pipes for damage and exhaust gas Exhaust piping replaceleakage (Check heat insulation cover and soot on heat ment insulation plate)
5
Air intake pipe and joint part failures.
6
Gas leakage from EGR piping
Unspecified fuel is used.
If drain fuel from fuel tank, rust or water comes out.
Air suction from the air intake pipe.
Gas leaking from EGR piping.
Remedy Use recommended fuel described in Operation and Maintenance Manual. Fuel replacement Air cleaner repair or replacement
Repair or replacement of air intake pipe and joint part. Replace EGR piping
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started. Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
7
Defective injector
•
8
Defective fuel return piping
When checking fuel return rate, fuel return rate is excessive. (Reference: See Testing and adjusting, “Testing fuel return rate and leakage”.)
Fuel return piping repair or replacement
9
defective temperature sensor
Replace a sensor, and check if it operates normally (failure code may be displayed due to dust attached to sensor).
Mass temperature sensor replacement
10
11
12
Defective valve clearance
Defective contact of valve and valve seat
Defective piston ring
40-346
•
When engine is operated, unusual noise is heard from around cylinder head.
•
Check valve clearance (Reference: See Testing ment and adjusting, “Testing and adjusting valve clearance”).
•
Measure compression pressure (See Standard value table). (Reference: See Testing and adjusting, “Testing compression pressure”.)
•
Check valve clearance (Reference: See Testing or replacement and adjusting, “Testing and adjusting valve clearance”).
•
Check exhaust gas color.(Reference: See “Testing and Adjusting”, “Checking exhaust gas color”).
•
Measure compression pressure (See standard value table). (Reference: See “Testing and Adjusting”, “Testing compression pressure”.)
•
Check piston ring and piston ring groove.
Valve clearance adjust-
Valve or valve seat repair
Piston ring and piston replacement
PC45MR-5, PC55MR-5
40 Troubleshooting
S-10 Engine Oil Consumption is Excessive
S-10 Engine Oil Consumption is Excessive Failure Related information
Engine oil consumption is excessive If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
Remedy
1
Dust intake from air intake system
If air intake piping between air cleaner and engine is removed, dust enters in piping.
Air intake piping cleaning or replacement
2
Breakage or wear of piston ring
Measure compression pressure (See standard value Piston ring replacement or table). (Reference: See “TESTING AND ADJUSTING”, repair “Testing compression pressure”.)
3
Oil leakage out of engine Check for oil leakage.
4
Oil leakage from oil filter
5
Oil leakage from oil piping
6
Oil leakage from oil drain Check oil leakage from oil drain plug. plug
7
Oil leakage from oil pan
8 9
10
11
12
Oil leakage part repair
Check for oil leakage from oil filter.
Oil filter re installation or replacement
Check for oil leakage from oil piping
Oil piping repair or replacement Retighten oil drain plug
Check for oil leakage from oil pan.
Oil pan repair or replacement
Oil leakage from cylinder head
Check for oil leakage from cylinder head.
Cylinder head repair or replacement
Wear of damage of rear oil seal
Oil in clutch chamber or damper chamber on mounted machine side is increased.
Rear oil seal repair or replacement
Oil leakage from oil cooler
Oil leakage from EGR valve system Wear or damage of valve guide or stem seal
PC45MR-5, PC55MR-5
•
Oil is mixed in coolant.
•
Remove oil cooler, and visually check for oil leakage from the oil cooler surface.
•
Oil cooler replacement
Check oil cooler for leakage by air pressure test.
Outlet port is stained with oil after the EGR valve is disEGR valve replacement connected. •
Check valve guide and stem seal.
•
Remove cylinder head and check guide internal Valve guide and stem seal surface and stem seal for damage (Reference: replacement See Maintenance standard).
40-347
S-11 Oil Becomes Dirty Quickly
40 Troubleshooting
S-11 Oil Becomes Dirty Quickly Failure Related information
Oil becomes contaminated quickly If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
1
Unspecified fuel is used.
2
Use of oil out of specification
3
Exhaust gas color of KDPF is black.
Check exhaust gas color of KDPF (See standard value Perform troubleshooting of table.) (Reference: See Testing and adjusting, “Ex“KDPF gets clogged in a haust gas color”). short times”
4
Addition of too much oil
Check for high oil level (If oil is added too much, it becomes high temperature and is deteriorated rapidly).
Lower oil level to appropriate level.
5
Dirt on oil cooler element
Visually check oil cooler element for dirt (temperature rise caused by dirt of oil cooler element)
Oil cooler element repair or replacement
6
Wear in the EGR valve guide
7
Breakage or wear of piston ring
8
Wear or damage of valve guide or stem seal
40-348
Point to check, remarks
Remedy
Unspecified fuel is used.
Use recommended fuel described in Operation and Maintenance Manual.
Oil out of specification is used
Use recommended oil described in Operation and Maintenance Manual.
•
Disconnect the EGR valve to check a stem seal, guide, and system.
•
Outlet port is stained with oil after the EGR valve is disconnected.
EGR valve replacement
Measure compression pressure (See standard value Piston ring replacement or table). (Reference: See “TESTING AND ADJUSTING”, repair “Testing compression pressure”.) •
Check valve guide and stem seal.
•
Remove cylinder head and check guide internal Valve guide and stem seal surface and stem seal for damage (Reference: replacement See Maintenance standard).
PC45MR-5, PC55MR-5
40 Troubleshooting
S-12 Fuel Consumption is Excessive
S-12 Fuel Consumption is Excessive Failure Related information No.
1
Fuel consumption is excessive. If any failure code is displayed, perform troubleshooting for that code first. Cause
Point to check, remarks
Leakage from injector (Reference: See “Testing and Adjusting”,“Testing fuel discharge, return and leakMuch leakage from injec- age”). tor
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started.
Remedy •
Replace injector.
•
Excessive dust may be in fuel. Confirm quality control of fuel.
2
Defective injector
•
Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
3
Fuel leakage from inside of cylinder head
•
Check if oil level is increasing.
•
Check if there is smell of diesel fuel.
Fuel leakage supply pump oil seal part
•
4
Check if oil level is increasing or there is smell of diesel fuel.
•
Check supply pump oil seal.
5
External fuel leakage
PC45MR-5, PC55MR-5
Check for fuel leakage to outside of engine.
Defective parts repair supply pump oil seal replacement Defective parts repair
40-349
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant
40 Troubleshooting
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Failure Related information No.
Oil is in coolant (or coolant spurts back or coolant level goes down) If any failure code is displayed, perform troubleshooting for that code first. Cause
Point to check, remarks Engine oil is increasing and milky.
Remedy
1
Engine oil is milky.
Perform troubleshooting of “WATER MIXES INTO ENGINE OIL (MILKY)” in S mode, and take corrective action.
2
Breakage of oil cooler el- Check oil cooler element. ement
Oil cooler element replacement
• 3
Breakage of cylinder head
• •
4
Breakage of head gasket
5
Cracking or hole caused by pitting in cylinder block
40-350
There are many bubbles in radiator and coolant blows back. Cylinder head replacement Disassemble engine and check cylinder head for abnormality by pressure test. Many bubbles and blow-back are found in radiator.
Cylinder head gasket replacement
•
Disassemble and inspect engine. Check cylinder head gasket for failure.
•
Engine oil is increasing and milky.
•
Disassemble engine and check inside of cylin- ment der block for cracking or hole caused by pitting.
Cylinder block replace-
PC45MR-5, PC55MR-5
40 Troubleshooting
S-14 Oil Pressure Drops
S-14 Oil Pressure Drops Failure Related information
Oil pressure drops. •
If any failure code is displayed, perform troubleshooting for that code first.
•
Check if machine is operated on slopes steeper than angle specified in Operation and Maintenance Manual.
No.
Cause
1
Insufficient oil in oil pan
2
Defective oil pressure sensor or wiring harness
Point to check, remarks
Remedy
Oil level in oil pan is insufficient.
3
4
5
Fuel mixed in oil
Water mixed in oil
Clogged oil filter
Oil pressure monitor indicates low oil pressure on slopes.
Oil refiling
Check oil pressure sensor, wiring harness, and connectors
Oil pressure sensor, wiring harness, and connectors replacement
•
Perform oil analysis and check for mixing of oil
•
Oil smells of diesel fuel.
•
Perform oil analysis and check for mixing of wa- If water is mixed into oil, perform troubleshooting of ter
•
Oil is milky.
•
Check oil filter.
(Reference: Oil filter is used for more than specified period, oil is deteriorated badly, etc.) •
If fuel is mixed into oil, perform troubleshooting of “FUEL MIXES INTO ENGINE OIL” in S mode, and take corrective action.
“WATER MIXES INTO ENGINE OIL (MILKY)” in S mode, and take corrective action.
Oil filter replacement
Oil filter may be blocked by water.
6
Clogged oil strainer
Check oil strainer.
Oil strainer cleaning
7
Flattened or clogged hydraulic piping
Hydraulic piping is flattened or clogged.
Hydraulic piping replacement
8
Defective oil pump
9
Defective regulator valve
Check whether the valve spring is deformed and damaged
10
Defective oil pump relief valve
Valve and spring of oil pump relief valve are weakening Oil pump relief valve exand damaged. change
11
Cracking in oil pump suc- Check around oil pump suction piping (for cracking ing Oil pump suction piping tion piping piping). replacement Defective seal between oil pump and oil pump suction piping
Check sealing portion.
12
13
Leakage from EGR hydraulic piping
Check EGR hydraulic piping.
14
Wear of main journal bearing
PC45MR-5, PC55MR-5
•
Check oil pump (for wear or breakage of gear)
•
Oil pump is heavy in turning or has play.
Oil pump replacement Regulator valve exchange
Seal replacement EGR hydraulic piping replacement
•
Check main journal bearing.
•
Metal particles are contained in oil drained from placement oil pan.
Bearing of main journal re-
40-351
S-14 Oil Pressure Drops
No.
Cause
15
Wear of pin journal bearing
40-352
40 Troubleshooting
Point to check, remarks •
Check pin journal bearing.
•
Oil drained from oil pan contains metallic powder.
Remedy Bearing of pin journal replacement
PC45MR-5, PC55MR-5
40 Troubleshooting
S-15 Fuel Mixes Into Engine Oil
S-15 Fuel Mixes Into Engine Oil Failure Related information No.
Fuel mixes into engine oil. •
If any failure code is displayed, perform troubleshooting for that code first.
Cause
Point to check, remarks
Remedy
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started. Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1
Defective injector
•
2
Fuel leakage from injector or O-ring (spill circuit)
Check injector and O-ring.
3
Defective seal between Check of seal between injector and inspection pipe, injector and inspection check of injection pipe for cracking pipe, or cracked injection pipe
Repair or replacement
4
Internal defect of supply pump
Supply pump replacement
PC45MR-5, PC55MR-5
Replace supply pump, and check if mixing of fuel is prevented.
Injector and O-ring replacement
40-353
S-16 Water Mixes Into Engine Oil (Milky)
40 Troubleshooting
S-16 Water Mixes Into Engine Oil (Milky) Failure Related information No.
Water mixes into engine oil (milky) •
If oil mixes into coolant, perform troubleshooting for “Oil mixes into coolant”.
•
If any failure code is displayed, perform troubleshooting for that code.
If coolant level lowers rapidly and coolant leakage is suspected, perform following troubleshooting. Cause
Point to check, remarks •
1
Remedy
Water containing coolant is draining after disconnecting the inlet and outlet gas piping of EGR cooler (check if it is antifreeze because it may be condensed water).
A crack on the EGR cool(Reference: A crack in the EGR cooler, if any, may be EGR cooler replacement er caused by lowered coolant level in the coolant system. Check if there is no water leakage from the piping of the coolant system or radiator when the replacing the EGR cooler.) •
Check oil cooler element and O-ring
•
Leakage form oil cooler is detected by pressure ring replacement test.
2
Breakage of oil cooler element or O-ring
3
Leakage through water pump mechanical seal
Check water pump mechanical seal for leakage
Mechanical sealed part of water pump replacement
4
Clogged water pump drain hole
Check water pump drain hole.
Water pump drain hole cleaning
5
Breakage of cylinder head or head gasket
Disassemble engine and check cylinder head and head gasket
Cylinder head and head gasket replacement
•
Engine oil is increasing and milky.
6
Cracking or hole caused by pitting in cylinder block
•
Disassemble engine and check inside of cylin- ment der block for cracking or hole caused by pitting.
40-354
Oil cooler element and O-
Cylinder block replace-
PC45MR-5, PC55MR-5
40 Troubleshooting
S-17 Coolant Temperature Increases Too High (Overheating)
S-17 Coolant Temperature Increases Too High (Overheating) Failure Related information No. 1
Coolant temperature rises too high (overheating) If any failure code is displayed, perform troubleshooting for that code first. Cause
Clogged radiator core
Point to check, remarks
Remedy
Check for clogging of radiator core and crushing of fin.
Cleaning of radiator core
Thermostat does not open at cracking temperature. 2
Malfunction of thermostat
3
Defective coolant temperature gauge
REMARK For thermostat opening temperature, see Engine Shop Manual
Thermostat replacement
The error is detected in coolant temperature gauge system, but measured coolant temperature in radiator is normal.
Coolant temperature sensor, monitor or wiring harness replacement
Fuel injection amount is excessive.
Perform troubleshooting of “FUEL CONSUMPTION IS EXCESSIVE” in S mode, and take corrective action.
Check coolant level for decrease.
Refilling with coolant
Check coolant piping for coolant leakage.
Coolant piping replacement
4
Increase of fuel injection amount
5
Low coolant level
6
Coolant leakage
7
Broken water pump
8
Overheat due to increase Check for defective mass temperature sensor. in EGR ratio (EGR amount against fresh air intake amount) caused by defective temperature sensor
Mass temperature sensor replacement
9
Overheat caused by increase of EGR ratio (quantity of EGR to fresh intake air) caused by deformation of air cleaner
Air cleaner repair or replacement
10
Defective cylinder head or head gasket
11
Defective piston ring
PC45MR-5, PC55MR-5
Visually check water pump (check of water leakage through shaft seal, breakage of impeller, breakage of shaft)
Check air cleaner and rectifying wire net for deformation.
Water pump replacement
Check if there are many bubbles in radiator and if cool- Perform troubleshooting of ant blows back. “OIL IS IN COOLANT” in S mode, and take corrective action. •
Check exhaust gas color.(Reference: See “TESTING AND ADJUSTING”, “Checking exhaust gas color”).
•
Measure compression pressure (See standard placement value table). (Reference: See “TESTING AND ADJUSTING”, “Testing compression pressure”.)
•
Check piston ring and piston ring groove.
Piston ring and piston re-
40-355
S-18 Unusual Noise is Heard
40 Troubleshooting
S-18 Unusual Noise is Heard Failure
Unusual noise is heard. •
Check place of sound source, inside or outside, then perform troubleshooting.
•
While engine is not warmed up sufficiently, it is operated in warm-up mode and it generates a little larger sound. This is not abnormal.
•
When engine is accelerated, it is set in acceleration mode and it generates a little larger sound for approximately 3 to 5 seconds. This is not abnormal.
•
If any failure code is displayed, perform troubleshooting for that code first.
Related information
No.
Cause
1
Gas leakage from each part of the piping
2
Vibration of exhaust piping and exhaust bellows
3
KDPF broken internally
Point to check, remarks •
Gas leakage from following parts; between cylinder head and exhaust manifold
•
Gas leakage from EGR piping or air intake piping
Problematic portions repair or replacement
Confirm the presence of vibration by visual check
Check and retighten piping fixed bracket
Check internal KDPF.
KDPF cleaning or replacement
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started. Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
4
Defective injector
•
5
Defective valve clearance
Check valve clearance (Reference: See Testing and adjusting, “Testing and adjusting valve clearance”).
Seizure of pin bushing, front bearing, or main bearing
Check inside of oil pan for metallic powder.
6
1.
Valve clearance adjustment Damaged parts repair or replacement
If metal particles are found in oil pan or oil filter, overhaul engine and check piston rings and cylinder block. Replace piston ring, repair or replace cylinder block Measure pressure (See Standard value table) (Reference: See Testing and adjusting, “Testing compression pressure”)
7
Worn piston ring or cylinder block 2.
8
Broken valve or rocker arm
Overhaul engine and check valve and rocker arm parts.
9
Broken peripheral parts of idler gear
Overhaul engine and inspect idler gear parts.
10
Defective alternator belt
40-356
Remedy
Check if alternator belt is damaged or interfered
Valve or rocker arm replacement Idler gear replacement Replace alternator belt and damaged parts
PC45MR-5, PC55MR-5
40 Troubleshooting
S-19 Vibration is Excessive
S-19 Vibration is Excessive Failure Related information
Vibration is excessive. •
If unusual noise is heard and vibration is excessive, perform troubleshooting for “Unusual noise is heard” as well.
•
If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
Point to check, remarks
1
Loose engine mounting bolts or defective cushions
2
Abnormality of output Check output shaft and damper for internal damage. shaft and inside of damper
3
Misalignment and facial runout at connection of engine output side is out of standard range.
Visually check engine mounting bolts for looseness and cushions for cracks and hardening.
Measure misalignment and facial runout at connection of engine output side.
Remedy Retighten bolts or cushions replacement Defective parts replacement
Defective parts replacement
•
Some cylinder is found to be cool when exhaust manifolds are touched by hand immediately after engine is started.
•
Perform cylinder cutout mode operation to iden- Replace injector. tify cylinder that does not change in speed (see “TESTING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
4
Defective injector
5
Wear of main bearing If metallic powder is found in oil pan and oil filler, disasDamaged parts repair and and connecting rod bear- semble engine and check it. replacement ing
6
Broken valve or rocker arm
If there is metallic powder in oil pan or oil filter, open head cover and check valve and rocker arm.
Damaged parts repair and replacement
7
Worn camshaft bushing
If metal particles are found in oil pan or oil filter, overhaul engine and check camshaft bushings.
Camshaft bushings replacement
PC45MR-5, PC55MR-5
40-357
S-20 Air Cannot be Bled from Fuel Circuit
40 Troubleshooting
S-20 Air Cannot be Bled from Fuel Circuit Failure Related information
Air cannot be bled from fuel circuit. If any failure code is displayed, perform troubleshooting for that code first.
No.
Cause
1
Fuel level is low.
If fuel tank is checked, it is empty.
Refueling
2
Looseness of fuel prefilter drain valve
Check for loosened fuel prefilter drain valve (Air mixed for loosened fuel prefilter drain valve).
Close drain valve
3
Clogged fuel filter element
Check used hours of fuel filter element. If it is used Fuel filter element replaceover specified time, fuel filter element may be clogged. ment
4
Air mixed in fuel piping system
When performing bleeding air from the fuel system, air comes out. (For details, see Testing and Adjusting, “Bleed Air from Fuel System”).
5
Leakage from fuel piping system
Fuel leaks from fuel piping. (For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”).
Correct or replace fuel piping related parts
6
Feed pomp error.
Feed pump does not operate.
Feed pump replacement.
40-358
Point to check, remarks
Remedy
•
Perform air bleeding operation
•
Correct or replace fuel piping
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
PC45MR-5, PC55MR-5
50-1
Table of Contents
50 Disassembly and Assembly
Table of Contents Abbreviation List ............................................................................................................................................ 50-5 Precautions Before Work ..............................................................................................................................50-11 Related Information on Disassembly and Assembly..................................................................................... 50-12 How to Read This Manual ..................................................................................................................... 50-12 Coating Materials List............................................................................................................................ 50-13 Special Tool List .................................................................................................................................... 50-18 Sketches of Special Tools ..................................................................................................................... 50-23 Engine and Cooling System ......................................................................................................................... 50-24 Remove and Install Supply Pump Assembly ......................................................................................... 50-24 Remove Supply Pump Assembly ................................................................................................... 50-24 Install Supply Pump Assembly ....................................................................................................... 50-27 Remove and Install Starter Assembly ................................................................................................... 50-31 Remove Starting Motor Assembly .................................................................................................. 50-31 Install Starting Motor Assembly ...................................................................................................... 50-32 Remove and Install Radiator Assembly................................................................................................. 50-33 How to Remove Radiator Assembly............................................................................................... 50-33 How to Install Radiator Assembly................................................................................................... 50-36 Remove and Install Hydraulic Oil Cooler Assembly............................................................................... 50-40 How to Remove Hydraulic Oil Cooler Assembly............................................................................. 50-40 How to Install Hydraulic Oil Cooler Assembly................................................................................. 50-43 Remove and Install Engine and Main Pump Assembly ......................................................................... 50-47 Remove Engine and Main Pump Assembly ................................................................................... 50-47 Install Engine and Main Pump Assembly ....................................................................................... 50-53 Remove and Install Fuel Tank Assembly............................................................................................... 50-60 Remove Fuel Tank Assembly......................................................................................................... 50-60 Install Fuel Tank Assembly............................................................................................................. 50-62 Remove and Install KDPF Assembly..................................................................................................... 50-65 How to Remove KDPF Assembly................................................................................................... 50-65 How to Install KDPF Assembly....................................................................................................... 50-67 Disassemble and Assemble KDPF Assembly ....................................................................................... 50-69 Power Train.................................................................................................................................................. 50-70 Remove and Install Travel Motor and Final Drive Assembly.................................................................. 50-70 Remove Travel Motor and Final Drive Assembly............................................................................ 50-70 Install Travel Motor and Final Drive Assembly................................................................................ 50-72 Disassemble and Assemble Final Drive Assembly ................................................................................ 50-74 How to Disassemble Final Drive Assembly .................................................................................... 50-74 How to Assemble Final Drive Assembly ......................................................................................... 50-78 Remove and Install Swing Motor and Swing Machinery Assembly........................................................ 50-83 Remove Swing Motor and Swing Machinery Assembly.................................................................. 50-83 Install Swing Motor and Swing Machinery Assembly...................................................................... 50-84 Disassemble and Assemble Swing Machinery Assembly ...................................................................... 50-85 Disassemble Swing Machinery Assembly ...................................................................................... 50-85 Assemble Swing Machinery Assembly ........................................................................................... 50-88 Remove and Install Swing Circle Assembly .......................................................................................... 50-92 Remove Swing Circle Assembly..................................................................................................... 50-92 Install Swing Circle Assembly ........................................................................................................ 50-92 Undercarriage and Frame ............................................................................................................................ 50-93 Disassemble and Assemble Recoil Spring Assembly............................................................................ 50-93 Disassemble Recoil Spring Assembly ............................................................................................ 50-93 Assemble Recoil Spring Assembly................................................................................................. 50-94 Separate and Connect Track Assembly ................................................................................................ 50-96 Separate Track Assembly .............................................................................................................. 50-96 Install Track Assembly ................................................................................................................... 50-96 Disassemble and Assemble Idler Assembly .......................................................................................... 50-98 Disassemble Idler Assembly .......................................................................................................... 50-98 Assemble Idler Assembly ............................................................................................................... 50-99 50-2
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Table of Contents
Disassemble and Assemble Track Roller Assembly.............................................................................50-101 Disassemble Track Roller Assembly .............................................................................................50-101 Assemble Track Roller Assembly ..................................................................................................50-102 Disassemble and Assemble Carrier Roller Assembly...........................................................................50-104 Disassemble Carrier Roller Assembly ...........................................................................................50-104 Assemble Carrier Roller Assembly................................................................................................50-105 Remove and Install Revolving Frame Assembly ..................................................................................50-107 Remove Revolving Frame Assembly ............................................................................................50-107 Install Revolving Frame Assembly ................................................................................................50-108 Remove and Install Counterweight Assembly ......................................................................................50-110 Remove Counterweight Assembly ................................................................................................50-110 Install Counterweight Assembly ....................................................................................................50-113 Hydraulic System ........................................................................................................................................50-118 Remove and Install Center Swivel Joint Assembly ...............................................................................50-118 Remove Center Swivel Joint Assembly .........................................................................................50-118 Install Center Swivel Joint Assembly.............................................................................................50-119 Disassemble and Assemble Center Swivel Joint Assembly..................................................................50-122 Disassemble Center Swivel Joint Assembly ..................................................................................50-123 Assemble Center Swivel Joint Assembly.......................................................................................50-124 Remove and Install Hydraulic Tank Assembly ......................................................................................50-125 Remove Hydraulic Tank Assembly ................................................................................................50-125 How to Install Hydraulic Tank Assembly ........................................................................................50-128 Remove and Install Main Pump Assembly ...........................................................................................50-131 Remove Main Pump Assembly .....................................................................................................50-131 Install Main Pump Assembly .........................................................................................................50-133 Remove and Install Accumulator Assembly .........................................................................................50-137 How to Remove Accumulator Assembly (EU Specification) ..........................................................50-137 How to Remove Accumulator Assembly (North America Specification, for Machine with Quick Coupler). ..................................................................................................................................................50-138 How to Install Accumulator Assembly (EU Specification) ..............................................................50-140 How to Install Accumulator Assembly (North America Specification, for Machine with Quick Coupler)..... ..................................................................................................................................................50-141 Disassemble and Assemble Work Equipment PPC Valve Assembly ....................................................50-143 Disassemble Work Equipment PPC Valve Assembly ....................................................................50-143 How to Assemble Work Equipment PPC Valve Assembly .............................................................50-144 Disassemble and Assemble Travel PPC Valve Assembly ....................................................................50-146 Disassemble Travel PPC Valve Assembly.....................................................................................50-146 How to Assemble Travel PPC Valve Assembly .............................................................................50-147 Work Equipment .........................................................................................................................................50-149 Remove and Install Blade Assembly ....................................................................................................50-149 Remove Blade Assembly ..............................................................................................................50-149 Install Blade Assembly ..................................................................................................................50-150 Remove and Install Work Equipment Assembly ...................................................................................50-151 Remove Work Equipment Assembly .............................................................................................50-151 Install Work Equipment Assembly .................................................................................................50-152 Disassemble and Assemble Work Equipment Cylinder Assembly........................................................50-155 How to Disassemble Work Equipment Cylinder Assembly ............................................................50-156 How to Assemble Work Equipment Cylinder Assembly .................................................................50-159 CAB Related Parts ......................................................................................................................................50-164 Remove and Install Operator CAB Assembly (CAB Specification) .......................................................50-164 Remove Operator CAB Assembly (CAB Specification) .................................................................50-164 Install Operator CAB Assembly (CAB Specification) .....................................................................50-167 Remove and Install Floor Frame Assembly (Canopy Specification) .....................................................50-171 Remove Floor Frame Assembly (Canopy Specification) ...............................................................50-171 Install Floor Frame Assembly (Canopy Specification) ...................................................................50-174 Remove and Install Operator Cab Glass (Adhered Glass) ...................................................................50-177 Remove Operator CAB Glass (Adhered Glass).............................................................................50-178 Install Operator CAB Glass (Adhered Glass) ................................................................................50-179 PC45MR-5, PC55MR-5
50-3
Table of Contents
50 Disassembly and Assembly
Remove and Install Front Window Assembly .......................................................................................50-187 Remove Front Window Assembly .................................................................................................50-187 Install Front Window Assembly .....................................................................................................50-188 Remove and Install Air Conditioner Unit Assembly ..............................................................................50-190 Remove Air Conditioner Unit Assembly.........................................................................................50-190 Install Air Conditioner Unit Assembly ............................................................................................50-194 Remove and Install Operator Seat .......................................................................................................50-199 Remove Operator's Seat...............................................................................................................50-199 Install Operator's Seat...................................................................................................................50-199 How to Remove and Install Seat Belt ...................................................................................................50-201 How to Remove Seat Belt .............................................................................................................50-201 How to Install Seatbelt ..................................................................................................................50-201 Electrical System ........................................................................................................................................50-202 Remove and Install Engine Controller Assembly..................................................................................50-202 Remove Engine Controller Assembly ............................................................................................50-202 Install Engine Controller Assembly................................................................................................50-203 Remove and Install Machine Controller Assembly ...............................................................................50-204 Remove Machine Controller Assembly..........................................................................................50-204 Install Machine Controller Assembly .............................................................................................50-205 Remove and Install Machine Monitor Assembly ...................................................................................50-207 Remove Machine Monitor Assembly .............................................................................................50-207 Install Machine Monitor Assembly .................................................................................................50-208 Remove and Install KOMTRAX Terminal Assembly .............................................................................50-210 Remove KOMTRAX Terminal Assembly .......................................................................................50-210 Install KOMTRAX Terminal Assembly ...........................................................................................50-211
50-4
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
50-5
Abbreviation List
Abbreviation
Actual word spelled out
50 Disassembly and Assembly
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
50-6
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
50-7
Abbreviation List
50 Disassembly and Assembly
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
50-8
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
50-9
Abbreviation List
50 Disassembly and Assembly
Abbreviation S/T STRG
Actual word spelled out Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
50-10
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Precautions Before Work
Precautions Before Work Before you start, read the “Safety Notice for Operation” of the “Index and Foreword” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a dan-
ger that you can get caught in the machine. •
Do not wear oversized clothes or accessories.
•
Be sure to tie the long hair that comes out from the helmet.
•
Decide on the work procedure.
•
Obey the specified signal during the work.
k When you work together with more than one person, do the preparation that follows.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange an
observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not to
let the machine move. •
Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
•
Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts, there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.
PC45MR-5, PC55MR-5
50-11
How to Read This Manual
50 Disassembly and Assembly
Related Information on Disassembly and Assembly How to Read This Manual This section gives information for the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown. This shop manual does not include disassembly and assembly of the parts that consist engine. For details, see engine edition of shop manual for the engine model installed in the machine.
Reading the special tools list •
The special tools required for removal, installation, disassembly, and assembly work are shown in the list as symbols such as A, ..., X.
•
For details of the special tool, see “Special Tool List”. For details of the sketches, see “Sketches of Special Tools”. Special tools required for a specified work is also given in each work procedures.
Reading the work procedures All the necessary information for the work procedure, precautions, and prior knowledge related to the work procedures are shown step by step.
Reading the symbols Important safety and quality parts are marked with the symbols that follow to use Shop Manual effectively. Symbol
Item
Summary
Danger
This symbol shows extremely high possibility of danger which will result in death or personal injury if it is not avoided.
Warning
This symbol shows a potentially dangerous situation which will result in death or personal injury if it is not avoided.
Caution
This symbol shows a potentially dangerous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This symbol shows the weight of parts and components. Be careful when you select wires and working attitude for lifting work.
Tightening torque
This symbol shows the tightening torque for parts which requires special care in assembly work.
Coat
This symbol shows a lubrication point with adhesive, grease, or such in assembly work.
Oil and coolant
This symbol shows a point to supply oil, coolant, or such along with the quantity. (*1)
Drain
This symbol shows a point to drain oil, coolant, or such and the quantity.
*1: For details of a place to supply oil, coolant, etc. and the quantity, see SPECIFICATIONS.
Reading the signal word The signal word for NOTICE and REMARK show the contents that follow. Symbol
Item
Summary
NOTICE
Notice
If you do not obey the precaution of this signal word, the machine can have damage or the service life can be shortened.
REMARK
Remarks
Information shown in this signal word is useful to know.
Reading the unit International System of Units (SI) is used in this manual. For reference, the conventional units are given in { }.
50-12
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Coating Materials List
Coating Materials List Coating materials which are not listed below, use the equivalent of products shown in this manual.(Rev.2023.2) Liquid Adhesive Komatsu code LT-1A
LT-1B
LT-2
Part No.
Volume
Container
790-129-9030
150 g
Tube
20 g (2 pieces)
Polyethylene container
790-129-9180
50 g
Polyethylene container
790-129-9060
Adhesive 1 kg
790-129-9050
Container
LT-3
Set of adhesive and hardener
LT-4
790-129-9040
250 g
Polyethylene container
790-129-9120
75 g
Tube
50 g
Polyethylene container
2g
Polyethylene container
Holts MH705 ThreeBond 1735
Aron Alpha 201
Loctite 499
Loctite 648-50
790-129-9140
790-129-9130
428-99-80070
79A-129-9110
Hardener 500 g
20 cc
50 cc
Main features and applications •
Use to prevent rubber gaskets, rubber cushions, and cork plugs from falling off.
•
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
•
Features: Resistance to heat and chemicals
•
Use to keep bolts and plugs from coming loose. It can also be used as a sealant.
•
Use to bond and seal metal, glass, and plastics etc.
•
Used as sealant for plugs for machined holes.
•
Heat-resistant seal used to repair engines
•
Instantaneous adhesive
•
Curing time: From 5 sec. to 3 min.
•
Use to bond mainly metals, rubbers, plastics, and woods.
•
Instantaneous adhesive
•
Quick-curing type (max. strength is obtained after 30 minutes)
•
Use to bond rubbers, plastics, and metals.
•
General-purpose instantaneous adhesive with excellent resistance to heat and impact
•
Use for the bushing mounting faces of axle supports.
•
Features: Resistance to heat and chemicals
•
Use to bond high-temperature fit parts.
Tube
Polyethylene container
Liquid Gasket Komatsu code LG-1
Part No.
Volume
Container
790-129-9010
200 g
Tube
PC45MR-5, PC55MR-5
Main features and applications •
Used to stick or seal gaskets and packings of power train case, etc.
50-13
Coating Materials List
Komatsu code
50 Disassembly and Assembly
Part No.
Volume
Container
1 kg
Polyethylene container
Main features and applications •
Use to seal various threaded portions, pipe joints, and flanges.
•
Use to seal taper plugs, elbows, and nipples for hydraulic piping.
•
Features: Silicon-based heat and cold-resistant
•
Use to seal flange surface and threaded portions
•
Use to seal the Oil pan, final drive case, etc.
•
Features: Silicon-based quick-curing sealant
•
Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
•
Features: Silicon-based heat, vibration, and shock-resistant
•
Use to seal transfer case, etc.
•
Use for coarse rough surfaces such as the upper seal of a circle gear that does not require fastening and waterproof for weld gaps etc.
•
Can be coated with paint.
•
Use as lubricant or sealant when inserting radiator hoses
1206E
•
Can be coated with paint.
LG-11
•
Feature: Can be used together with solid gaskets.
•
Use for covers of the transmission case and steering case etc.
•
Feature: Acrylic, flexible after hardening
•
Use as flange sealant for rigid case
•
Liquid gasket used to repair engine
•
Apply on the outer circumference of the oil seal and dust seal to prevent oil leakage
•
Thick viscous liquid, and can be used with rubber packing
•
Semi-dry viscoelastic type
LG-5
LG-6
LG-7
790-129-9080
790-129-9160
790-129-9170
200 g
1 kg
Tube
Tube
LG-8 ThreeBond
419-15-18131
100 g
Tube
1207B LG-9 ThreeBond
790-129-9310
200 g
Tube
1206D LG-10 ThreeBond
ThreeBond
790-129-9320
790-129-9330
200 g
200 g
Tube
Tube
1121 LG-12 Loctite
-
515 ThreeBond 1211
SEALEND 242
50 mℓ 300 mℓ
Tube
790-129-9090
100 g
Tube
790-129-9340
150 g
Tube
790-129-9350
500 g
Container
790-129-9360
1 kg
Container
Molybdenum Disulfide Lubricant Komatsu code
LM-P
50-14
Part No.
-
Volume
200 g
Container
Main features and applications •
Use to prevent galling and seizure of press-fitting portions, shrink-fitted portions, and threaded portion.
•
Use to lubricate linkages, bearings, etc.
Tube
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Komatsu code
Part No.
LM-S
-
Coating Materials List
Volume
190 g
Container
Main features and applications •
Spray type
•
Thin molybdenum disulfide films are made on metal surfaces to prevent the metals from galling.
•
Use for drive shaft splines, needle bearings, various link pins, bolts, etc.
Container
Seizure Prevention Compound Komatsu code
Part No.
LC-G
Volume
Container
-
-
Container
Part No.
Volume
Container
Various
Various
NEVER-SEEZ
Main features and applications •
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc.
•
Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Grease Komatsu code
Main features and applications
SYG2-400LI SYG2-350LI G2-LI G0-LI (*) *: For cold regions
SYG2-400LI-A SYG2-160LI SYGA-160CNLI
•
Lithium grease with extreme pressure lubrication performance, general purpose type.
•
Use for parts under heavy load.
•
Caution: DO NOT use this grease for roller bearings, such as swing circle bearings, etc. or splines.
•
Caution: Use this grease for work equipment pins only when installing them, but do not use it afterwards.
•
Higher seizure resistance, heat resistance, and waterproof than molybdenum disulfide grease
•
Not conspicuous on machine since color is white.
•
Reduces effect on microorganisms, animals, and plants. This is based on swift decomposition by natural bacteria.
SYG0-400LI-A (*) SYG0-16CNLI (*)
Grease that includes molybdenum disulfide
SYG2-400M
400 g×10
SYG2-400M-A
400 g×20
Bellowstype container
LM-G (G2-M)
SYGA-16CNM
16 kg
Container
Hyper white grease
SYG2-400T-A
G2-T
SYG2-16CNT
400 g
G0-T (*)
SYG0-400T-A (*)
16 kg
Bellowstype container
*: For cold regions
SYG0-16CNT (*)
Biogrease G2-B G2-BT (*)
Container
SYG2-400B SYGA-16CNB
SYG2-400BT (*) *: For use at high SYGA-16CNBT temperature and (*) under high load
PC45MR-5, PC55MR-5
400 g 16 kg
Bellowstype container Container
50-15
Coating Materials List
Komatsu code
50 Disassembly and Assembly
Part No.
Volume
Container
G2-S ThreeBond
-
200 g
Main features and applications •
Feature: Silicon-based grease with wider operating temperature range and superior thermal oxidative stability to prevent deterioration of rubber and plastic.
•
Use for oil seals of the transmission, etc.
•
Feature: Urea (organic) grease with heat resistance and long service life, inclusion type.
•
Use for rubber, bearing and oil seal in damper.
•
Caution: Do not mix with lithium grease.
Tube
1855
G2-U-S ENS Grease
427-12-11871
2 kg
Container
Primer
Loctite 712 Primer 435-98 for SUNSTAR Coating
Part No.
Volume
Container
428-99-80080
100 mℓ
Glass container
22M-54–27260
150 mℓ
Glass container
SUNSTAR Primer 435-41 for glass
22M-54-27240
150 mℓ
Steel can
SUNSTAR sash primer GP-402
22M-54-27250
900 mℓ
Steel can
Komatsu code
Part No.
Volume
Container
Japan Sikaflex 256HV
20Y-54-39850
310 mℓ
Polyethylene container
SUNSTAR Penguin Super 560
22M-54-27210
320 mℓ
Ecocart (special container)
SUNSTAR Penguin Seal #560
416-926-6950
320 mℓ
Ecocart (special container)
Main features and applications •
For adhered window glass
Komatsu code
Use to accelerate hardening of instantaneous adhesive. •
Use as primer for cab side (Expiration date: 4 months after its production date)
•
Use as primer for black ceramic-coated glass surface and for hard polycarbonate-coated surface (expiration date: 6 months after its production date)
•
Use as primer for ceramic coated glass (expiration date: 6 months after its production date)
Adhesive
50-16
For adhered window glass
Main features and applications •
Use as adhesive for glass (Expiration date: 6 months after its production date)
•
Use as adhesive for glass (Expiration date: 6 months after its production date)
•
Use as adhesive for glass (Expiration date: 6 months after its production date)
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Coating Materials List
Caulking Material Part No.
Volume
Container
SUNSTAR Penguin Seal No. 2505
417-926-3920
320 mℓ
Polyethylene container
SEKISUI Silicone 20Y-54-55130 Sealant
333 mℓ
Polyethylene container
GE TOSHIBA SILICONES TOSSEAL381
22M-54-27220
PC45MR-5, PC55MR-5
333 mℓ
Cartridge
Main features and applications For adhered window glass
Komatsu code
•
Use to seal for joint between glasses (Expiration date: 4 months after its production date)
•
Use to seal front window (Expiration date: 6 months after its production)
•
Translucent white seal used for joint between glasses (Expiration date: 12 months after its production date)
•
Translucent white seal
50-17
Special Tool List
50 Disassembly and Assembly
Special Tool List How to Read the Tool List •
Part No. Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
•
Necessity: ■: Tools not substituted, must always be equipped. ●: Very useful tools which can be substituted with commercially available tools.
•
New/Redesign: N: Tools with new part numbers, newly developed for this model. R: Tools, with advanced part numbers, developed by improving existing tools for other models. Blank: Tools already available for other models that can be used without any modification.
•
Sketch: ○: Tools marked with ○ in the sketch column have the sketches. Sketches are introduced in “SKETCHES OF SPECIAL TOOLS”, and all sketches of “79*T-***-***”are described.
Commercially available
Puller
■
1
Sketch
A
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Removal and Installation of Supply Pump Assembly
Remarks
Removal of gear
Q'ty
A
Commercially available
Block
●
2
B
Commercially available
Lifting tool
●
1
Part name
Sketch
Part No.
New/Redesign
Symbol
Necessity
Tools for Removal and Installation of Travel Motor and Final Drive Assembly
Remarks
Removal and installation of travel motor and final drive assembly
Commercially available
50-18
Forcing screw
■
2
Sketch
A
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Removal and Installation of Swing Motor and Swing Machinery Assembly
Remarks
Removal of swing motor and swing machinery assembly
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Special Tool List
Q'ty
796T-126-1210 Wrench
■
1
790-101-5201
Push tool kit
■
1
790-101-5251
Plate
■
1
790-101-5221
Grip
■
1
01010-51225
Bolt
■
1
790-101-5201
Push tool kit
■
1
790-101-5311
Plate
■
1
790-101-5221
Grip
■
1
01010-51225
Bolt
■
1
790-101-5201
Push tool kit
■
1
790-101-5341
Plate
■
1
790-101-5221
Grip
■
1
01010-51225
Bolt
■
1
E
796-465-1120
Push tool
■
1
Press-fit of seal
F
796-765-1110
Push tool
■
1
Press-fit of bearing
G
Commercially available
Block
■
1
Disassembly and assembly of swing machinery assembly
Symbol
A
B
C
D
Part No.
Part name
Sketch
Necessity
New/Redesign
Tools for Disassembly and Assembly of Swing Machinery Assembly
Remarks
○ Tightening of nut
Press-fit of oil seal
Press-fit of outer race
Press-fit of outer race
792-371-1400
Sleeve
■
1
Sketch
A
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Recoil Spring Assembly
Remarks
Disassembly and assembly of recoil spring assembly
A
B
Push tool kit
■
1
790-101-5081
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
791-430-3230
Installer
■
1
PC45MR-5, PC55MR-5
Part name
Sketch
790-101-5001
Part No.
New/Redesign
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Idler Assembly
Remarks
Press-fit of idler
Installation of floating seal
50-19
Special Tool List
50 Disassembly and Assembly
A
B
Push tool kit
■
1
790-101-5081
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
791-430-3230
Installer
■
1
Part name
Sketch
790-101-5001
Part No.
New/Redesign
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Track Roller Assembly
Remarks
Press-fit of bushing
Installation of floating seal
A
B
Push tool kit
■
1
790-101-5081
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
790-101-5001
Push tool kit
■
1
790-101-5111
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
Part name
Sketch
790-101-5001
Part No.
New/Redesign
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Carrier Roller Assembly
Remarks
Press-fit of bearing
Press-fit of dust seal
A
50-20
●
1
790-101-2501
Push puller
790-101-2510
Block
1
790-101-2520
Screw
1
791-112-1180
Nut
1
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
Sketch
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Center Swivel Joint Assembly
Remarks
Disassembly and assembly of center swivel joint assembly
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Special Tool List
796T-13S-1010 Torque adapter
●
1
New/Redesign
Part name
Sketch
A
Part No.
Q'ty
Symbol
Necessity
Tools for Removal and Installation of Main Pump Assembly
Remarks
○
Removal and installation of main pump assembly
A B
C
D
Cylinder repair stand
■
1
790-101-1102
Hydraulic pump
■
1
790-330-1100
Wrench assembly
■
1
790-302-1270
Socket (width across flats50 mm)
■
1
790-302-1280
Socket (width across flats55 mm)
■
1
790-302-1470
Socket (width across flats55 mm long socket type)
■
1
790-302-1310
Socket (width across flats65 mm)
■
1
790-302-1320
Socket (width across flats65 mm long socket type)
■
1
790-201-1702
Push tool kit
■
1
790-101-5021
•
Grip
1
01010-50810
•
Bolt
1
790-201-1731
•
Push tool
1
790-201-1741
•
Push tool
1
790-201-1751
•
Push tool
1
790-201-1761
•
Push tool
1
790-201-1771
•
Push tool
1
PC45MR-5, PC55MR-5
Sketch
790-502-1003
Part No.
New/Redesign
Part name
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Work Equipment Cylinder Assembly
Remarks
Disassembly and assembly of hydraulic cylinder Removal and installation of cylinder head
Removal and installation of nut
Press-fit of bushing
50-21
E
F
G
■
1
790-201-1500
Push tool kit
790-101-5021
•
Grip
1
01010-50816
•
Bolt
1
790-201-1540
•
Plate
1
790-201-1550
•
Plate
1
790-201-1560
•
Plate
1
790-201-1570
•
Plate
1
790-201-1580
•
Plate
1
790-720-1000
Expander
●
1
796-720-1620
Ring
●
1
07281-00609
Clamp
●
1
796-720-1640
Ring
●
1
07281-00909
Clamp
●
1
796-720-1650
Ring
●
1
07281-01029
Clamp
●
1
796-720-1670
Ring
●
1
07281-01279
Clamp
●
1
Sketch
Part name
New/Redesign
Part No.
Q'ty
Symbol
50 Disassembly and Assembly
Necessity
Special Tool List
Remarks
Press-fit of dust seal
Installation of piston ring
Installation of piston ring
Q'ty
A
793-498-1210
Lifter (suction cup)
■
2
B
Commercially available
Seal cutter
■
1
C
Commercially available
Extra fine wire (piano wire, etc)
■
1
D
Commercially available
Pliers
■
1
E
Commercially available
Cutter knife
■
1
F
Commercially available
Scraper
■
1
G
Commercially available
Caulking gun
■
1
50-22
Part name
Sketch
Part No.
New/Redesign
Symbol
Necessity
Tools for Removal and Installation of Operator's Cab Glass (Bonded Window Glass)
Remarks
Removal and installation of operator's cab glass (adhered glass)
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Sketches of Special Tools
Sketches of Special Tools
k Komatsu does not take any responsibility for special tools manufactured according to these sketch-
es. 796T-126-1210: Wrench
796T-13S-1010: Torque Adaptor
PC45MR-5, PC55MR-5
50-23
Remove and Install Supply Pump Assembly
50 Disassembly and Assembly
Engine and Cooling System Remove and Install Supply Pump Assembly
Counterweight
Draining
Air conditioner compressor (machine with air conditioner only)
Cooling
Supply pump assembly
Commercially available
Puller
■
1
Sketch
A
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Removal and Installation of Supply Pump Assembly
Remarks
Removal of gear
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Supply Pump Assembly Counterweight 1. Remove counterweight assembly. For details, see “Remove and Install Counterweight Assembly”. Draining 2. Loosen drain valve (1), and drain coolant. 6 Radiator: 8.9 ℓ
REMARK Check that coolant is completely drained, and then tighten drain valve (1).
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50 Disassembly and Assembly
Remove and Install Supply Pump Assembly
Cooling 3. Remove bolts (2) (5 pieces), and remove fan guard (3). REMARK For machine with air conditioner, 4 pieces of bolts (2) are provided.
4.
Remove clamp (4).
5.
Loosen clamp (5) and (6), and remove hose (7).
Air conditioner compressor (machine with air conditioner only) 6. Remove bolts (8) (2 pieces), and remove guard (9). 7.
Loosen bolt (10), and tighten bolt (11).
8.
Loosen air conditioner compressor belt (12), and then remove air conditioner compressor belt (12).
9.
Disconnect connector M12 (13).
10. Remove bolts (14) (2 pieces) and (15), and remove air conditioner compressor assembly (16).
11. Remove bolts (17) (2 pieces), and remove bracket (18). 12. Remove bolts (19) (4 pieces), and remove idle pulley (20). 13. Remove bolts (21) (4 pieces), and remove bracket (22).
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Remove and Install Supply Pump Assembly
50 Disassembly and Assembly
Supply pump assembly 14. Disconnect hoses (23) and (24). 15. Remove clamp (25). 16. Remove bolts (26) (2 pieces), and move fuel element assembly (27) aside so that it does not hinder the work.
17. Disconnect hose (28). 18. Disconnect connector (29).
19. Loosen sleeve nuts (30) and (31), and remove high-pressure pipe (32). 20. Disconnect connector M14 (33).
21. Remove bolts (34) (4 pieces), and remove cover (35).
22. Put marks (a) between supply pump drive gear (36) and idler gear (37).
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50 Disassembly and Assembly
Remove and Install Supply Pump Assembly
23. Remove nut (38) and washer (39). 24. Remove supply pump drive gear (36) by using puller (A).
25. Remove bolts (40) (3 pieces), and remove supply pump assembly (41).
Install Supply Pump Assembly Supply pump assembly 1. Install supply pump assembly (41) with bolts (40) (3 pieces). REMARK Apply lubricating oil to O-ring, and take care not to turn it up when installing the assembly.
3 Bolt (40): 22.6 to 28.4 Nm {2.3 to 2.9 kgfm}
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Remove and Install Supply Pump Assembly
2.
Align marks (a) between supply pump drive gear (36) and idler gear (37), and install supply pump drive gear (36).
3.
Install washer (39) and nut (38).
50 Disassembly and Assembly
3 Nut (38): 75 to 85 Nm {7.7 to 8.7 kgfm}
REMARK Check that marks (a) between supply pump drive gear (36) and idler gear (37) are not misaligned.
4.
Install cover (35) with bolts (34) (4 pieces).
5.
Connect connector M14 (33).
6.
Install high-pressure pipe (32) according to the following procedure. 1) Apply fuel to the threaded portions of sleeve nuts (30) and (31). 2) Fix high-pressure pipe (32) so that sleeve nuts (30) and (31) can be rotated smoothly by hand. 3) Finger-tighten sleeve nuts (30) and (31) lightly.
3 Bolt (34): 22.6 to 28.4 Nm {2.3 to 2.9 kgfm}
4)
Tighten sleeve nuts (30) and (31) to the specified torque. 3 Sleeve nuts (30) and (31): 29.4 to 34.3 Nm {3.0 to 3.5 kgfm}
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50 Disassembly and Assembly
7.
Connect connector (29).
8.
Connect hose (28).
9.
Install fuel element assembly (27) with bolts (26) (2 pieces).
Remove and Install Supply Pump Assembly
3 Bolt (26): 35 to 43 Nm {3.6 to 4.4 kgfm}
10. Install clamp (25). 11. Connect hoses (23) and (24).
Air conditioner compressor (machine with air conditioner only) 12. Install bracket (22) with bolts (21) (4 pieces). 3 Bolt (21) on the engine mount side: 59 to 74 Nm {6.0 to 7.5 kgfm}
13. Install idle pulley (20) with bolts (19) (4 pieces). 14. Install bracket (18) with bolts (17) (2 pieces).
15. Install air conditioner compressor assembly (16) with bolts (14) (2 pieces) and (15). 16. Connect connector M12 (13).
17. Install air conditioner compressor belt (12). 18. Rotate bolt (11) in loosening direction, and adjust air conditioner compressor belt (12). REMARK Adjust the air conditioner compressor belt tension. For details, see Testing and Adjusting, “Examine and Adjust Air Conditioner Compressor Belt Tension”. 19. Tighten bolt (10). 20. Install guard (9) with bolts (8) (2 pieces).
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Remove and Install Supply Pump Assembly
50 Disassembly and Assembly
Cooling 21. Fasten clamps (5) and (6) to install hose (7). 3 Clamp (5): 5.9±0.49 Nm {0.6±0.05 kgfm}
3 Clamp (6): 4.4±0.49 Nm {0.45±0.05 kgfm}
22. Install clamp (4).
23. Install fan guard (3) with bolts (2) (4 pieces).
Counterweight assembly 24. Install the counterweight assembly. For details, see “Remove and Install Counterweight Assembly”. Refilling radiator with coolant 25. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant, and then check the coolant level again. 5 Radiator: 8.9 ℓ
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50 Disassembly and Assembly
Remove and Install Starter Assembly
Remove and Install Starter Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Starting Motor Assembly Floor 1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Starting motor assembly 2. Remove bolts (1) (2 pieces), and remove heat insulation plate (2).
3.
Remove clamp (3).
4.
Disconnect terminals M5 (4) and M6 (5).
5.
Remove bolts (6) (2 pieces), and remove starting motor assembly (7).
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Remove and Install Starter Assembly
50 Disassembly and Assembly
Install Starting Motor Assembly Starting motor assembly 1. Install starting motor assembly (7) with bolts (6) (2 pieces).
2.
Connect terminals M5 (4) and M6 (5).
3 Terminal M6 (5): 1.7 to 2.4 Nm {0.17 to 0.24 kgfm} 3 Terminal M5 (4): 7.4 to 9.8 Nm {0.76 to 1.0 kgfm}
3.
Install clamp (3).
4.
Install heat insulation cover (2) with bolts (1) (2 pieces).
Floor 5. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
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50 Disassembly and Assembly
Remove and Install Radiator Assembly
Remove and Install Radiator Assembly
Floor
Draining
Air conditioner condenser assembly (machine with air conditioner only)
Fuel cooler assembly
Radiator assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k If you drain the radiator coolant when it is still hot, you may be scalded. Accordingly, wait for the
coolant temperature to drop before draining.
k Loosen the cap of the radiator gradually, and release the pressure inside of the radiator.
REMARK Put a mark on the tube so that the insertion depth can be easily checked when removing the hose.
How to Remove Radiator Assembly Floor 1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Draining 2. Open cover (1). NOTICE Be sure to lock cover (1) when it has been opened.
3.
Loosen drain valve (2), and drain coolant. 6 Radiator: 8.9 ℓ
REMARK Check that coolant is completely drained, and then tighten drain valve (2).
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Remove and Install Radiator Assembly
4.
Remove bolts (10) (2 pieces).
5.
Remove bolts (13) (2 pieces), and remove partition plate (14).
6.
Loosen clamp (15), and disconnect hose (16).
7.
Remove clamp (17).
8.
Disconnect hose (18).
9.
Remove bolts (19) (3 pieces), and remove chamber (20).
50 Disassembly and Assembly
Air conditioner condenser assembly (machine with air conditioner only) 10. Remove bolts (21) (2 pieces), and move receiver drier (22) aside so that it does not hinder the work.
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Radiator Assembly
11. Remove bolts (23) (4 pieces), and move air conditioner condenser assembly (25) so that it does not hinder the work.
Fuel cooler assembly 12. Remove bolts (26a) (2 pieces), and remove fuel cooler assembly (24).
Radiator assembly 13. Remove bolts (26) (2 pieces). (machine with air conditioner only)
14. Remove bolts (27) (4 pieces), and remove cover (28).
15. Loosen clamp (29), and disconnect radiator lower hose (30).
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Remove and Install Radiator Assembly
50 Disassembly and Assembly
16. Move cover (12) sideways, loosen clamp (31), and disconnect radiator upper hose (32).
17. Remove bolts (33) (4 pieces), and remove bracket (34). 18. Remove radiator assembly (35).
How to Install Radiator Assembly Radiator assembly 1. Install radiator assembly (35). REMARK Check that convex portions (a) of radiator assembly (35) is securely fitted in concave portions (b). 2.
Install bracket (34) with bolts (33) (4 pieces).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
3.
Remove and Install Radiator Assembly
Connect radiator upper hose (32), and fasten it with clamp (31). 3 Clamp (31): 5.9±0.49 Nm {0.6±0.05 kgfm}
4.
Connect radiator lower hose (30), and fasten it with clamp (29). 3 Clamp (29): 5.9±0.49 Nm {0.6±0.05 kgfm}
5.
Install cover (28) with bolts (27) (4 pieces).
6.
Install bolts (26) (2 pieces). (machine with air conditioner only)
Fuel cooler assembly 7. Install fuel cooler assembly (24) with bolts (23a) (2 pieces).
PC45MR-5, PC55MR-5
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Remove and Install Radiator Assembly
50 Disassembly and Assembly
Air conditioner condenser assembly (machine with air conditioner only) 8. Install air conditioner condenser assembly (25) with bolts (23) (4 pieces).
9.
Install receiver drier (22) with bolts (21) (2 pieces).
Cover 10. Install chamber (20) with bolts (19) (3 pieces).
11. Connect hose (18). 12. Install clamp (17).
13. Connect hose (16), and fasten it with clamp (15). 14. Install partition plate (14) with bolts (13) (2 pieces).
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50 Disassembly and Assembly
Remove and Install Radiator Assembly
15. Install cover (12) with bolts (10) (2 pieces).
16. Close cover (1).
Floor 17. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Refilling radiator with coolant 18. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant, and then check the coolant level again. 5 Radiator: 8.9 ℓ
PC45MR-5, PC55MR-5
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Remove and Install Hydraulic Oil Cooler Assembly
50 Disassembly and Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Draining
Floor
Cover
Air conditioner condenser assembly (machine with air conditioner only)
Hydraulic oil cooler assembly, Fuel cooler assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “Re-
lease Remained Pressure in Hydraulic Circuit”.
How to Remove Hydraulic Oil Cooler Assembly Draining 1. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. 2. Remove bolts (1) (6 pieces), and remove cover (2).
3.
Remove drain plug (3), and drain the hydraulic oil.
6 Hydraulic tank: 20 ℓ
REMARK Check that hydraulic oil is completely drained, and then tighten drain plug (3).
Floor 4. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Cover 5. Open covers (4) and (5). NOTICE Be sure to lock the covers when they have been opened.
6.
Remove bolts (15) (2 pieces), and remove partition plate (16).
7.
Loosen clamp (17), and disconnect hose (18).
8.
Remove clamp (19).
9.
Remove clamps (20) (2 places).
10. Disconnect hose (21), and remove sub-tank (22).
11. Remove bolts (23) (3 pieces), and remove chamber (24). (Except for the machines ready for installation of quick coupler)
Pre-cleaner (for the machines ready for installation of quick coupler) 12. Remove the clamp (38), and remove the pre-cleaner (39).
PC45MR-5, PC55MR-5
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Remove and Install Hydraulic Oil Cooler Assembly
50 Disassembly and Assembly
Air conditioner condenser assembly (machine with air conditioner only) 13. Remove bolts (25) (2 pieces), and move receiver drier (26) aside so that it does not hinder the work.
14. Remove bolts (27) (4 pieces), and move air conditioner condenser assembly (29) so that it does not hinder the work.
Hydraulic oil cooler assembly, fuel cooler assembly 15. Remove bolts (27a) (2 pieces), and remove fuel cooler assembly (28).
16. Remove clamp (30), and disconnect hose (31).
17. Remove bolts (32) (3 pieces), and remove bracket (33).
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50 Disassembly and Assembly
Remove and Install Hydraulic Oil Cooler Assembly
18. Disconnect hoses (34) and (35).
19. Remove bolts (36) (4 pieces), and remove oil cooler assembly (37).
How to Install Hydraulic Oil Cooler Assembly Oil cooler assembly 1. Install oil cooler assembly (37) with bolts (36) (4 pieces).
2.
Connect hoses (34) and (35).
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Remove and Install Hydraulic Oil Cooler Assembly
3.
Install bracket (33) with bolts (32) (3 pieces).
4.
Connect hose (31), and install clamp (30).
50 Disassembly and Assembly
Fuel cooler assembly 5. Install fuel cooler assembly (28) with bolts (27a) (2 pieces).
Air conditioner condenser assembly (machine with air conditioner only) 6. Install air conditioner condenser assembly (29) with bolts (27) (4 pieces).
7.
Install receiver drier (26) with bolts (25) (2 pieces). (machine with air conditioner only)
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50 Disassembly and Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Cover 8. Install chamber (24) with bolts (23) (3 pieces). (Except for the machines ready for installation of quick coupler)
9.
Install the pre-cleaner (39), and install the clamp (38). (For the machines ready for installation of quick coupler) REMARK Install it so that the water drain outlet faces downward.
3 Clamp (38): 6.8±0.49 Nm {0.7±0.05 kgfm}
10. Connect hose (21), and install sub-tank (22). 11. Install clamps (20) (2 places). 12. Install clamp (19).
13. Connect hose (18), and fasten clamp (17). 14. Install partition plate (16) with bolts (15) (2 pieces).
15. Close covers (4) and (5).
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Remove and Install Hydraulic Oil Cooler Assembly
50 Disassembly and Assembly
16. Tighten drain plug (3).
3 Drain plug (3): 58.8 to 78.4 Nm {6 to 8 kgfm}
17. Install cover (2) with bolts (1) (6 pieces).
Floor 18. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Refilling hydraulic tank with oil 19. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. 5 Hydraulic tank: 20 ℓ
20. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.
50-46
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50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
Remove and Install Engine and Main Pump Assembly
Counterweight
Hydraulic tank
Draining
Partition plate
Belt
A
A
Air conditioner condenser assembly (machine with air conditioner only)
Fan
Fuel hose
Wiring harness
Oil hose
B
B
Engine, main pump assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Release the remaining pressure in the hydraulic system. For details, see Testing and Adjusting, “Re-
lease Remained Pressure in Hydraulic Circuit”.
Remove Engine and Main Pump Assembly Counterweight 1. Remove counterweight assembly. For details, see “Remove and Install Counterweight Assembly”. Hydraulic tank 2. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. Draining 3. Loosen drain valve (1), and drain coolant. 6 Radiator: 8.9 ℓ
REMARK Check that coolant is completely drained, and then tighten drain valve (1).
PC45MR-5, PC55MR-5
50-47
Remove and Install Engine and Main Pump Assembly
4.
Remove bolts (2) (6 pieces), and remove cover (3).
5.
Remove drain plug (4), and drain the hydraulic oil.
50 Disassembly and Assembly
6 Hydraulic tank: 20 ℓ
REMARK Check that hydraulic oil is completely drained, and then tighten drain plug (4).
Partition plate 6. Remove bolts (5) (2 pieces), and remove partition plate (6). 7. Loosen clamp (7), and disconnect hose (8).
8.
Remove bolts (9) (3 pieces), and remove partition plate (10).
Belt 9. Remove bolts (11) (5 pieces), and remove fan guards (12) (2 pieces). REMARK For machine with air conditioner, 4 pieces of bolts are provided.
50-48
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50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
Air conditioner compressor (machine with air conditioner only) 10. Remove bolts (13) (2 pieces), and remove guard (14). 11. Loosen bolt (15), and tighten bolt (16). 12. Loosen air conditioner compressor belt (17), and then remove air conditioner compressor belt (17).
13. Disconnect connector M12 (18). 14. Remove bolts (19) (2 pieces) and (20), and remove air conditioner compressor assembly (21).
15. Remove bolts (22) (2 pieces), and remove bracket (23). 16. Remove bolts (24) (4 pieces), and remove idle pulley (25). 17. Remove bolts (26) (4 pieces), and remove bracket (27).
18. Loosen bolt (28).
19. Loosen bolt (29). 20. Loosen nut (30) and bolt (31). 21. Loosen alternator belt (32), and then remove alternator belt (32).
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Remove and Install Engine and Main Pump Assembly
50 Disassembly and Assembly
Fan 22. Disconnect heater hoses (33) and (34). (machine with air conditioner only) 23. Loosen clamps (35) and (36), and remove hose (37).
24. Remove clamp (38). 25. Loosen clamps (39) and (40), and remove hose (41). 26. Remove bolts (42) (5 pieces), and move shroud (43) closer to the engine.
27. Remove bolts (44) (4 pieces), and remove fan (45). 28. Remove shroud (43).
Fuel hose 29. Remove clamps (46) (2 places). 30. Disconnect fuel hoses (47) and (48).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
Wiring harness 31. Cut cable ties (49) (2 places). 32. Disconnect connectors M25 (50), M27 (51), and M26 (52).
33. Disconnect connectors M23 (53), M12 (54), and M24 (55). 34. Disconnect connectors M14 (56) and M11 (57).
35. Remove clamp (58). 36. Disconnect connectors M34 (59), M31 (60), M32 (61), and M33 (62).
37. Remove heat insulation plate (63).
38. Disconnect ground cable (64).
PC45MR-5, PC55MR-5
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Remove and Install Engine and Main Pump Assembly
50 Disassembly and Assembly
39. Remove clamp (65). 40. Disconnect terminals M5 (66) and M6 (67).
41. Remove clamp (68). 42. Disconnect connector M10 (69) and terminal M2 (70).
Hydraulic hose 43. Disconnect hoses (71), (72) and (73).
44. Disconnect hoses (74) and (75).
45. Disconnect hoses (76) and (77).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
46. Remove bolts (78) (4 pieces), and disconnect suction hose (79).
Engine and main pump assembly 47. Remove nuts (80) (4 places), and remove U-bolt. 48. Remove clamp (81), and remove exhaust pipe (82).
49. Remove mount nuts (83) (4 pieces), sling engine and main pump assembly (84), and remove it. REMARK • Check that all the wirings and pipings are disconnected. • Be careful not to interfere with the parts around it when removing the assembly.
4 Engine and main pump assembly (84): 265 kg
Install Engine and Main Pump Assembly Engine and main pump assembly 1. Sling engine and main pump assembly (84), and set it on the machine. REMARK Be careful not to interfere with the parts around it when installing the assembly.
4 Engine and main pump assembly: 265 kg
2.
Sling the engine and main pump assembly, and hold it.
3.
Install mount nuts (83) (4 pieces). 2 Mount nut (83): Liquid adhesive (LT-2)
3 Mount nut (83): 59 to 74 Nm {6 to 7.5 kgfm}
PC45MR-5, PC55MR-5
50-53
Remove and Install Engine and Main Pump Assembly
4.
Install exhaust pipe (82) with clamp (81).
5.
Fix exhaust pipe (82) with nuts (80) (4 places) and U-bolt.
50 Disassembly and Assembly
Hydraulic hose 6. Connect suction hose (79) with bolts (78) (4 pieces).
7.
Connect hoses (76) and (77).
8.
Connect hoses (74) and (75).
9.
Connect hoses (73), (72) and (71).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
Wiring harness 10. Connect connector M10 (69) and terminal M2 (70). 3 Terminal M2 (70): 5.9 to 9.8 Nm {0.6 to 1.0 kgfm}
11. Install clamps (68).
12. Connect terminals M5 (66) and M6 (67).
3 Terminal M6 (67): 1.7 to 2.4 Nm {0.17 to 0.24 kgfm} 3 Terminal M5 (66): 7.4 to 9.8 Nm {0.76 to 1.0 kgfm}
13. Install clamp (65).
14. Connect ground cable (64).
15. Install heat insulation plate (63).
16. Connect connectors M33 (62), M32 (61), M31 (60), and M34 (59). 17. Install clamp (58).
PC45MR-5, PC55MR-5
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Remove and Install Engine and Main Pump Assembly
50 Disassembly and Assembly
18. Connect connectors M14 (56) and M11 (57). 19. Connect connectors M23 (53), M12 (54), and M24 (55).
20. Connect connectors M25 (50), M27 (51), and M26 (52). 21. Install cable ties (49) (2 places).
Fuel hose 22. Connect fuel hoses (47) and (48). 23. Install clamps (46) (2 places).
Fan 24. Move shroud (43) closer to the engine. 25. Install fan (45) with bolts (44) (4 pieces).
26. Install shroud (43) with bolts (42) (5 pieces). 27. Install hose (41), and fasten it with clamps (39) and (40). 3 Clamp (39): 5.9±0.49 Nm {0.6±0.05 kgfm}
3 Clamp (40): 4.4±0.49 Nm {0.45±0.05 kgfm}
28. Install clamp (38).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
29. Install hose (37), and fasten it with clamps (35) and (36). 3 Clamp (35): 5.9±0.49 Nm {0.6±0.05 kgfm}
3 Clamp (36): 4.4±0.49 Nm {0.45±0.05 kgfm}
30. Connect heater hoses (33) and (34). (machine with air conditioner only)
Belt 31. Set alternator belt (32). 32. Tighten bolt (31), and adjust alternator belt (32). REMARK “”Adjust the alternator belt tension. For details, see Testing and Adjusting, “Examine and Adjust Alternator Belt Tension”. 33. Tighten nut (30) and bolt (29).
34. Tighten bolt (28).
Air conditioner compressor (machine with air conditioner only) 35. Install bracket (27) with bolts (26) (4 pieces). 3 Bolt (26) on the engine mount side: 59 to 74 Nm {6.0 to 7.5 kgfm}
36. Install idle pulley (25) with bolts (24) (4 pieces). 37. Install bracket (23) with bolts (22) (2 pieces).
38. Install air conditioner compressor assembly (21) with bolts (19) (2 pieces) and (20). 39. Connect connector M12 (18).
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Remove and Install Engine and Main Pump Assembly
50 Disassembly and Assembly
40. Install air conditioner compressor belt (17). 41. Rotate bolt (16) in loosening direction, and adjust air conditioner compressor belt (17). REMARK Adjust the air conditioner compressor belt tension. For details, see Testing and Adjusting, “Examine and Adjust Air Conditioner Compressor Belt Tension”. 42. Tighten bolt (15). 43. Install guard (14) with bolts (13) (2 pieces). Fan guard 44. Install fan guards (12) (2 pieces) with bolts (11) (5 pieces). REMARK For machine with air conditioner, 4 pieces of bolts (11) are provided.
Partition plate 45. Install partition plate (10) with bolts (9) (3 pieces).
46. Connect hose (8), and fasten it with clamp (7). 47. Install partition plate (6) with bolts (5) (2 pieces).
48. Tighten drain plug (4).
3 Drain plug (4): 58.8 to 78.4 Nm {6 to 8 kgfm}
50-58
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Engine and Main Pump Assembly
49. Install cover (3) with bolts (2) (6 pieces).
Counterweight 50. Install the counterweight assembly. For details, see “Remove and Install Counterweight Assembly”. Refilling radiator with coolant 51. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant, and then check the coolant level again. 5 Radiator: 8.9 ℓ
Refilling hydraulic tank with oil 52. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. 5 Hydraulic tank: 20 ℓ
Air bleeding 53. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.
PC45MR-5, PC55MR-5
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Remove and Install Fuel Tank Assembly
50 Disassembly and Assembly
Remove and Install Fuel Tank Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Fuel Tank Assembly Draining 1. Open covers (1) and (2). NOTICE Be sure to lock the covers when they have been opened.
2.
Open fuel drain valve (3), and drain fuel. 6 When filled up with fuel: 65 ℓ
REMARK Check that fuel is completely drained, and then tighten drain valve (3).
Cover 3. Open cover (4).
4.
Remove pin (5).
5.
Remove bolts (6) (4 pieces), and remove cover (4).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
6.
Remove bolts (7) and (8).
7.
Remove bolts (9) (3 pieces), and remove cover (10).
Remove and Install Fuel Tank Assembly
Fuel tank assembly 8. Remove bolts (11) (2 pieces), and remove tank and bracket assembly (12). (Cab specification machine)
9.
Disconnect connector M6 (13).
10. Remove clamp (14). 11. Disconnect hoses (white) (15) and (black) (16). 12. Disconnect drain hose (17).
PC45MR-5, PC55MR-5
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Remove and Install Fuel Tank Assembly
50 Disassembly and Assembly
13. Remove bolts (18) and (19) (2 pieces each), and remove bands (20) (2 pieces). 14. Remove fuel tank assembly (21).
Install Fuel Tank Assembly Fuel tank assembly 1. Set fuel tank assembly (21) on the machine. 2.
Install bands (20) (2 pieces) with bolts (19) and (18) (2 pieces each).
3.
Connect drain hose (17).
4.
Connect hoses (white) (15) and (black) (16).
5.
Install clamp (14).
6.
Connect connector M6 (13).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
7.
Remove and Install Fuel Tank Assembly
Install tank and bracket assembly (12) with bolts (11) (2 pieces). (Cab specification machine)
Cover 8. Install cover (10) with bolts (7), (8) and (9) (3 pieces).
9.
Install cover (4) with bolts (6) (4 pieces).
10. Install pin (5).
11. Close cover (4).
PC45MR-5, PC55MR-5
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Remove and Install Fuel Tank Assembly
50 Disassembly and Assembly
12. Close covers (2) and (1).
Refilling fuel tank with fuel 13. Refill with fuel to the specified level through the fuel filler port. 6 When filled up with fuel: 65 ℓ
Testing fuel circuit for leakage 14. Check the fuel system for leakage. For details, see Testing and Adjusting, “Examine Fuel Circuit for Leakage”. Bleeding air from fuel circuit 15. Bleed air in the fuel system. For details, see Testing and Adjusting, “Bleed Air from Fuel System”.
50-64
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install KDPF Assembly
Remove and Install KDPF Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Turn the starting switch to OFF position to stop the engine.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes out.
k Since KDPF assembly and around it are heated to 500 °C or above, take care not to get burn injury.
k If KDPF assembly and around it are hot, wait until they have cooled down before starting any work.
k Check that no combustible material (dry leaves, twigs, etc.) is accumulated in the KDPF assembly
and around it. If any dusts or combustible materials are found, remove them.
k Since KDPF assembly is fragile against shock such as falling, handle it with care. Do not reuse the
damaged parts.
k When cleaning, replacing, or disposing KDPF assembly, use anti-dust mask during the work to pre-
vent inhaling accumulated soot, ash, mat material or metallic powder inside of KDPF.
k When removing the soot filter from the KDPF for cleaning purposes, soot ash remaining in the filter
may scatter. Wear gloves, anti-dust masks, eye protection and other protective equipment.
k When transporting a KDPF unit with a soot filter for maintenance or cleaning, fix it firmly in the pack-
age to prevent soot ash scattering during transport.
k Soot Ash removed from the soot filter may be considered as industrial waste. Adequate provision
must be assured for the containment of the material once it is removed. Disposal should be performed in accordance with local laws and regulations.
How to Remove KDPF Assembly Opening and closing the floor 1. Open the floor. See Testing and Adjusting, “How to Open and Close Floor Unit”. Cover 2. Remove the bolts (1) (7 pieces), and remove the cover (2).
3.
Remove the bolts (3) (2 pieces), and remove the heat insulation cover (4).
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Remove and Install KDPF Assembly
50 Disassembly and Assembly
KDPF assembly 4. Disconnect the connectors M26 (5), M27 (6), and M25 (7).
5.
Remove the bolts (8) (2 pieces), and remove the differential pressure sensor (9).
6.
Remove the nuts (10) (4 pieces), and remove U-bolt (11).
7.
Remove the clamp (12), and remove the exhaust pipe (13).
8.
Remove the bolts (14) (4 pieces).
9.
Remove the nuts (15) (4 pieces).
10. Sling KDPF assembly (16), and remove it.
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50 Disassembly and Assembly
Remove and Install KDPF Assembly
How to Install KDPF Assembly KDPF assembly 1. Sling KDPF assembly (16), and align it with the installing position. REMARK Replace the gasket (17) with a new one. 2.
Tighten the nuts (15) (4 pieces) lightly.
3.
Tighten the bolts (14) (4 pieces) lightly.
4.
Tighten the nuts (15) (4 pieces) to the specified torque.
3 Nut (15): 16±5 Nm {1.63±0.51 kgfm}
5.
Tighten the bolts (14) (4 pieces) to the specified torque.
6.
Install the exhaust pipe (13) with the clamp (12).
7.
Fix the exhaust pipe (13) with the nuts (10) (4 pieces) and U-bolt (11).
8.
Install the differential pressure sensor (9) with the bolts (8) (2 pieces).
3 Bolt (14): 49±5 Nm {5±0.51 kgfm}
3 Bolt (8): 5.6 to 8.4 Nm {0.57 to 0.85 kgfm}
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Remove and Install KDPF Assembly
9.
50 Disassembly and Assembly
Connect the connectors M26 (5), M27(6), M25(7).
Cover 10. Install the heat insulation cover (4) with the bolts (3) (2 pieces).
11. Install the cover (2) with the bolts (1) (7 pieces).
Opening and closing the floor 12. Close the floor. See Testing and Adjusting, “How to Open and Close Floor Unit”. “KDPF Memory Reset” resets KDPF information saved in the machine. Refer to this section to reset KDPF memory when KDPF is cleaned or replaced. 13. After replacement of KDPF, please reset KDPF memory and perform regeneration in accordance with Section 30 TESTING AND ADJUSTING(METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET) and METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble KDPF Assembly
Disassemble and Assemble KDPF Assembly NOTICE Only precautions are described. For details, see“HOW TO REMOVE AND REATTACH THE DIESEL PARTICULATE FILTER (KDPF)”in SHOP MANUAL for ENGINE 86E-7 to 98E-7 series.
k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Since KDPF assembly becomes extremely hot, take care not to get burn injury.
k If KDPF assembly is hot, wait until it has cooled down before starting any work.
k Check that no combustible material (dry leaves, twigs, etc.) is accumulated around KDPF assembly.
If any dusts or combustible materials are found, remove them.
k KDPF assembly is fragile against shock such as falling, handle with care, and do not reuse it if it is
damaged.
k Keep the record for each KDPF assembly unit to manage the service life, and never use KDPF ex-
ceeding its service life.
k After cleaning or replacing KDPF assembly, clean and degrease KDPF main unit and around it, start
the engine, and then check for oil leakage and soot attached.
k When you do cleaning work, replacement of the KDPF assembly or KCSF, or when you dispose of
these, wear protective eye glasses, dust prevention mask and gloves. Soot, ash, mat material, metal powder which is accumulated inside can get into your mouth or eyes if you do not wear protective equipment..
k If you blow air into the KDPF for cleaning, ash inside it can be scattered. Clean it with brush or waste
clothes. Also, if you blow air into the KDPF for cleaning , ash inside it can be scattered. Clean it with brush or an waste cloth.
k When transporting a KDPF unit with a soot filter for maintenance or cleaning, fix it firmly in the pack-
age to prevent soot ash scattering during transport.
k Soot Ash removed from the soot filter may be considered as industrial waste. Adequate provision
must be assured for the containment of the material once it is removed. Disposal should be performed in accordance with local laws and regulations.
k After replacement of soot filter, please reset KDPF memory in accordance with Section 30 TESTING
AND ADJUSTING(METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)).
k After replacement of KDPF, please reset KDPF memory and perform regeneration in accordance with
Section 30 TESTING AND ADJUSTING(METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET) and METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)).
PC45MR-5, PC55MR-5
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Remove and Install Travel Motor and Final Drive Assembly
50 Disassembly and Assembly
Power Train Remove and Install Travel Motor and Final Drive Assembly
Q'ty
A
Commercially available
Block
●
2
B
Commercially available
Lifting tool
●
1
Part name
Sketch
Part No.
New/Redesign
Symbol
Necessity
Tools for Removal and Installation of Travel Motor and Final Drive Assembly
Remarks
Removal and installation of travel motor and final drive assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Release the remaining pressure in the hydraulic system. For details, see Testing and Adjusting, “Re-
lease Remained Pressure in Hydraulic Circuit”.
Remove Travel Motor and Final Drive Assembly Track shoe assembly 1. Separate the track shoe assembly. For details, see “Separate and Connect Track Assembly”. Sprocket 2. Set block (A) under the track frame. 3.
Remove bolts (1) (12 pieces), and remove sprocket (2).
4.
Remove bolts (3) (3 pieces), and remove cover (4).
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50 Disassembly and Assembly
Remove and Install Travel Motor and Final Drive Assembly
Hose 5. Disconnect hoses (5), (6), (7), and (8).
6.
Remove adapters (9), (10), (11), and (12).
Travel motor and final drive assembly 7. Sling travel motor and final drive assembly (13) and hold it by using lifting tool (B).
8.
Remove bolts (14) (12 pieces), sling travel motor and final drive assembly (13), and remove it.
4 Travel motor and final drive assembly (13): 56 kg
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Remove and Install Travel Motor and Final Drive Assembly
50 Disassembly and Assembly
Install Travel Motor and Final Drive Assembly Travel motor and final drive assembly 1.
Sling travel motor and final drive assembly (13) and set it to the machine by using lifting tool (B). 4 Travel motor and final drive assembly (13): 56 kg
2.
Install travel motor and final drive assembly (13) with mounting bolts (14) (12 pieces). 3 Bolt (14): 156 to 198 Nm {16.0 to 20.0 kgfm}
Hose 3. Install adapters (12), (11), (10), and (9).
4.
Connect hoses (8), (7), (6), and (5).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
5.
Remove and Install Travel Motor and Final Drive Assembly
Install cover (4) with bolts (3) (3 pieces).
Sprocket 6. Install sprocket (2) with bolts (1) (12 pieces). 2 Threaded portion of bolt (1): Adhesive (LT-2)
3 Bolt (1): 156 to 198 Nm {16.0 to 20.0 kgfm}
7.
Push up the machine body by using the work equipment and blade.
8.
Remove block (A) from under the track frame.
Track shoe assembly 9. Install the track shoe assembly. For details, see “Separate and Connect Track Assembly”. Air bleeding 10. Bleed air from the hydraulic circuit. For details, see Testing and Adjusting, “Bleed Air from Hydraulic System”. 11. Bleed air from the travel motor. For details, see Testing and Adjusting, , “How to Release Remained Pressure from Travel Motor Circuit”. Refilling with oil 12. Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping, and check the oil level again.
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Disassemble and Assemble Final Drive Assembly
50 Disassembly and Assembly
Disassemble and Assemble Final Drive Assembly
k Do the work in a clean area, and be careful to prevent dirt, dust, paint chips, moisture, etc.
Prepare a clean container for the disassembled parts.
k Remove stain from the external side of the travel motor before disassembly, and remove paint from
the joints of each part with a wire brush, etc.
k Make the marks to the parts before disassembly in order to install them in their original positions
when you assemble them.
k Handle disassembled parts carefully in order to prevent damage. k Clean disassembled parts fully with flushing oil.
k Inspect disassembled parts for abnormal wear or seizure, and remove burr or sharp edge, etc. k Replace seals and snap ring with new ones. k Drain oil before work.
How to Disassemble Final Drive Assembly 1.
Remove the plug (1).
2.
Remove the plugs (2) (2 pieces).
3.
Remove the snap ring (3). REMARK Insert a flat-head screwdriver or etc. to the notch, and pull out the snap ring (3).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
4.
Disassemble and Assemble Final Drive Assembly
Remove the cover (4). REMARK • If you tighten the plug lightly and put a flat-head screwdriver or etc. on the collar of the plug, you can remove it easily. • Be careful not to damage the threaded part of the plug or cover (4).
5.
Remove the slide ring (5) from the cover (4).
6.
Remove the O-ring (6).
7.
Remove the carrier (7) and gears (8) and (9).
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Disassemble and Assemble Final Drive Assembly
8.
Remove the snap ring (10) on the carrier (7).
9.
Remove the thrust plate (11), gear (12), needles (13) (23 pieces) and thrust washer (14).
50 Disassembly and Assembly
REMARK Because the needles (13) tend to fall apart, be careful not to lose them.
10. Remove the snap ring (15), and remove the thrust washer (16).
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50 Disassembly and Assembly
Disassemble and Assemble Final Drive Assembly
11. Remove the gear (17), needles (18) (24 pieces), ring (19), lower thrust washer (20) and center thrust washer (21). REMARK Because the needles (18) tend to fall apart, be careful not to lose them.
12. Remove the snap ring (22). REMARK If you fix it with a vise or etc. as shown in the figure, you can remove it easily.
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Disassemble and Assemble Final Drive Assembly
50 Disassembly and Assembly
13. Remove the bearings (23) and (24), floating seal (25) and O-ring (26) together with the body (27), and remove the floating seal (25) and O-ring (26). REMARK Because the bearings (23) and (24) are press-fitted, you cannot disassemble them.
14. Remove the floating seal (29) and O-ring (30) from the motor (28).
How to Assemble Final Drive Assembly 1.
Install the floating seal (29) and O-ring (30) to the motor (28).
2.
Assemble the bearing (24), snap ring (31) and bearing (23) to the body (27) in sequence. REMARK When you press-fit the bearings (23) and (24), make sure that the thicker sides of the inner rings are external to the snap ring (31).
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50 Disassembly and Assembly
Disassemble and Assemble Final Drive Assembly
3.
Install the floating seal (25) and O-ring (26) to the body (27).
4.
Assemble the body (27) and motor (28), and install the snap ring (22). REMARK • Remove oil from the seal surfaces of the floating seals (24) and (28), and remove dust, etc. • If the body (27) is hard to get into, tap the full part equally with a plastic hammer or etc. • Fix it with a vise or etc. as shown in the figure, and install the snap ring (22). • The bearing preload is adjusted by the thickness of the snap ring (22).
5.
Put the thrust washer (21) on the center part.
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Disassemble and Assemble Final Drive Assembly
6.
50 Disassembly and Assembly
Assemble the ring (19), lower thrust washer (20), gear (18), needles (17) (24 pieces) and thrust washer (16) in sequence, and fix them with the snap ring (15). REMARK • The installation directions of the gear (18) and snap ring (15) are set. Install them in the same direction when you removed them. • If you expand the snap ring (15) too wide, it loses the strained force. If it loses the strained force, replace it with a new one.
7.
Assemble the thrust washer (14), gear (12), needles (13) (23 pieces), thrust plate (11) and snap ring (10) to the carrier (7) in sequence. REMARK • The installation directions of the gear (12) and snap ring (10) are set. Install them in the same direction when you removed them. • If you expand the snap ring (10) too wide, it loses the strained force. If it loses the strained force, replace it with a new one.
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
8.
Install the gear (8) to the carrier (7).
9.
Install the gear (9).
Disassemble and Assemble Final Drive Assembly
10. Install the carrier (7) and gear (8). REMARK • While you install the carrier (7) and gear (8), hold them with your hand to prevent the separation. • When it is hard to install because the gears do not engage, adjust them for installation.
11. Install the O-ring (6). REMARK • Apply grease on the O-ring (6). • Make sure that there is no dirt on the mounting part of the O-ring (6), and then install it.
12. Install the slide ring (5) to the cover (4). REMARK • Apply grease on the insertion part of the cover to prevent drop of the slide ring (5). • The installation direction of the slide ring (5) is set. Install it in the same direction when you removed it.
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Disassemble and Assemble Final Drive Assembly
50 Disassembly and Assembly
13. Add oil, and install the cover (4). REMARK • Be careful not to damage the O-ring (6) when you install it. • Align the top and bottom tapped holes with the notches of body, and install it. Oil: 0.7 to 0.8 mℓ
14. Install the snap ring (3). REMARK Put a flat-head screwdriver or etc. to the end surface of the snap ring (3), tap it into the circumferential direction.
15. Install the plugs (2) (2 pieces).
3 Plug (2): 46 to 51 Nm {4.7 to 5.2 kgfm}
16. Install the plug (1).
3 Plug (1): 12 to 18 Nm {1.2 to 1.8 kgfm}
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Swing Motor and Swing Machinery Assembly
Remove and Install Swing Motor and Swing Machinery Assembly
Commercially available
Forcing screw
■
2
Sketch
A
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Removal and Installation of Swing Motor and Swing Machinery Assembly
Remarks
Removal of swing motor and swing machinery assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off. REMARK • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove Swing Motor and Swing Machinery Assembly Swing motor and swing machinery assembly 1. Remove the floor frame assembly. For details, see “Remove and Install Floor Frame Assembly (Canopy Specification)”. REMARK Remove the operator's cab assembly of the cab specification machine. For details, see “Remove and Install Operator CAB Assembly (CAB Specification)”. 2.
Disconnect hoses (1) to (5).
3.
Remove mounting bolts (7) (8 pieces), and remove the swing machinery from the frame by using forcing screws (A) (2 pieces).
4.
Sling swing motor and swing machinery assembly (6), and remove it. 4 Swing motor and swing machinery assembly: 45 kg
PC45MR-5, PC55MR-5
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Remove and Install Swing Motor and Swing Machinery Assembly
50 Disassembly and Assembly
Install Swing Motor and Swing Machinery Assembly Swing motor and swing machinery assembly 1. Sling swing motor and swing machinery assembly (6), and install it. 4 Swing motor and swing machinery assembly (6): 45 kg
2.
Install mounting bolts (7) (8 pieces).
3.
Connect hoses (1) to (5).
4.
Install the floor frame assembly. For details, see “Remove and Install Floor Frame Assembly (Canopy Specification)”.
3 Mounting bolt (7): 98 to 123 Nm {10 to 12.5 kgfm}
REMARK Install the operator's cab assembly of the cab specification machine. For details, see “Remove and Install Operator CAB Assembly (CAB Specification)”.
Refilling hydraulic tank with oil 5. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. (For details, see Structure and Function, “Table of Fuel, Coolant, and Lubricants”.) Air bleeding 6. Bleed air. For details, see Testing and Adjusting, “Bleed Air from Hydraulic System”.
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble Swing Machinery Assembly
Disassemble and Assemble Swing Machinery Assembly Swing motor assembly
A
No.1 sun gear
No.1 planetary carrier, No.2 sun gear assembly
No.2 planetary carrier assembly
Pinion shaft, bearing assembly
A
Swing machinery case
Q'ty
796T-126-1210 Wrench
■
1
790-101-5201
Push tool kit
■
1
790-101-5251
Plate
■
1
790-101-5221
Grip
■
1
01010-51225
Bolt
■
1
790-101-5201
Push tool kit
■
1
790-101-5311
Plate
■
1
790-101-5221
Grip
■
1
01010-51225
Bolt
■
1
790-101-5201
Push tool kit
■
1
790-101-5341
Plate
■
1
790-101-5221
Grip
■
1
01010-51225
Bolt
■
1
E
796-465-1120
Push tool
■
1
Press-fit of seal
F
796-765-1110
Push tool
■
1
Press-fit of bearing
G
Commercially available
Block
■
1
Disassembly and assembly of swing machinery assembly
Symbol
A
B
C
D
Part No.
Part name
Sketch
Necessity
New/Redesign
Tools for Disassembly and Assembly of Swing Machinery Assembly
Remarks
○ Tightening of nut
Press-fit of oil seal
Press-fit of outer race
Press-fit of outer race
Disassemble Swing Machinery Assembly REMARK The drain plug is not provided. Prepare an oil pan, etc. and drain oil from the swing machinery case during the disassembling work. 6 Swing machinery case: Approximately 1.3 ℓ
PC45MR-5, PC55MR-5
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Disassemble and Assemble Swing Machinery Assembly
50 Disassembly and Assembly
Swing motor assembly 1. Set the swing motor and swing machinery assembly on block (G), and remove swing motor assembly (1).
No.1 sun gear 2. Remove No.1 sun gear (2).
No.1 planetary carrier, No.2 sun gear assembly 3. Remove No.1 planetary carrier and No.2 sun gear assembly (3). 4. Remove snap ring (4), and remove thrust washer (5), No.1 planetary gear (6), needle bearing (7), spacer (8), and thrust washer (9). 5. Remove snap ring (10), and remove No.1 planetary carrier (11) from No.2 sun gear (10a).
No.2 planetary carrier assembly 6. Remove snap ring (12), and remove thrust washer (13), No.2 planetary gear (14), needle bearing (15), spacer (16), and thrust washer (17).
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50 Disassembly and Assembly
Disassemble and Assemble Swing Machinery Assembly
7.
Remove nut (18) by using wrench (A).
8.
Remove No.2 planetary carrier and bearing assembly (19). REMARK Press the end surface of pinion shaft (24) by using the press, etc.
9.
Remove bearing (21) from No.2 planetary carrier (20).
Pinion shaft, bearing assembly 10. Remove bearing (25) and seal (26) from pinion shaft (24).
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Disassemble and Assemble Swing Machinery Assembly
50 Disassembly and Assembly
Swing machinery case 11. Remove outer races (27), (28), and oil seal (29) from swing machinery case (22).
Assemble Swing Machinery Assembly Swing machinery case 1. Press fit oil seal (29) to swing machinery case (22) until it hits the end by using push tool (B). REMARK • Install the oil seal with its spring facing upward. • Be careful not to allow liquid gasket to attach to the oil seal lip and shaft sliding part.
2 Press-fitting surface of oil seal: Liquid gasket (LG-6)
2.
Press fit outer races (28) and (27) to the swing machinery case by using push tools (C) and (D). Push tool (C): Outer race (28) Push tool (D): Outer race (27) REMARK The figure shows an example of outer race (28).
Pinion shaft, bearing assembly 3. Install seal (26) to pinion shaft (24). 2 Seal sliding surface: Grease (G2-LI)
4.
Press fit bearing (25) to pinion shaft (24) by using push tool (E). Press-fitting force: 7.3 to 19.7 kN {0.74 to 2.01 t}
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
5.
Disassemble and Assemble Swing Machinery Assembly
Set swing machinery case (22) on pinion shaft and bearing assembly (23). Seal grease (G2-LI) in 40 to 60 % of clearance (a) between the swing machinery case and bearing. REMARK Be careful not to damage the oil seal.
No.2 planetary carrier assembly 6. Press fit bearing (21) to No.2 planetary carrier (20) by using push tool (F). Press-fitting force: 2.94 to 11.18 kN {0.3 to 1.14 t}
7.
Set No.2 planetary carrier and bearing assembly (19) on pinion shaft (24), and press fit it by using the press, etc. REMARK Press fit the case gradually while rotating it. 2 Spline: Grease (G2-LI)
Press-fitting force: 4.90 to 18.8 kN {0.50 to 1.92 t}
8.
Tighten nut (18) by using wrench (A). 2 Nut: Liquid adhesive (LT-2)
3 Nut: 392 to 441 Nm {40 to 45 kgfm}
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Disassemble and Assemble Swing Machinery Assembly
9.
50 Disassembly and Assembly
Measure the starting torque of pinion shaft (24) by using wrench (A), and check that the measured value is within the following range. Starting torque: 13.2 Nm {1.35 kgfm}
10. Install thrust washer (17), spacer (16), needle bearing (15), No.2 planetary gear (14), thrust washer (13), and snap ring (12). REMARK Check that there is no play of No.2 planetary gear.
No.1 planetary carrier, No.2 sun gear assembly 11. Install No.1 planetary carrier (11) to No.2 sun gear (10a), and install snap ring (10). 12. Install thrust washer (9), spacer (8), needle bearing (7), No.1 planetary gear (6), and thrust washer (5), and install snap ring (4). REMARK Check that there is no play of No.1 planetary gear.
13. Install No.1 planetary carrier and No.2 sun gear assembly (3).
No.1 sun gear 14. Install No.1 sun gear (2). Refilling with oil 15. Refill the inside of machinery case with power train oil.
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50 Disassembly and Assembly
Disassemble and Assemble Swing Machinery Assembly
5 Swing machinery case: Approximately 1.3 ℓ (TO10)
Swing motor assembly 16. Fit the O-ring, and install swing motor assembly (1). 3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgfm}
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Remove and Install Swing Circle Assembly
50 Disassembly and Assembly
Remove and Install Swing Circle Assembly
k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Swing Circle Assembly Revolving frame assembly 1. Remove the revolving frame assembly. For details, see “Remove and Install Revolving Frame Assembly”. Swing circle assembly 2. Remove mounting bolts (1) (24 pieces). 3.
Sling swing circle assembly (2), and remove it.
4 Swing circle assembly (2): 65 kg
Install Swing Circle Assembly Swing circle assembly 1. Sling swing circle assembly (2), and set it on the machine. 4 Swing circle assembly: 65 kg
2.
Sling the swing circle assembly, and install it so that “S mark” of inner ring soft zone (a) of the inner race and outer race soft zone (b) come to the positions respectively shown in the figure. 2 Inner race tooth surface: Grease (G2-LI)
3.
Install mounting bolts (1) (24 piece). 2 Mounting bolts (1): Adhesive (LT-2)
3 Mounting bolt (1): 98 to 122.5 Nm {10 to 12.5 kgfm}
Revolving frame assembly 4. Install the revolving frame assembly. For details, see “Remove and Install Revolving Frame Assembly”. 50-92
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble Recoil Spring Assembly
Undercarriage and Frame Disassemble and Assemble Recoil Spring Assembly
792-371-1400
■
1
Sleeve
Sketch
A
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Recoil Spring Assembly
Remarks
Disassembly and assembly of recoil spring assembly
Disassemble Recoil Spring Assembly Piston 1. Remove valve (1). 2.
Remove piston (2).
Recoil spring 3. Set the recoil spring on the press by using sleeve (A).
k Since the load at installation of the spring is large
and dangerous, set the recoil spring assembly securely to the sleeve. 4.
Apply oil pressure slowly to compress the spring, remove screw (3), and remove nut (4). REMARK Compress the spring until the nut is loose. •
Rubber shoe specification Load at installation of spring: 42.4 kN {4326 kgf}
•
Iron and road liner shoe specification Load at installation of spring: 26.9 kN {2748 kgf}
PC45MR-5, PC55MR-5
50-93
Disassemble and Assemble Recoil Spring Assembly
5.
50 Disassembly and Assembly
Release oil pressure slowly to extend the spring, and remove stopper (5) and spring (6) from cylinder assembly (7). Free height of spring: 302 mm
Cylinder 6. Remove snap ring (8), and remove spacer (9) from cylinder (10). 7. Remove dust seal (11). 8.
Remove O-ring (12) and buffer ring (13).
Assemble Recoil Spring Assembly Cylinder 1. Install O-ring (12) and buffer ring (13) to cylinder (10). 2.
Install dust seal (11).
3.
Fit spacer (9), and fix it with snap ring (8).
Recoil spring 4. Assemble cylinder assembly (7), spring (6), and stopper (5).
50-94
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
5.
Disassemble and Assemble Recoil Spring Assembly
Set the recoil spring on the press by using sleeve (A).
k Since the load at installation of the spring is large
and dangerous, set the recoil spring assembly securely to the sleeve.
6.
Apply oil pressure slowly to compress the spring, fit nut (4), and install screw (3). •
Rubber shoe specification Installed height of spring: 202.2 mm Load at installation of spring: 42.4 kN {4326 kgf}
•
Iron and road liner shoe specification Installed height of spring: 238.2 mm Load at installation of spring: 26.9 kN {2748 kgf}
REMARK After assembling the recoil spring, check that the parallelism of surface (a) of cylinder (7) and surface (b) of stopper (5) is 0.5 mm or less. Piston 7. Tighten plug (1) lightly. REMARK Tighten the plug temporarily and then return it by approximately 2 turns to discharge grease from grease hole (c). 8.
Fill the cylinder with approximately 120 cc of grease (G2LI).
9.
Install cylinder (2), and press it until grease comes out from grease hole (c).
10. Tighten valve (1). REMARK After tightening the valve, check that the grease fitting faces the outside of the machine (sideways).
PC45MR-5, PC55MR-5
50-95
Separate and Connect Track Assembly
50 Disassembly and Assembly
Separate and Connect Track Assembly Separate Track Assembly Track shoe 1. Rotate upper structure by 180 °, and lift the machine by using the work equipment and blade. 2.
Loosen valve (1), remove the grease, and loosen the track shoe tension.
k Do not loosen valve (1) by more than one turn, be-
cause the valve may fly out due to the high internal pressure of the grease.
3.
Sling track shoe assembly (2), and pull it backward to remove it. 4 Rubber shoe: 190 kg
4 Double grouser shoe: 290 kg 4 Triple shoe: 240 kg 4 Road liner: 290 kg
Install Track Assembly Track shoe 1.
Sling track shoe assembly (2), and install it. 4 Rubber shoe: 190 kg
4 Double grouser shoe: 290 kg 4 Triple shoe: 240 kg 4 Road liner: 290 kg
50-96
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
2.
Separate and Connect Track Assembly
Tighten valve (1), grease the track shoe, and adjust the track shoe tension. REMARK Adjust the track shoe tension. For details, see Testing and Adjusting, “Examine and Adjust Track Tension”.
PC45MR-5, PC55MR-5
50-97
Disassemble and Assemble Idler Assembly
50 Disassembly and Assembly
Disassemble and Assemble Idler Assembly
A
B
Push tool kit
■
1
790-101-5081
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
791-430-3230
Installer
■
1
Part name
Sketch
790-101-5001
Part No.
New/Redesign
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Idler Assembly
Remarks
Press-fit of idler
Installation of floating seal
Disassemble Idler Assembly Idler, support, shaft assembly 1.
Remove cover (1).
2.
Remove bracket (2).
3.
Remove support (3).
4.
Drain engine oil from the idler.
6 Inside of idler: Approximately 20 cc
5.
Remove the idler from support and shaft assembly (4).
6.
Remove O-ring, shaft (5), and support (6).
50-98
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble Idler Assembly
Floating seal 7. Remove floating seal (7) of supports (3) and (6). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
Idler 8. Remove floating seals (8) (2 pieces) of idler (9). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
9.
Remove bushings (10) (2 pieces) from idler (9).
Assemble Idler Assembly Idler 1. Press fit bushings (10) (2 pieces) to idler (9) by using push tool (A).
PC45MR-5, PC55MR-5
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Disassemble and Assemble Idler Assembly
2.
50 Disassembly and Assembly
Install floating seals (8) (2 pieces) to idler (9) by using installer (B). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
Floating seal 3. Install floating seal (7) to supports (3) and (6) by using installer (B). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
Idler, support, shaft assembly 4. Fit O-ring, and install shaft (5) to support (6).
5.
Install support and shaft assembly (4) to the idler.
6.
Refill the inside of idler with engine oil.
5 Inside of idler: Approximately 20 cc (EO30-CD)
7.
Install support (3).
8.
Install bracket (2).
2 Mounting bolt: Liquid adhesive (LT-2) 2 Mounting bolt: Liquid adhesive (LT-2)
3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgfm}
9.
Install cover (1).
50-100
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble Track Roller Assembly
Disassemble and Assemble Track Roller Assembly
A
B
Push tool kit
■
1
790-101-5081
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
791-430-3230
Installer
■
1
Part name
Sketch
790-101-5001
Part No.
New/Redesign
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Track Roller Assembly
Remarks
Press-fit of bushing
Installation of floating seal
Disassemble Track Roller Assembly Collar 1. Remove snap ring and collar (1). 2.
Drain engine oil from the roller.
6 Engine oil: Approximately 135 cc
3.
Remove snap ring and collar (2).
Shaft 4. Remove O-ring and shaft (3) from the roller. Floating seal 5. Remove floating seal (4) from collars (1) and (2). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
PC45MR-5, PC55MR-5
50-101
Disassemble and Assemble Track Roller Assembly
6.
50 Disassembly and Assembly
Remove floating seals (5) (2 pieces) from roller (6). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
Bushing 7. Remove bushings (7) (2 pieces) from roller (6).
Assemble Track Roller Assembly Bushing 1. Press fit bushings (7) (2 pieces) to roller (6) by using push tool (A).
Floating seal 2. Install floating seals (5) (2 pieces) to roller (6) by using installer (B). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
3.
Disassemble and Assemble Track Roller Assembly
Install floating seal (4) to collars (1) and (2) by using installer (B). REMARK • Clean, completely degrease and dry O-ring and the contacting surfaces of O-rings. • Apply engine oil (EO30-CD) to the sliding surface of the floating seal, and take care that dust does not stick to it.
Shaft 4. Fit O-ring, and install shaft (3) to the roller.
Collar 5. Fit collar (2), and fix it with the snap ring. 6.
Refill the inside of roller with engine oil.
5 Inside of roller: Approximately 135 cc (EO30-CD)
7.
Fit collar (1), and fix it with the snap ring.
PC45MR-5, PC55MR-5
50-103
Disassemble and Assemble Carrier Roller Assembly
50 Disassembly and Assembly
Disassemble and Assemble Carrier Roller Assembly
A
B
Push tool kit
■
1
790-101-5081
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
790-101-5001
Push tool kit
■
1
790-101-5111
Plate
■
1
790-101-5021
Grip
■
1
01010-50816
Bolt
■
1
Part name
Sketch
790-101-5001
Part No.
New/Redesign
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Carrier Roller Assembly
Remarks
Press-fit of bearing
Press-fit of dust seal
Disassemble Carrier Roller Assembly 1.
Remove cap (1).
2.
Remove snap ring (2).
3.
Remove shaft (3) from the roller.
4.
Drain oil from the roller.
6 Inside of roller: Approximately 30 cc
50-104
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
5.
Remove dust seal (4) from roller (5).
6.
Remove ball bearings (6) (2 pieces) from roller (5).
Disassemble and Assemble Carrier Roller Assembly
Assemble Carrier Roller Assembly 1.
Press fit ball bearings (6) (2 pieces) to roller (5) by using push tool (A).
2 Bearing ball: Grease (Showa Shell Sekiyu, Alvania EP-2 or equivalent)
2.
Press fit dust seal (4) to roller (5) by using push tool (B).
3.
Seal grease in the roller.
2 Inside of roller: Grease (Showa Shell Sekiyu, Alvania EP-2 or equivalent)
Quantity of grease: Approximately 30 cc
PC45MR-5, PC55MR-5
50-105
Disassemble and Assemble Carrier Roller Assembly
4.
Install shaft (3) to the roller.
5.
Install snap ring (2).
50 Disassembly and Assembly
REMARK Install the snap ring with the inside edge facing the shaft end side.
6.
Press fit cap (1) by using push tool (A). Cap press-fitting depth (a): 10 mm
50-106
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Revolving Frame Assembly
Remove and Install Revolving Frame Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Revolving Frame Assembly Work equipment assembly 1. Remove the work equipment assembly. For details, see “Remove and Install Work Equipment Assembly”. 2.
Remove the floor frame assembly. For details, see “Remove and Install Floor Frame Assembly (Canopy Specification)”. REMARK Remove the operator's cab assembly of the cab specification machine. For details, see “Remove and Install Operator CAB Assembly (CAB Specification)”.
Boom cylinder assembly 3. Pull out pin (1), sling boom cylinder assembly (2), and remove it. 4 Boom cylinder: 45 kg
Center swivel joint 4. Disconnect hoses (3) to (11) from the center swivel joint, and remove lever (12).
PC45MR-5, PC55MR-5
50-107
Remove and Install Revolving Frame Assembly
50 Disassembly and Assembly
Revolving frame assembly 5. Sling the revolving frame assembly, hold it, and remove mounting bolt (13). REMARK Leave mounting bolts approximately 2 pieces each on the front and rear side.
6.
Remove the remaining mounting bolts, sling revolving frame assembly (14), and remove it. REMARK • Remove remaining mounting bolts (13) while keeping a balance in all directions of the assembly by using a lever block, etc. • Check that all the pipings are disconnected, and remove the center swivel joint while taking care not to damage it.
4 Revolving frame assembly: 2250 kg
Install Revolving Frame Assembly Revolving frame assembly 1. Sling revolving frame assembly (14), and set it on the machine. REMARK Be careful not to damage the center swivel joint when installing it.
4 Revolving frame assembly: 2250 kg
2.
Sling the revolving frame assembly, hold it, and install it with mounting bolt (13). 2 Revolving frame assembly mounting bolt: Liquid adhesive (LT-2) 3 Revolving frame assembly mounting bolt: 117.6 to 137.2 Nm {12 to 14 kgfm}
50-108
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Revolving Frame Assembly
Center swivel joint 3. Install lever (11), and connect hoses (3) to (10) to the center swivel joint. 2 Lever mounting bolt: Liquid adhesive (LT-2)
3 Lever mounting bolt: 98 to 123 Nm {10 to 12.5 kgfm}
Boom cylinder assembly 4. Sling boom cylinder assembly (2), hold it, and insert pin (1). k Never
insert your finger into the pin hole when aligning pin hole position.
4 Boom cylinder: 45 kg
2 Sliding surface on the pin and swing bracket side: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installation: Hyper white grease (G2-T)
5.
Install the floor frame assembly. For details, see “Remove and Install Floor Frame Assembly (Canopy Specification)”. REMARK Install the operator's cab assembly of the cab specification machine. For details, see “Remove and Install Operator CAB Assembly (CAB Specification)”.
Work equipment assembly 6. Install the work equipment assembly. For details, see “Remove and Install Work Equipment Assembly”. Refilling hydraulic tank with oil 7. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. Air bleeding 8. Bleed air. For details, see Testing and Adjusting, “Bleed Air from Fuel System”.
PC45MR-5, PC55MR-5
50-109
Remove and Install Counterweight Assembly
50 Disassembly and Assembly
Remove and Install Counterweight Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Counterweight Assembly Floor 1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Cover 2. Remove bolts (1) and (2) (4 pieces) and bolts (2a) (2 pieces), and remove cover (3).
3.
Open covers (4) and (5). NOTICE Be sure to lock the covers when they have been opened.
4.
Remove pin (6).
5.
Remove bolts (7) (4 pieces), and remove cover (5).
50-110
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
6.
Remove bolts (8) and (9).
7.
Remove bolts (10) (3 pieces), and remove cover (11).
8.
Remove bolts (12) (2 pieces).
9.
Remove bolts (13) (2 pieces), and remove cover (14).
Remove and Install Counterweight Assembly
Air cleaner assembly 10. Loosen clamp (15).
PC45MR-5, PC55MR-5
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Remove and Install Counterweight Assembly
50 Disassembly and Assembly
11. Loosen clamp (16). 12. Remove bolts (17) (2 pieces), and remove air cleaner assembly (18).
13. Remove clamp (19).
Counterweight assembly 14. Remove bolt (20), and move bracket (21) aside so that it does not hinder the work. (machine with air conditioner only)
15. Remove bolts (22) (2 pieces) and move bracket (23) aside so that it does not hinder the work.
16. Remove bolts (24) (2 pieces), and remove cover (25).
50-112
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Counterweight Assembly
17. Remove bolts (26) (4 pieces), sling bracket (27), and remove it. 4 Bracket (27): 70 kg
18. Sling additional counterweight (29), and hold it. (machine with additional counterweight only) 19. Remove bolts (28) (2 pieces), sling additional counterweight (29), and remove it. 4 Additional counterweight (29): 250 kg
20. Sling counterweight assembly (31), and hold it. 21. Remove bolts (30) (4 pieces), sling counterweight assembly (31), and remove it. REMARK Sling the assembly while sliding it rearward horizontally to prevent it from interfering with the machine body.
4 Counterweight assembly (31): 650 kg
Install Counterweight Assembly Counterweight assembly 1. Sling counterweight assembly (31), and set it on the machine. REMARK Lower the assembly while sliding it forward horizontally to prevent it from interfering with the machine body. 4 Counterweight assembly (31): 650 kg
2.
Install counterweight assembly (31) with bolts (30) (4 pieces). 2 Bolt (30): Liquid adhesive (LT-2)
3 Bolt (30): 785 to 980 Nm {80 to 100 kgfm}
PC45MR-5, PC55MR-5
50-113
Remove and Install Counterweight Assembly
3.
50 Disassembly and Assembly
Install additional counterweight (29) with bolts (28) (2 pieces). (machine with additional counterweight only) 4 Additional counterweight (29): 250 kg
3 Bolt (28): 455 to 565 Nm {46.5 to 58 kgfm}
4.
Sling bracket (27), and install it with bolts (26) (4 pieces). 4 Bracket (27): 70 kg
2 Bolt (26): Liquid adhesive (LT-2)
3 Bolt (26): 785 to 980 Nm {80 to 100 kgfm}
5.
Install cover (25) with bolts (24) (2 pieces).
6.
Install bracket (23) with bolts (22) (2 pieces).
7.
Install bracket (21) with bolt (20). (machine with air conditioner only)
50-114
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Counterweight Assembly
Air cleaner assembly 8. Install clamp (19).
9.
Install air cleaner assembly (18) with bolts (17) (2 pieces). 10. Fasten clamp (16). 3 Clamp (16): 5.9±0.49 Nm {0.6±0.05 kgfm}
11. Fasten clamp (15).
3 Clamp (15): 5.9±0.49 Nm {0.6±0.05 kgfm}
Cover 12. Install cover (14) with bolts (12) and (13) (2 pieces each).
PC45MR-5, PC55MR-5
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Remove and Install Counterweight Assembly
50 Disassembly and Assembly
13. Install cover (11) with bolts (8), (9) and (10) (3 pieces).
14. Install cover (5) with bolts (7) (4 pieces). 15. Install pin (6).
16. Close covers (4) and (5).
17. Install cover (3) with bolts (1) and (2) (4 pieces) and bolts (2a) (2 pieces).
50-116
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Counterweight Assembly
Floor 18. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
PC45MR-5, PC55MR-5
50-117
Remove and Install Center Swivel Joint Assembly
50 Disassembly and Assembly
Hydraulic System Remove and Install Center Swivel Joint Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Release the remaining pressure in the hydraulic circuit. For details, see Testing and Adjusting, “Re-
lease Remained Pressure in Hydraulic Circuit”.
Remove Center Swivel Joint Assembly Hydraulic tank 1. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. Floor frame 2. Open the floor frame. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. 3. Remove bolts (1) (4 pieces) and bolts (1a) (2 pieces), and remove cover (2).
4.
Loosen mounting bolt (2), and slide cover (3).
Center swivel joint assembly 5. Disconnect hoses (3) to (11). 6.
Remove lever (12) from the center swivel joint.
50-118
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
7.
Disconnect hoses (13) to (20).
8.
Disconnect hoses (21) and (22).
9.
Remove elbow (23).
Remove and Install Center Swivel Joint Assembly
10. Remove mounting bolt (24), and remove the center swivel joint assembly.
Install Center Swivel Joint Assembly Center swivel joint assembly 1. Install the center swivel joint assembly with mounting bolt (24). 3 Mounting bolt (24): 39.2 to 49 Nm {4 to 5 kgfm}
2.
Install elbow (23).
3.
Connect hoses (21) and (22).
PC45MR-5, PC55MR-5
50-119
Remove and Install Center Swivel Joint Assembly
4.
Connect hoses (13) to (20).
5.
Install lever (12) to the center swivel joint.
50 Disassembly and Assembly
2 Lever mounting bolt: Liquid adhesive (LT-2)
3 Lever mounting bolt: 153 to 190 Nm {15.5 to 19.5 kgfm}
6.
Connect hoses (3) to (11).
7.
Install cover (3) with mounting bolt (2).
8.
Install cover (2) with bolts (1) (4 pieces) and bolts (1a) (2 pieces).
9.
Close the floor frame. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
50-120
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Center Swivel Joint Assembly
Refilling hydraulic tank with oil 10. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. Air bleeding 11. Bleed air. For details, see Testing and Adjusting, “Bleed Air from Fuel System”.
PC45MR-5, PC55MR-5
50-121
Disassemble and Assemble Center Swivel Joint Assembly
50 Disassembly and Assembly
Disassemble and Assemble Center Swivel Joint Assembly
A
50-122
●
1
790-101-2501
Push puller
790-101-2510
Block
1
790-101-2520
Screw
1
791-112-1180
Nut
1
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
Sketch
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Center Swivel Joint Assembly
Remarks
Disassembly and assembly of center swivel joint assembly
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble Center Swivel Joint Assembly
Disassemble Center Swivel Joint Assembly Center swivel joint assembly 1. Remove bolt (1), and remove plate (2). 2.
Remove O-ring (3) and snap ring (4).
3.
Remove rotor (9) from swivel joint (5) by using push puller (A).
4.
Remove dust seal (6), plug (7), and plugs (8) (4 pieces) from swivel shaft (5).
5.
Remove ring (10), O-ring (11), and packings (13) (8 pieces) from rotor (9).
PC45MR-5, PC55MR-5
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Disassemble and Assemble Center Swivel Joint Assembly
50 Disassembly and Assembly
Assemble Center Swivel Joint Assembly Center swivel joint assembly 1. Install O-ring (11) and packings (13) (8 pieces) to rotor (9). 2.
Install dust seal (6) to swivel shaft (5).
3.
Install plug (7) (1 piece) and plugs (8) (4 pieces) to swivel shaft (5).
2 Dust seal lip: Grease (G2-LI)
REMARK • Thoroughly degrease, clean and dry the threaded parts. • After installing, check that the plug end surface is lower than the shaft end surface.
3 Plug (5): 16.8 to 22.6 Nm {1.71 to 2.3 kgfm} 3 Plug (6): 16.7 to 24.5 Nm {1.7 to 2.5 kgfm}
4.
Set swivel shaft (5) on the block, install rotor (9) by tapping it lightly with a plastic hammer, etc. by using a push tool. REMARK Take extreme care not to damage the slipper seal and Oring. 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) with bolt (1).
3 Bolt (1): 39.2 to 49 Nm {4 to 5 kgfm}
50-124
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Hydraulic Tank Assembly
Remove and Install Hydraulic Tank Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Release the remaining pressure in the hydraulic system. For details, see Testing and Adjusting, “Re-
lease Remained Pressure in Hydraulic Circuit”.
Remove Hydraulic Tank Assembly Draining 1. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. 2. Remove bolts (1) (6 pieces), and remove cover (2).
3.
Remove drain plug (3), and drain the hydraulic oil.
6 Hydraulic tank: 20 ℓ
REMARK Check that the hydraulic oil is completely drained, and tighten drain plug (3).
Fuel tank 4. Remove the fuel tank assembly. For details, see “Remove and Install Fuel Tank Assembly”. Cover 5. Remove bolts (4) (3 pieces), and remove cover (5).
PC45MR-5, PC55MR-5
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Remove and Install Hydraulic Tank Assembly
6.
Remove clamps (6) (2 places).
7.
Disconnect hose (7), and remove sub-tank (8).
8.
Remove clamp (9).
9.
Loosen clamp (10), and disconnect hose (11).
50 Disassembly and Assembly
10. Remove bolts (12) (3 pieces), and remove chamber (13).
11. Remove bolts (14) (2 pieces), and remove cover (15).
12. Remove clamp (16), and disconnect hose (17).
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50 Disassembly and Assembly
Remove and Install Hydraulic Tank Assembly
13. Remove bolts (18) (3 pieces), and remove bracket (19).
Hydraulic tank assembly 14. Disconnect hoses (20) to (24). (20): Swivel joint (T) (21): Main valve (Ts) (22): Main valve (Ptr) (23): Solenoid valve (T) (24): Floor (T) block 15. Disconnect hose (25).
16. Remove clamp (26), and disconnect suction hose (27).
17. Remove bolt (28). 18. Remove bolts (29) (4 pieces), sling hydraulic tank assembly (30), and remove it. 4 Hydraulic tank assembly (30): 40 kg
PC45MR-5, PC55MR-5
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Remove and Install Hydraulic Tank Assembly
50 Disassembly and Assembly
How to Install Hydraulic Tank Assembly Hydraulic tank assembly 1. Sling hydraulic tank assembly (30), and set it on the machine. 4 Hydraulic tank assembly (30): 40 kg
2.
Install hydraulic tank assembly (30) with bolts (29) (4 pieces). 2 Threaded portion of bolt (29): Adhesive (LT-2)
3 Bolt (29): 98 to 123 Nm {10 to 12.5 kgfm}
3.
Install bolt (28).
4.
Connect suction hose (27) with clamp (26).
5.
Connect hose (25).
6.
Connect hoses (20) to (24).
3 Clamp (26): 8.8±0.5 Nm {0.9±0.05 kgfm}
(20): Swivel joint (T) (21): Main valve (Ts) (22): Main valve (Ptr) (23): Solenoid valve (T) (24): Floor (T) block
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Hydraulic Tank Assembly
Cover 7. Install bracket (19) with bolts (18) (3 pieces).
8.
Connect hose (17).
9.
Install clamp (16).
10. Install cover (15) with bolts (14) (2 pieces).
11. Install chamber (13) with bolts (12) (3 pieces).
12. Connect hose (11), and fasten clamp (10). 13. Install clamp (9).
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Remove and Install Hydraulic Tank Assembly
50 Disassembly and Assembly
14. Install sub-tank (8). 15. Connect hose (7). 16. Install clamps (6) (2 places).
17. Install cover (5) with bolts (4) (3 pieces).
Fuel tank 18. Install the fuel tank assembly. For details, see “Remove and Install Fuel Tank Assembly”. 19. Tighten drain plug (3).
3 Drain plug (3): 58.8 to 78.4 Nm {6 to 8 kgfm}
20. Install cover (2) with bolts (1) (6 pieces).
Refilling hydraulic tank with oil 21. Check that the drain plug is closed before refilling. 22. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. 5 Hydraulic tank: 20 ℓ
Air bleeding 23. Bleed air. For details, see TESTING AND ADJUSTING, “Bleed air from each part”. 50-130
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Main Pump Assembly
Remove and Install Main Pump Assembly
796T-13S-1010 Torque adapter
●
1
New/Redesign
Part name
Sketch
A
Part No.
Q'ty
Symbol
Necessity
Tools for Removal and Installation of Main Pump Assembly
Remarks
○
Removal and installation of main pump assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Release the remaining pressure in the hydraulic system. For details, see Testing and Adjusting, “Re-
lease Remained Pressure in Hydraulic Circuit”.
Remove Main Pump Assembly Draining 1. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. 2. Remove bolts (1) (6 pieces), and remove cover (2).
3.
Remove drain plug (3), and drain the hydraulic oil. 6 Hydraulic tank: 20 ℓ
REMARK Check that hydraulic oil is completely drained, and then tighten drain plug (3).
Floor 4. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
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Remove and Install Main Pump Assembly
5.
Remove bolts (4) and (5) (4 pieces) and bolts (5a) (2 pieces), and remove cover (6).
6.
Remove bolts (7) (2 pieces), and remove heat insulation plate (8).
7.
Remove nuts (14) (4 places), and remove U-bolt.
8.
Remove clamp (15), and remove exhaust pipe (16).
9.
Disconnect hoses (19), (20) and (21). (Except for the machines ready for installation of quick coupler)
50 Disassembly and Assembly
10. Disconnect the hoses (20), (21), and (30). (For the machines ready for installation of quick coupler)
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50 Disassembly and Assembly
Remove and Install Main Pump Assembly
11. Disconnect hoses (22) and (23).
12. Disconnect hoses (24) and (25).
13. Remove bolts (26) (4 pieces), and disconnect suction hose (27).
14. Sling main pump assembly (29), and hold it. 15. Remove bolts (28) (4 pieces) by using torque adapter (A), sling main pump assembly (29), and remove it. 4 Main pump assembly (29): 30 kg
Install Main Pump Assembly 1.
Sling main pump assembly (13), and set it on the engine. 4 Main pump assembly (29): 30 kg
PC45MR-5, PC55MR-5
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Remove and Install Main Pump Assembly
2.
Install main pump assembly (29) with bolts (28) (4 pieces) by using torque adapter (A).
3.
Connect suction hose (27) with bolts (26) (4 pieces).
4.
Connect hoses (24) and (25).
5.
Connect hoses (22) and (23).
6.
Connect hoses (19), (20) and (21). (Except for the machines ready for installation of quick coupler)
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
7.
Connect the hoses (20), (21), and (30). (For the machines ready for installation of quick coupler)
8.
Install exhaust pipe (16) with clamp (15).
9.
Fix exhaust pipe (16) with nuts (14) (4 places) and U-bolt.
Remove and Install Main Pump Assembly
10. Install heat insulation plate (8) with bolts (7) (2 pieces).
11. Install cover (6) with bolts (4) and (5) (4 pieces) and bolts (5a) (2 pieces).
12. Tighten drain plug (3).
3 Drain plug (3): 58.8 to 78.4 Nm {6 to 8 kgfm}
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Remove and Install Main Pump Assembly
50 Disassembly and Assembly
13. Install cover (2) with bolts (1) (6 pieces).
Floor 14. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Refilling hydraulic tank with oil 15. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. 5 Hydraulic tank: 20 ℓ
16. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.
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50 Disassembly and Assembly
Remove and Install Accumulator Assembly
Remove and Install Accumulator Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes out.
k Release the remaining pressure in the PPC accumulator circuit. See TESTING AND ADJUSTING,
“RELEASE REMAINING PRESSURE IN PPC ACCUMULATOR CIRCUIT”.
How to Remove Accumulator Assembly (EU Specification) Accumulator assembly 1. Release the remaining pressure from the hydraulic tank. See Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. 2. Remove the bolts (1) (3 pieces), and remove the cover (2).
3.
Remove the bolt (3), and remove the cover (4).
4.
Remove the bolts (5) (2 pieces), and remove the plate (6).
PC45MR-5, PC55MR-5
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Remove and Install Accumulator Assembly
5.
Remove the bolts (7) (2 pieces), and remove the clamp (8).
6.
Move the hose aside so that it does not hinder the work.
7.
Remove the nuts (9) (2 pieces), and remove U-bolt (10).
8.
Remove the accumulator (11).
50 Disassembly and Assembly
How to Remove Accumulator Assembly (North America Specification, for Machine with Quick Coupler) Accumulator assembly 1. Release the remaining pressure from the hydraulic tank. See Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. 2. Remove the bolts (1) (3 pieces), and remove the cover (2).
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50 Disassembly and Assembly
3.
Remove the bolt (3), and remove the cover (4).
4.
Remove the bolt (5), and remove the horn (6).
5.
Remove the solenoid valve assembly bracket (7).
6.
Remove the solenoid valve assembly (8).
7.
Remove the accumulator (9).
PC45MR-5, PC55MR-5
Remove and Install Accumulator Assembly
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Remove and Install Accumulator Assembly
50 Disassembly and Assembly
How to Install Accumulator Assembly (EU Specification) Accumulator assembly 1. Install the accumulator (11).
2.
Install U-bolt (10) with the nuts (9) (2 pieces).
3.
Install the clamp (8) with the bolt (5).
4.
Install the plate (6) with the bolts (5) (2 pieces).
5.
Install the cover (4) with the bolt (3).
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50 Disassembly and Assembly
6.
Remove and Install Accumulator Assembly
Install the cover (2) with the bolts (1) (3 pieces).
How to Install Accumulator Assembly (North America Specification, for Machine with Quick Coupler) Accumulator assembly 1. Install the accumulator (9) to the solenoid valve assembly.
2.
Install the solenoid valve assembly bracket (7) to the revolving frame.
3.
Install the solenoid valve assembly (8) to the solenoid valve assembly bracket (7).
PC45MR-5, PC55MR-5
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Remove and Install Accumulator Assembly
4.
Install the horn (6) with the bolt (5).
5.
Install the cover (4) with the bolt (3).
6.
Install the cover (2) with the bolts (1) (3 pieces).
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PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Disassemble and Assemble Work Equipment PPC Valve Assembly
Disassemble and Assemble Work Equipment PPC Valve Assembly Disassemble Work Equipment PPC Valve Assembly
Only precautions for disassembling the work equipment PPC valve assembly are explained below. 2 each of 2 different types of springs with different load at installed height are installed to springs (6) and (7). Check the installing position (hydraulic port) to prevent any wrong installation.
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Disassemble and Assemble Work Equipment PPC Valve Assembly
50 Disassembly and Assembly
How to Assemble Work Equipment PPC Valve Assembly
Only precautions for disassembling and assembling the work equipment PPC valve assembly are explained below. NOTICE Carefully clean and inspect the parts to prevent failure due to dust, rust, scratch, etc., and then take extreme care when assembling them. •
Plugs (2) and (3) are not supplied.
•
When assembling piston (8), apply grease (G2-LI) to the periphery of the piston and inside wall of the hole of valve body (1).
•
When installing spring (5), install the end surface of the smaller end turn diameter to shim (4) side. End turn diameter of spring
•
•
Smaller diameter end: φ4.9
•
Larger diameter end: φ5.55
As springs (6) and (7), different springs are used for different hydraulic ports. Check them before installing. • Installed height: 34 mm (all) •
Load at installed height: Spring (6) (P1, P2) 1.8 kg Spring (7) (P3, P4) 1.0 kg
3 Bolt (11): 11.8 to 14.7 Nm {1.2 to 1.5 kgfm}
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50 Disassembly and Assembly
•
Disassemble and Assemble Work Equipment PPC Valve Assembly
When installing joint (12) to body (1), apply Loctite according to the following procedure. 1. When installing the joint, apply 1 drop (approximately 0.02 g) of Loctite (No. 648) to the female threaded parts (A) (2 places) of the body. Before installing, thoroughly degrease and dry the threaded part of the joint and the female threaded part of the body by using parts cleaner. 2. The drop positions of Loctite are shown in the figure. 2 Female threaded part (A) of body: Loctite (No. 648) 3 Joint (12): 39 to 49 Nm {4 to 5 kgfm}
•
Apply grease (G2-LI) to the contact surfaces of disc (13) and piston (8). Application amount: 2 Rocking portion of joint: Grease (G2-LI) (7 to 10 ml/entire circumference) 2 Rocking portion of disc and piston: Grease (G2-LI) (0.3 to 0.8 ml/place)
•
When assembling disc (13), adjust play of the lever end so that the play is within the range from 0.5 to 3 mm at the point of 200 mm from the rotation center. See Testing and Adjusting, “Adjust Play of Work Equipment and Swing PPC Valves”. 3 Nut (14): 69 to 88 Nm {7 to 9 kgfm}
PC45MR-5, PC55MR-5
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Disassemble and Assemble Travel PPC Valve Assembly
50 Disassembly and Assembly
Disassemble and Assemble Travel PPC Valve Assembly Disassemble Travel PPC Valve Assembly
1.
Remove screw (22), and remove damper assembly (21).
2.
Remove mounting bolt (14), and remove case (10), shaft (12), and lever (11) together as a unit.
3.
Remove mounting bolts (16), and remove plate (13). REMARK • Check the thickness and installing position of washer (17). • Pull out pin (23) from body (1).
4.
Remove seal (8) and collar (9).
5.
Pull out piston (7), and remove retainer (5), springs (6) and (4), and shim (3). REMARK Check the thickness and quantity of shim (3) at each installing position, and store them.
6.
Pull out valve (2) from body (1).
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50 Disassembly and Assembly
Disassemble and Assemble Travel PPC Valve Assembly
How to Assemble Travel PPC Valve Assembly
k Carefully clean and inspect the parts to prevent failure due to dust, rust, scratch, etc., and then take
extreme care when assembling them. 1.
When assembling piston (7), apply grease (G2-L1) to the periphery of the piston and inside wall of the hole of valve body (1).
2.
Install valve (2) to body (1).
3.
When installing spring (4), install the end surface of the smaller end turn diameter to shim (3) side. •
End turn diameter of spring (inside diameter) Small diameter: 4.9 mm Large diameter: 5.16 mm
4.
Apply grease (G2-LI) to the contact surfaces of lever (11) and piston (7) and to the contact surfaces of damper (21) and pin (23).
2 Connecting portion of lever and piston: Grease (G2-LI) (0.3 to 0.8 ml/place) 2 Connecting portion of damper and pin: Grease (G2-LI) (0.3 to 0.8 ml/place)
5.
Install retainer (5) and spring (6), and then install piston (7). REMARK Check the thickness and quantity of shim (3) at each installing position.
6.
Install seal (8) and collar (9).
7.
Install plate (13) with mounting bolts (16). REMARK Install washer (17) (t = 1.6). If the difference between the right and left full stroke angles exceeds 0.7 °, reduce it to 0.7 ° or less by changing the washer thickness. (When the washer thickness is decreased 0.3 mm, the full stroke angle increases 0.39 °.)
PC45MR-5, PC55MR-5
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Disassemble and Assemble Travel PPC Valve Assembly
50 Disassembly and Assembly
Washer type and thickness = 1.0, 1.3, 1.6, 1.9, 2.2 mm 3 Bolt (16): 27 to 34 Nm {2.8 to 3.5 kgfm}
8.
Install shaft (12) and lever (11) to case (10), and install them with mounting bolt (14).
9.
Install damper assembly (21) with screw (22).
3 Bolt (14): 25 to 31 Nm {2.5 to 3.2 kgfm}
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50 Disassembly and Assembly
Remove and Install Blade Assembly
Work Equipment Remove and Install Blade Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to the LOCK position.
k Disconnect the (-) terminal more than 2 minutes after the engine is stopped, or after you make sure
that the system operating lamp is not lit.
Remove Blade Assembly Blade assembly 1. Lift the blade cylinder (1), and hold it. 2.
Remove the lock plate (2), and remove the pin (3).
k Be sure to lift the blade cylinder (1) when you re-
move the pin (3). Otherwise, the blade cylinder (1) could possibly falls off.
k Place the blade cylinder (1) on the block, etc.
3.
Remove the R.H. and L.H. lock plates (5), and remove the pin (6) of the blade and frame.
4.
Lift the blade assembly (4), and remove it. Blade assembly (4): 280 kg
PC45MR-5, PC55MR-5
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Remove and Install Blade Assembly
50 Disassembly and Assembly
Install Blade Assembly Blade assembly 1. Lift the blade assembly (4), and set it to the installation position. Blade assembly (4): 280 kg
2.
Install the pin (6) of the blade and frame with the R.H. and L.H. lock plates (5). Pin (6): Grease (G2-T)
k You must not put your finger into the pin hole when
you align the pin holes. REMARK Adjust the shims. See MAINTENANCE STANDARD, “MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE”. 3.
Lift the blade cylinder (1), and hold it.
4.
Install the pin (3) with the lock plate (2). Pin (3): Grease (G2-T)
k You must not put your finger into the pin hole when
you align the pin holes. REMARK Adjust the shims. See MAINTENANCE STANDARD, “MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE”.
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50 Disassembly and Assembly
Remove and Install Work Equipment Assembly
Remove and Install Work Equipment Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Work Equipment Assembly Clamp, cover 1. Remove clamps (1), disconnect connector W2 (2), and remove it from the boom.
2.
Remove mounting bolts (3) (2 pieces), and remove cover (4). REMARK Keep the cylinder guide without losing it.
Hose 3. Disconnect hoses (5) to (12) (8 pieces). (Except for the machines ready for installation of quick coupler)
4.
Disconnect the hoses (20), (21), (22), (23), (24), (25), (26), (27), (28), and (29) (10 pieces in total). (For the machines ready for installation of quick coupler)
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Remove and Install Work Equipment Assembly
50 Disassembly and Assembly
Work equipment assembly 5. Sling boom cylinder (13), and hold it. 4 Boom cylinder (13): 45 kg
6.
Remove plate (14), and remove head side pin (15). REMARK Lower the boom cylinder onto block, etc.
7.
Sling work equipment assembly (19), and hold it.
8.
Remove plate (17), and remove boom foot pin (18).
9.
Sling work equipment assembly (19), and remove it from the machine body. 4 Work equipment assembly (19): 510 kg
Install Work Equipment Assembly Work equipment assembly 1. Sling work equipment assembly (19), and install it. 4 Work equipment assembly (19): 510 kg
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50 Disassembly and Assembly
2.
Remove and Install Work Equipment Assembly
Insert boom foot pin (18), and install plate (17). k Never
insert your finger into the pin hole when aligning pin hole position.
2 Sliding surface on the pin and swing bracket side: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installation: Grease (Hyper white grease)
3.
Sling boom cylinder (13), and hold it.
4.
Insert head side pin (15), and install plate (14).
4 Boom cylinder (13): 45 kg k Never
insert your finger into the pin hole when aligning pin hole position.
2 Sliding surface on the pin and boom side: Molybdenum disulfide lubricant (LM-P) 2 Greasing after installation: Grease (Hyper white grease)
5.
Adjust clearance (a) between boom cylinder head (14) and boom (15) to 1 mm or lower by using shims. Shim thickness: 1 mm
6.
Connect hoses (5) to (12) (8 pieces). (Except for the machines ready for installation of quick coupler)
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Remove and Install Work Equipment Assembly
7.
Connect the hoses (20), (21), (22), (23), (24), (25), (26), (27), (28), and (29) (10 pieces in total). (For the machines ready for installation of quick coupler)
8.
Install cover (4) with mounting bolts (3) (2 pieces).
9.
Install clamps (1) to the boom, and connect connector W2 (2).
50 Disassembly and Assembly
Refilling hydraulic tank with oil 10. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. Air bleeding 11. Bleed air. For details, see Testing and Adjusting, “Bleed Air from Fuel System”.
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50 Disassembly and Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly Piston assembly, cylinder head assembly
Piston rod assembly
A
Disassembly of cylinder head assembly
Disassembly of piston assembly
Piston rod
A
Cylinder
A B
C
D
Cylinder repair stand
■
1
790-101-1102
Hydraulic pump
■
1
790-330-1100
Wrench assembly
■
1
790-302-1270
Socket (width across flats 50 mm)
■
1
790-302-1280
Socket (width across flats 55 mm)
■
1
790-302-1470
Socket (width across flats 55 mm long socket type)
■
1
790-302-1310
Socket (width across flats 65 mm)
■
1
790-302-1320
Socket (width across flats 65 mm long socket type)
■
1
790-201-1702
Push tool kit
■
1
790-101-5021
•
Grip
1
01010-50810
•
Bolt
1
790-201-1731
•
Push tool
1
790-201-1741
•
Push tool
1
790-201-1751
•
Push tool
1
790-201-1761
•
Push tool
1
790-201-1771
•
Push tool
1
PC45MR-5, PC55MR-5
Sketch
790-502-1003
Part No.
New/Redesign
Part name
Q'ty
Symbol
Necessity
Tools for Disassembly and Assembly of Work Equipment Cylinder Assembly
Remarks
Disassembly and assembly of work equipment cylinder assembly Removal and installation of cylinder head
Removal and installation of nut
Press-fit of bushing
50-155
E
F
G
■
1
790-201-1500
Push tool kit
790-101-5021
•
Grip
1
01010-50816
•
Bolt
1
790-201-1540
•
Plate
1
790-201-1550
•
Plate
1
790-201-1560
•
Plate
1
790-201-1570
•
Plate
1
790-201-1580
•
Plate
1
790-720-1000
Expander
●
1
796-720-1620
Ring
●
1
07281-00609
Clamp
●
1
796-720-1640
Ring
●
1
07281-00909
Clamp
●
1
796-720-1650
Ring
●
1
07281-01029
Clamp
●
1
796-720-1670
Ring
●
1
07281-01279
Clamp
●
1
50 Disassembly and Assembly
Sketch
Part name
New/Redesign
Part No.
Q'ty
Symbol
Necessity
Disassemble and Assemble Work Equipment Cylinder Assembly
Remarks
Press-fit of dust seal
nstallation of piston ring
Installation of piston ring
How to Disassemble Work Equipment Cylinder Assembly Piston rod assembly 1. Set cylinder assembly (1) on cylinder repair stand (A). 2.
Remove cylinder head assembly (2) by using wrench assembly (B).
3.
Sling piston rod assembly (4), and pull it out from tube (3).
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Disassemble and Assemble Work Equipment Cylinder Assembly
Piston assembly, cylinder head assembly 4. Set piston rod assembly (4) on cylinder repair stand (A). 5.
Remove nut (5) by using socket (C).
Width across flats of nut (mm) Boom
Arm
Bucket
Swing
Blade
PC45MR-5
65
60
50
55
55
PC55MR-5
65
65
50
55
55
6.
Remove piston assembly (6) from piston rod (7).
7.
Remove cushion plunger (8) from piston rod (7). (Only for boom cylinder)
8.
Remove cylinder head assembly (2) from piston rod (7).
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50 Disassembly and Assembly
Disassembly of piston assembly 9. Remove wear ring (10) from piston (9). 10. Remove piston ring (11) from piston (9).
Disassembly of cylinder head assembly 11. Remove snap ring (12), and remove dust seal (13). 12. Remove rod packing (14). 13. Remove bushing (15). 14. Remove O-ring (16) and backup ring (17).
15. Remove O-ring (18) and backup rings (19) (2 pieces). (Only for boom cylinder)
Piston rod 16. Remove dust seals (20) (2 pieces) from piston rod (7). 17. Remove bushing (21) from piston rod (7).
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50 Disassembly and Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
Cylinder 18. Remove dust seals (22) (2 pieces) from cylinder (3). 19. Remove bushing (23) from cylinder (3).
How to Assemble Work Equipment Cylinder Assembly NOTICE • Apply engine oil to the sliding surface of each part, and take care not to damage the packing, dust seals, O-rings, etc. • When inserting the backup ring, do not fit in it forcibly. Warm it in hot water at approximately 50 to 60 °C, and then insert it. Cylinder 1. Press fit bushing (23) to cylinder (3). 2.
Install dust seals (22) (2 pieces) to cylinder (3).
Piston rod 3. Press fit bushing (21) to piston rod (7). 4.
Install dust seals (20) (2 pieces) of piston rod (7).
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50 Disassembly and Assembly
Assembly of cylinder head assembly 5. Press fit bushing (15) by using push tool kit (D). 6.
Install rod packing (14).
7.
Press fit dust seal (13) by using push tool kit (E).
8.
Install snap ring (12).
9.
Install the backup ring (17) and O-ring (16).
10. Remove backup rings (19) (2 pieces) and O-ring (18). (Only for boom cylinder)
Assembly of piston assembly 11. Set piston ring (11) on expander (F), and rotate the handle by 8 to 10 turns to expand it. 12. Remove piston ring (11) from expander (F), and install it to piston (9).
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50 Disassembly and Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
13. Compress piston ring (11) by using ring (G). 14. Install wear ring (10) to piston (9).
Piston assembly, cylinder head assembly 15. Install cylinder head assembly (2) to piston rod (7).
16. Install cushion plunger (8) to piston rod (7). (Only for boom cylinder)
17. Install piston assembly (6) to piston rod (7).
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50 Disassembly and Assembly
18. Set piston rod assembly (4) on cylinder repair stand (A). 19. Install nut (5) by using socket (C). Width across flats of nut (mm) Boom
Arm
Bucket
Swing
Blade
PC45MR-5
65
60
50
55
55
PC55MR-5
65
65
50
55
55
2 Nut (5): Loctite No. 262
REMARK Tighten the nut with its machined surface facing the piston side. 3 Nut (5) (boom) (PC45/55MR-5): 2.65±0.27 kNm {270±27 kgfm} 3 Nut (5) (arm) (PC45MR-5): 2.16±0.22 kNm {220±22 kgfm}
3 Nut (5) (arm) (PC55MR-5): 2.3±0.23 kNm {235±23.5 kgfm}
3 Nut (5) (bucket) (PC45/55MR-5): 1.08±0.11 kNm {110±11.0 kgfm}
3 Nut (5) (swing) (PC45/55MR-5): 1.42±0.14 kNm {145±14.5 kgfm} 3 Nut (5) (blade) (PC45/55MR-5): 1.42±0.14 kNm {145±14.5 kgfm}
Piston rod assembly 20. Set tube (3) on cylinder repair stand (A). 21. Sling piston rod assembly (4), and insert it into tube (3). REMARK Fully push the piston rod in.
22. Set cylinder assembly (1) on cylinder repair stand (A). 23. Install cylinder head assembly (2) by using wrench assembly (B). head assembly 3 Cylinder (PC45/55MR-5): 1.13±0.11 kNm {115±11.5 kgfm}
(2)
(boom)
3 Cylinder head assembly (2) (arm) (PC45MR-5): 785±78.5 Nm {80±8.0 kgfm} 3 Cylinder head assembly (2) (arm) (PC55MR-5): 961±96.1 Nm {98±9.8 kgfm}
3 Cylinder head assembly (2) (bucket) (PC45MR-5): 785±78.5 Nm {80±8.0 kgfm}
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50 Disassembly and Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
3 Cylinder head assembly (2) (bucket) (PC55MR-5): 863±86.5 Nm {88±8.8 kgfm} 3 Cylinder head assembly (2) (swing) (PC45MR-5): 676±67.6 Nm {69±6.9 kgfm} 3 Cylinder head assembly (2) (swing) (PC55MR-5): 735±73.5 Nm {75±7.5 kgfm}
3 Cylinder head assembly (2) (blade) (PC45/55MR-5): 931±93.1 Nm {95±9.5 kgfm}
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50 Disassembly and Assembly
CAB Related Parts Remove and Install Operator CAB Assembly (CAB Specification)
A
Collecting refrigerant
Draining
Hose, connector
Operator’s cab assembly
Hydraulic tank
Cab tilt
Cover
A
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k If you drain the radiator coolant when it is still hot, you may be scalded. Accordingly, wait for the
coolant temperature to drop before draining.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. If it touches your skin, you may
suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working clothes with long sleeves while you are collecting or filling the refrigerant. NOTICE • Never release the refrigerant to the atmosphere. • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove Operator CAB Assembly (CAB Specification) Collecting refrigerant 1. Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit (machine with air conditioner). Quantity of refrigerant to be collected: 550±50 g Draining 2.
Loosen drain valve (1), and drain the coolant. 6 Radiator: 8.9 ℓ
REMARK Check that the coolant is completely drained, and tighten drain plug (1).
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Remove and Install Operator CAB Assembly (CAB Specification)
Hydraulic tank 3. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. Cab tilt 4. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”. Cover 5. Open cover (1a), and lock it.
6.
Remove mounting bolts (4) (2 pieces), and remove cover (5).
7.
Disconnect heater hoses (6) and air conditioner tubes (7).
8.
Remove mounting bolts (8a), and remove cover (8).
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9.
50 Disassembly and Assembly
Remove rubber cover (9).
Hose, connector 10. Disconnect work equipment PPC hoses (10) to (17) (8 pieces) Band color of hose (10): Brown Band color of hose (11): Green Band color of hose (12): Blue Band color of hose (13): Yellow Band color of hose (14): Red Band color of hose (15): Brown Band color of hose (16): Black Band color of hose (17): White 11. Disconnect travel PPC hoses (18) to (21). Band color of hose (18): Yellow, brown Band color of hose (19): Yellow, orange Band color of hose (20): Yellow, green Band color of hose (21): Yellow, black 12. Disconnect swing PPC hoses (22) and (23). Band color of hose (22): Red, white Band color of hose (23): Blue, white 13. Disconnect connectors (24) to (27) at the front of the revolving frame, and ground cable (28). Connector (24): F03 Connector (25): F04 Connector (26): F05 Connector (27): F06 Ground cable (28): T01
Operator's cab assembly 14. Sling the operator's cab assembly, and hold it.
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Remove and Install Operator CAB Assembly (CAB Specification)
15. Disconnect wire (29). 16. Loosen mounting bolts (30) (2 pieces) gradually and alternately, and separate damper (31).
17. Disconnect hose (32). 18. Remove pin (33). 19. Remove right and left bolts (34), and pull out pin (35).
20. Sling operator's cab assembly (36), and remove it. REMARK • Check that all the wirings and pipings are disconnected before removing. • Pay attention to the balance when removing the assembly.
4 Operator's cab assembly (36): 450 kg
Install Operator CAB Assembly (CAB Specification) Operator's cab assembly 1. Sling operator's cab assembly (36), and install it. REMARK 4 Operator's cab assembly (36): 450 kg
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2.
50 Disassembly and Assembly
Install pin (35), and install right and left bolts (34).
k Never insert your finger during position alignment.
3.
Install pin (33).
4.
Connect hose (32).
5.
Tighten bolts (30) (2 pieces) gradually and alternately to install damper (31).
6.
Connect wire (29).
Hose, connector 7. Connect connectors (24) to (27) at the front of the revolving frame, and ground cable (28). Connector (24): F03 Connector (25): F04 Connector (26): F05 Connector (27): F06 Ground cable (28): T01
8.
Connect swing PPC hoses (22) and (23). Band color of hose (22): Red, white Band color of hose (23): Blue, white
9.
Connect travel PPC hoses (18) to (21). Band color of hose (18): Yellow, brown Band color of hose (19): Yellow, orange Band color of hose (20): Yellow, green Band color of hose (21): Yellow, black REMARK Check the identification mark and color before connecting.
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Remove and Install Operator CAB Assembly (CAB Specification)
10. Connect work equipment PPC hoses (10) to (17) (8 pieces). Band color of hose (10): Brown Band color of hose (11): Green Band color of hose (12): Blue Band color of hose (13): Yellow Band color of hose (14): Red Band color of hose (15): Brown Band color of hose (16): Black Band color of hose (17): White REMARK Check the identification mark and color before connecting. 11. Install rubber cover (9).
Cover 12. Install cover (8) with mounting bolts (8a).
13. Connect heater hoses (6) and air conditioner tubes (7).
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50 Disassembly and Assembly
14. Install cover (5) with mounting bolts (4) (2 pieces).
15. Close cover (1a), and lock it. 16. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
Refilling radiator with coolant 17. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant, and then check the coolant level again. 5 Radiator: 8.9 ℓ
Refilling with oil (hydraulic tank) 18. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. Filling of refrigerant (air conditioner gas: R134a) 19. Refill the air conditioner circuit with refrigerant (air conditioner gas: R134a) (machine with air conditioner). Filling quantity: 550±50 g
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50 Disassembly and Assembly
Remove and Install Floor Frame Assembly (Canopy Specification)
Remove and Install Floor Frame Assembly (Canopy Specification)
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off. REMARK • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove Floor Frame Assembly (Canopy Specification) Floor mat 1. Release the remaining pressure in the hydraulic tank. For details, see Testing and Adjusting, “How to Release Remained Pressure from Hydraulic Tank”. 2. Remove floor mat (1). 3.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
Canopy 4. Sling canopy (2), hold it, and remove right and left mounting bolts (3) (8 pieces). 5. Sling canopy (2), and remove it.
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6.
Remove mounting bolts (3), and remove cover (4).
7.
Remove rubber cover (5).
50 Disassembly and Assembly
Hose, connector 8. Disconnect work equipment PPC hoses (6) to (13) (8 pieces) Band color of hose (6): Brown Band color of hose (7): Green Band color of hose (8): Blue Band color of hose (9): Yellow Band color of hose (10): Red Band color of hose (11): Brown Band color of hose (12): Black Band color of hose (13): White 9.
Disconnect travel PPC hoses (14) to (17). Band color of hose (14): Yellow, brown Band color of hose (15): Yellow, orange Band color of hose (16): Yellow, green Band color of hose (17): Yellow, black
10. Disconnect swing PPC hoses (18) and (19). Band color of hose (18): Red, white Band color of hose (19): Blue, white 11. Disconnect the connector F51 (31) under the floor. (For the machines ready for installation of quick coupler)
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Remove and Install Floor Frame Assembly (Canopy Specification)
12. Disconnect connectors (20) to (23) at the front of the revolving frame, and ground cable (24). Connector (20): F03 Connector (21): F04 Connector (22): F05 Connector (23): F06 Ground cable (24): T01 13. Sling the floor frame assembly, and hold it. 14. Disconnect wire (25). 15. Loosen mounting bolts (26) (2 pieces) gradually and alternately, and separate damper (27).
Floor frame assembly 16. Remove pin (28). 17. Remove right and left mounting bolts (29), and remove pin (30).
18. Sling floor frame assembly (31), and remove it. REMARK • Check that all the wirings and pipings are disconnected before removing. • Pay attention to the balance when removing the assembly.
4 Floor frame assembly: 200 kg
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Remove and Install Floor Frame Assembly (Canopy Specification)
50 Disassembly and Assembly
Install Floor Frame Assembly (Canopy Specification) Floor frame assembly 1. Sling floor frame assembly (31), and install it. 4 Floor frame assembly (31): 200 kg
2.
Sling floor frame assembly (31), and hold it.
3.
Install pin (29), and install right and left mounting bolts (30). k Never insert your finger during position alignment.
4.
Install pin (28).
5.
Tighten mounting bolts (26) (2 pieces) gradually and alternately, and install damper (27).
6.
Connect wire (25).
Hose, connector 7. Connect the connector F51 (31) under the floor. (For the machines ready for installation of quick coupler)
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8.
Remove and Install Floor Frame Assembly (Canopy Specification)
Connect connectors (20) to (23) at the front of the revolving frame, and ground cable (24). Connector (20): F03 Connector (21): F04 Connector (22): F05 Connector (22): F06 Ground cable (24): T01
9.
Disconnect swing PPC hoses (18) and (19). Band color of hose (18): Red, white
Band color of hose (19): Blue, white 10. Connect travel PPC hoses (14) to (17). Band color of hose (14): Yellow, brown Band color of hose (15): Yellow, orange Band color of hose (16): Yellow, green Band color of hose (17): Yellow, black 11. Connect work equipment PPC hoses (6) to (13) (8 pieces). Band color of hose (6): Brown Band color of hose (7): Green Band color of hose (8): Blue Band color of hose (9): Yellow Band color of hose (10): Red Band color of hose (11): Brown Band color of hose (12): Black Band color of hose (13): White 12. Install rubber cover (5).
13. Install cover (4) with mounting bolts (3).
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50 Disassembly and Assembly
14. Sling canopy (2), hold it, and install right and left mounting bolts (3) (8 pieces). 15. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
16. Install floor mat (1).
Refilling with oil (hydraulic tank) 17. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again.
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50 Disassembly and Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Operator Cab Glass (Adhered Glass)
Q'ty
A
793-498-1210
Lifter (suction cup)
■
2
B
Commercially available
Seal cutter
■
1
C
Commercially available
Extra fine wire (piano wire, etc)
■
1
D
Commercially available
Pliers
■
1
E
Commercially available
Cutter knife
■
1
F
Commercially available
Scraper
■
1
G
Commercially available
Caulking gun
■
1
Part name
Sketch
Part No.
New/Redesign
Symbol
Necessity
Tools for Removal and Installation of Operator's Cab Glass (Bonded Window Glass)
Remarks
Removal and installation of operator's cab glass (adhered glass)
REMARK • Among 5 surfaces including the operator's cab ceiling, adhered window glasses are (1) to (9) shown in the figure (ceiling part (9) is a clear plate). • Always remove the front window assembly when front window glass (8) is to be replaced. (If the front window glass is installed to the operator's cab, it cannot be replaced.)
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50 Disassembly and Assembly
(1): R.H. sash window assembly
(6): Lower door window glass
(2); R.H. front lower triangle window glass
(7): Front window glass
(3): Rear window glass
(8): Clear plate
(4): L.H. rear window glass
(9): Center trim seal
(5): Upper door window glass
(10): Dam rubber
Remove Operator CAB Glass (Adhered Glass) Remove the window glass to be replaced according to the following procedure. Window glass 1.
Remove the adhesive between damaged window glass (12) and operator' cab (sheet metal) (13) by using seal cutter (B).
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Remove and Install Operator Cab Glass (Adhered Glass)
•
When seal cutter (B) is not provided 1) Make a hole in the adhesive and dam rubber by using a drill, and pass extra fine wire (C) through the hole. 2) Pinch the both ends of the extra fine wire passed through the hole with pliers (D), etc. (or wind it around to fix) and move it to the right and left alternately to cut the dam rubber. Since the wire may be broken by the frictional heat, apply lubricant to it. (The figure shows the operator's cab on a wheel loader.)
•
If the window glass is broken in small pieces, they may be removed with cutter knife (E) and a flat-head screwdriver. While widening the cut with a flat-head screwdriver, cut the adhesive and dam rubber with a cutter knife (E). (The figure shows the operator's cab on a wheel loader.)
2.
Remove the window glass.
Install Operator CAB Glass (Adhered Glass) Removal of adhesive and dam rubber 1. Remove the remaining adhesive and dam rubber from the sheet metal (adhesion surfaces) of the operator's cab by using a knife and scraper (F). NOTICE Remove the adhesive and dam rubber left on the sheet metal surface so that they do not become influential to the bonding effect of new adhesive. Be careful not to damage the coating surface by excessive scraping. (If the painted surfaces are damaged, adhesion will be lowered.) (The figure shows the operator's cab on a wheel loader.) Removal of oil, dust, dirt, etc. from adhesion surfaces 2. Remove oil, dust, and dirt from adhering surfaces on operator's cab (13) side and window glass (14) side by using white gasoline. NOTICE • Clean them thoroughly since insufficient cleaning induces adhesion failure. • Clean all the black parts on the back of the window glass. • After cleaning, leave them for 5 minutes or more for air drying.
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50 Disassembly and Assembly
Application of primer 3. Apply primer (15). NOTICE • Never apply the incorrect primer since the primer significantly affects the adhesion strength. If the incorrect primer is applied, completely wipe it off by the cleaning solvent. • Do not use the primer if it expires the date of 4 months from its production. • Make sure to use the primer within 2 hours after opening the cap. • Even when it is plugged again immediately after opening, be sure to use it within 24 hours after opening. (The primer must be disposed 24 hours after it has been opened.) 1) Stir both primers for paint surface and for glass thoroughly before use. REMARK If the primer has been refrigerated, leave it in a room temperature for a half day or more, and stir it. (If it is opened soon after having been refrigerated, condensation formed. Allow enough time for the primer to become the room temperature.) 2)
When reusing a brush (16) for applying the primer, clean it with white gasoline before use. REMARK • Check again that the brush is free from stains or fouling after cleaning. • 2 brushes must be prepared separately, one for the primer for paint surface and another for glass.
3)
Apply primer for paint surface evenly to the mounting part of the dam rubber (10) of operator's cab (13) and the place outside which adhesive is applied to. NOTICE • Limit the application of the primer to 2 times. (Application beyond 2 times causes degradation.) • After applying the primer, leave it for at least 5 minutes (maximum 8 hours) for air drying.
2 Primer for paint surface: SUNSTAR Paint Surface Primer 580 SUPER
REMARK Area to be coated: Entire area of dimension (a). Primer application dimension (a): 25 mm
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4)
Remove and Install Operator Cab Glass (Adhered Glass)
Apply the glass primer to the mounting surface of window glass (14). 2 Glass primer: SUNSTAR Glass Primer 580 SUPER
NOTICE • Limit the application of the primer to 2 times. (Application beyond 2 times causes degradation.) • Do not apply the primer to Approximately 5 mm of the border area between the black and transparent parts on the window glass. • After applying the primer, leave it for at least 5 minutes (maximum 8 hours) for air drying. REMARK Area to be coated: Apply the primer to the entire area of adhesion position (b) which is a periphery of whole area of window glass (14) relative to dam rubber (10) mounting position and operator's cab (13).
Dam rubber 4. Attach dam rubber (double-sided adhesive tape) (10) along the inner edge of window glass mounting surface. REMARK • The dam rubber is used to prevent the adhesive from flowing out to shape the appearance, align the adhesion thickness to stabilize the strength, and maintain the glass until the adhesive is hardened. • The dam rubber has 2 types of sectional dimensions. Use the dam rubber separately as described below. Dam rubber section size •
For general use: Thickness 5 mm x Width 7 mm
•
For front sash: Thickness 5 mm x Width 5 mm
• Do not remove the tape on glass-adhering side of the dam rubber until the window glass is installed. • When installing the dam rubber, do not touch the cleaned surface. • Take care that the dam rubber is not floated in each sticking corner. • When bonding the dam rubber around a window, be careful not to overlap the starting point with ending point, or be sure to provide the clearance of approximately 5 mm in the joining area. • Install the dam rubber according to each mounting portion by referring to the following figure.
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•
50 Disassembly and Assembly
Slide sash Install the dam rubber along the adhesive surface periphery of the sash frame.
•
Sheet metal part Install the dam rubber along the sheet metal edge.
•
Pipe material part Align the dam rubber with the position where the pipe round corner R ends, and install it.
•
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Front sash (glass adhesion side) Both sides of the frame
PC45MR-5, PC55MR-5
50 Disassembly and Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Bottom of the frame Dimension (c): 2.4 mm
•
Door (glass adhesion side) Install the dam rubber along the door outer edge. d: Inner e: Outer
Application of adhesive 5. Apply adhesive. NOTICE • Do not use the adhesive if it expires the date of 6 months from its production. • Adhesives must be stored at 25 °C or lower in a dark and cool place. • Do not heat the adhesive 30 °C or higher. • When reusing the adhesive, remove the hardened adhesive at the nozzle tip completely. 1) Break the aluminum dehumidification film (18) at the mouth of adhesive cartridge (17), and attach the nozzle.
2)
Cut the tip of adhesive nozzle (19) to dimensions (q) and (r) shown in the figure. Dimension (q): 10 mm Dimension (r): 15 mm
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Remove and Install Operator Cab Glass (Adhered Glass)
3)
50 Disassembly and Assembly
Set adhesive cartridge (17) on caulking gun (G). REMARK A better workability is obtainable from a power caulking gun.
4)
Remove the protective tape on the glass-bonding side of dam rubber.
5)
Apply adhesive (20) to the outside portion of dam rubber (10) on the operator's cab. 2 Adhesive: SUNSTAR Penguin Super 560
REMARK • Apply adhesive (20) to dam rubber (10) of operator's cab (13) according to the dimensions (s) and (t) indicated in the figure. Dimension (s): 10 mm Dimension (t): 15 mm • Thickness of applied adhesive (20) must be higher than that of dam rubber (10). • Height of applied adhesive must be even.
Slide sash assembly 6. Install the slide sash assembly. 1)
Clean the sash adhesion surface on the cab side and sash flange adhesion surface with cleaning solvent according to step 1 and step 2 as previously described.
2)
Apply the primer according to step 3 as previously described. REMARK Use the primer separately according to the sash type. •
When the sash has metallic luster 2 Primer: SUNSTAR sash primer GP-402
•
When the sash is painted black (no metallic luster) 2 Primer: SUNSTAR Paint Surface Primer 435-95
REMARK Do not apply the primer to the following water drain range.
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50 Disassembly and Assembly
3)
Remove and Install Operator Cab Glass (Adhered Glass)
Install the dam rubber according to step 4 as previously described. REMARK When installing dam rubber (10) to the sash bottom, avoid installing it to the range of dimension (v) in order to drain water from the periphery of the sash. Dimension (u): 150 mm Dimension (v): 50 mm
4)
Apply the adhesive according to step 5 as previously described. REMARK Do not apply the adhesive to the above water drain range.
5)
Install slide sash assembly (1) to operator's cab main unit (13). REMARK • Push the assembly securely so that there is no clearance around it. • If the adhesive protrudes, immediately wipe it off to prevent the protruding adhesive from hardening.
6)
After installing, fix the sash assembly with band, etc. for approximately 10 hours.
Window glass 7.
Install the window glass and clear plate. 1) Clean the glass adhesion surface on the cab side and adhesion surface on the glass side with cleaning solvent according to step 2 as previously described. 2) Apply the primer according to step 3 as previously described. 3)
Install the dam rubber according to step 4 as previously described.
4)
Apply the adhesive according to step 5 as previously described.
5)
Install the glass to the cab main unit. NOTICE • Since the window glass cannot be removed and installed again, install it with utmost caution. • Window glass bonding work must be finished within 5 minutes from application of adhesive.
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Remove and Install Operator Cab Glass (Adhered Glass)
6)
50 Disassembly and Assembly
After bonding the window glass, press down entire circumference of the window glass until it firmly sticks to dam rubber. REMARK • Especially, press the corners of the window glass firmly. • You can perform this work efficiently by pulling the window glass from the inside of the operator's cab by using lifter (A). (The figure shows the operator's cab of PC200-7.) REMARK Fix mating faces of the rear glass corners with caulking material (21) while the clearance is secured as described below. Dimension (W): 3 mm 2 Caulking material: GE TOSHIBA SILICONES TOSSEAL381
7) 8.
After adhesion, fix the sash assembly with band, etc. for approximately 10 hours.
Cure the adhered window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours of curing period. (Ambient temperature 20 °C/ Humidity 60 %) 2)
Before actual operation of the machine, leave it to cure for 14 hours after the stopper rubbers, styrene foam blocks, and rubber bands are removed, and for a total of 24 hours after the adhesive is applied. REMARK • Attach the center trim seal to the lower part of front window glass (8) after mounting it. • When caulking, shape the adhesive on the left and right end surfaces by using a rubber spatula, etc. • Caulk the entire periphery so that there is no clearance in area (x) between the glass and center trim seal to eliminate any gap.
2 Adhesive: Sika Japan Sikaflex 256HV
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50 Disassembly and Assembly
Remove and Install Front Window Assembly
Remove and Install Front Window Assembly
k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off. REMARK To replace the front window glass, the front window assembly must be removed from the operator's cab.
Remove Front Window Assembly Front window assembly 1. Lower the front window assembly. 2.
Remove wiper motor (1) and wiper blade (2). REMARK Also remove wiper curl code from the sash, and fix it in the operator's cab.
3.
Remove rollers (3) (right and left) on the lower side of the sash.
4.
Remove bolts (4), and disconnect pull-up link (5) so that it jumps up toward the ceiling.
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Remove and Install Front Window Assembly
5.
50 Disassembly and Assembly
Hold the handles, remove the latches, and remove front window assembly (6).
Install Front Window Assembly Front window assembly 1. Install front window assembly (6), hold the handles to lock the assembly with latches.
2.
Install pull-up link (5) jumping up toward the ceiling and sash with bolts (4).
3.
Install rollers (3) (right and left) on the lower side of the sash.
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4.
Remove and Install Front Window Assembly
Install wiper motor (1) and wiper blade (2). REMARK Install the wiper curl code.
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Remove and Install Air Conditioner Unit Assembly
50 Disassembly and Assembly
Remove and Install Air Conditioner Unit Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k If you drain the radiator coolant when it is still hot, you may be scalded. Accordingly, wait for the
coolant temperature to drop before draining.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. If it touches your skin, you may
suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working clothes with long sleeves while you are collecting or filling the refrigerant. NOTICE • Never release the refrigerant to the atmosphere. • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove Air Conditioner Unit Assembly Collecting refrigerant 1. Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. Quantity of refrigerant to be collected: 550±50 g 2.
Drain the coolant. 6 Radiator: 8.9 ℓ
Front window 3. Hold handles (2) on both sides of the front window in the operator's cab, and pull the window backward and unlock it while lowering lock lever (3).
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50 Disassembly and Assembly
4.
Remove and Install Air Conditioner Unit Assembly
Pull up the front window, and securely push up handles (2) until the lock engages at the position where the window does not move backward, and store front window (upper side) (1) in the ceiling.
Cover, connector 5. Remove floor mat (4). 6.
Remove screws (5) (2 pieces), and remove cover (6).
7.
Remove screws (7) (2 pieces), and remove cover (8).
8.
Remove clamp (9), and disconnect connector F18 (10).
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Remove and Install Air Conditioner Unit Assembly
9.
50 Disassembly and Assembly
Remove mounting bolt (11), and remove cover (12). REMARK Disconnect connector M01 (13) on the back side of cover (12).
10. Remove mounting bolts (14) (4 pieces), and pull out machine monitor assembly (15) in the direction of the arrow.
11. Remove mounting bolt (16), and remove cover (17).
12. Remove mounting bolts (19) (4 pieces) of right lever stand (18). 13. Move right lever stand (18) closer to the seat side.
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Remove and Install Air Conditioner Unit Assembly
14. Remove vents (20) (3 pieces).
15. Disconnect connectors (21) and (22). 16. Remove mounting bolts (23) (5 pieces), and remove cover (24).
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50 Disassembly and Assembly
Air conditioner unit assembly 17. Disconnect connectors (25) and (26). 18. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
19. Remove mounting bolts (27) (2 pieces), and remove cover (28).
20. Disconnect heater hoses (29) (2 pieces) and air conditioner tubes (30) (2 pieces). 21. Remove mounting bolts (31) (4 pieces), and remove air conditioner unit assembly (32).
Install Air Conditioner Unit Assembly Air conditioner unit assembly 1. Install air conditioner unit assembly (32) with mounting bolts (31) (4 pieces). 2. Connect heater hoses (29) (2 pieces) and air conditioner tubes (30) (2 pieces).
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50 Disassembly and Assembly
Remove and Install Air Conditioner Unit Assembly
3.
Install cover (28) with mounting bolts (27) (2 pieces).
4.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
Cover, connector 5. Connect connectors (25) and (26).
6.
Install cover (24) with mounting bolts (23) (5 pieces).
7.
Connect connectors (21) and (22).
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Remove and Install Air Conditioner Unit Assembly
8.
Install vents (20) (3 pieces).
9.
Install mounting bolts (19) (4 pieces) of right lever stand (18).
50 Disassembly and Assembly
10. Install cover (17) with mounting bolts (16) (2 pieces).
11. Insert machine monitor assembly (15) in the opposite direction to the arrow, and install the assembly with mounting bolts (14) (4 pieces).
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50 Disassembly and Assembly
Remove and Install Air Conditioner Unit Assembly
12. Install cover (12) with mounting bolts (11) (6 pieces). REMARK Connect connector M01 (13) on the back side of cover (12).
13. Connect connector F18 (10), and install clamp (9).
14. Install cover (8) with screws (7) (2 pieces).
15. Install cover (6) with screws (5) (2 pieces). 16. Install floor mat (4).
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50 Disassembly and Assembly
17. Pull down front window (upper side) (1) to the front.
18. Hold handles (2) on both sides of the front window in the operator's cab, and push the window forward and lock it while lowering lock lever (3). 19. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant, and then check the coolant level again. 5 Radiator: 8.9 ℓ
20. Refill the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. Filling quantity: 550±50 g
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50 Disassembly and Assembly
Remove and Install Operator Seat
Remove and Install Operator Seat
k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
k Removal and installation work must be done by 2 persons.
REMARK • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove Operator's Seat 1.
Pull lever (1) backward and move operator's seat (2) backward.
2.
Remove mounting bolts (3) (4 pieces). REMARK Move the operator's seat forward, and remove the mounting bolts (2 pieces) at the rear.
3.
Disconnect connector S19 (4) at the rear of the operator's seat.
4.
Remove operator's seat (2) while slowly lifting it by 2 persons. 4 Operator's seat assembly: 25 kg
Install Operator's Seat 1.
2.
Install operator's seat (2) by 2 persons.
4 Operator's seat assembly: 25 kg
Connect connector S19 (4) at the rear of the operator's seat.
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Remove and Install Operator Seat
3.
50 Disassembly and Assembly
Install mounting bolts (3) (4 pieces). REMARK Move the operator's seat forward, and install mounting bolts (2 pieces) at the rear.
4.
Pull lever (1) backward and move operator's seat (2) to the original position.
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50 Disassembly and Assembly
How to Remove and Install Seat Belt
How to Remove and Install Seat Belt
k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
How to Remove Seat Belt Operator's seat 1. Remove the operator's seat. For details, see “Remove and Install Operator Seat”. Seat belt 2. Remove mounting bolts (2) (1 piece each on right and left sides) of seat belt (1), and remove seat belt (1).
How to Install Seatbelt Seat belt 1. Install seat belt (1) with mounting bolts (2) (1 piece each on the right and left). 3 Mounting bolt (2): 19.6 to 29.4 Nm {2.0 to 3.0 kgfm}
Operator's seat 2. Install the operator's seat. For details, see “Remove and Install Operator Seat”.
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Remove and Install Engine Controller Assembly
50 Disassembly and Assembly
Electrical System Remove and Install Engine Controller Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off.
Remove Engine Controller Assembly 1.
Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
2.
Disconnect ground cable (2). REMARK • Blow off and remove the dust around the engine before starting the work. • Be sure to disconnect ground cable (2) on the revolving frame side.
3.
Disconnect connector CE2 (3) and connector CE1 (4). REMARK • Before starting the work, blow air again to ensure that there is no dust around the connector and (a) part to prevent any failure from occurring and to make removal and installation work easier. • Put the masking on the connector part and engine controller that have been removed.
4.
Remove mounting bolts (4), and remove engine controller assembly (5) together with bracket (6). REMARK Be careful that engine controller assembly (5) does not fall off during removal.
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50 Disassembly and Assembly
Remove and Install Engine Controller Assembly
5.
Remove bolt (7), and remove ground (8).
6.
Remove bolt (9), and remove engine controller assembly (5).
Install Engine Controller Assembly 1.
Install engine controller assembly (5) with bolt (9).
2.
Install ground (8) with bolt (7).
3.
Install engine controller assembly (5) together with bracket (6) with mounting bolts (4). REMARK Be careful that engine controller assembly (5) does not fall when it is being installed.
4.
Connect connector CE2 (3) and connector CE1 (4). REMARK Be careful not to allow dust to enter the clearance between engine controller and connector CE2 (3), or between engine controller and connector CE1 (4).
5.
Connect ground cable (2). REMARK Be sure to connect ground cable (2) on the revolving frame side.
6.
Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
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50 Disassembly and Assembly
Remove and Install Machine Controller Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off. REMARK Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down.
Remove Machine Controller Assembly KOMTRAX terminal assembly 1. Remove KOMTRAX terminal assembly. For details, see “Remove and Install KOMTRAX Terminal Assembly”. Cover 2. Remove mounting bolts (1) (4 pieces), and remove cover (2).
Connector 3. Disconnect connector CP01 (3) and connector CP02 (4). REMARK • Before starting the work, blow air again to ensure that there is no dust around the connector and (a) part to prevent any failure from occurring and to make removal and installation work easier. • Pull up levers (5) of connector CP01 (3) and connector CP02 (4) in the direction of the arrow while pressing hook (b). • Put the masking on the connector part and machine controller assembly (7) that have been removed.
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50 Disassembly and Assembly
Remove and Install Machine Controller Assembly
Machine controller assembly 4. Remove mounting bolts (6) (4 pieces), and remove machine controller assembly (7).
Install Machine Controller Assembly Machine controller assembly 1. Install machine controller assembly (7) with mounting bolts (6) (4 pieces). REMARK Be careful that machine controller assembly (7) does not fall when it is being installed.
Connector 2. Connect connector CP01 (3) and connector CP02 (4). REMARK • Be careful not to allow dust to enter the clearance between machine controller assembly (7) and connector CP01 (3), or between the assembly and connector CP02 (4). • Pull down levers (5) of connector CP01 (3) and connector CP02 (4) in the opposite direction to the arrow while pressing hook (b).
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50 Disassembly and Assembly
Cover 3. Install cover (2) with mounting bolts (1) (4 pieces).
KOMTRAX terminal assembly 4. Install KOMTRAX terminal assembly. For details, see “Remove and Install KOMTRAX Terminal Assembly”.
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50 Disassembly and Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Machine Monitor Assembly
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off. REMARK • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove Machine Monitor Assembly Machine monitor assembly 1. Remove floor mat (1). 2.
Remove screws (2) (2 pieces), and remove cover (3).
3.
Remove screws (4) (2 pieces), and remove cover (5).
4.
Remove clamp (6), and disconnect connector F18 (7).
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Remove and Install Machine Monitor Assembly
5.
Remove mounting bolts (8) (4 pieces), and pull out machine monitor assembly (9) in the direction of the arrow.
6.
Remove screws (10) (8 pieces), and remove covers (11) and (11a).
7.
Remove clamp (12), and disconnect connector F15 (13).
8.
Remove mounting bolts (14) (4 pieces), and remove machine monitor assembly (9).
50 Disassembly and Assembly
Install Machine Monitor Assembly Machine monitor assembly 1. Install machine monitor assembly (9) with mounting bolts (14) (4 pieces). 2. Connect connector F15 (13), and install clamp (12).
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50 Disassembly and Assembly
Remove and Install Machine Monitor Assembly
3.
Install covers (11) and (11a) with screws (10) (8 pieces).
4.
Insert machine monitor assembly (9) in the opposite direction to the arrow, and install the assembly with mounting bolts (8) (4 pieces).
5.
Connect connector F18 (7), and install clamp (6).
6.
Install cover (5) with screws (4) (2 pieces).
7.
Install cover (3) with screws (2) (2 pieces).
8.
Install floor mat (1).
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Remove and Install KOMTRAX Terminal Assembly
50 Disassembly and Assembly
Remove and Install KOMTRAX Terminal Assembly
k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operating lamp goes off. REMARK • Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them down. • When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.
Remove KOMTRAX Terminal Assembly Cover 1. Remove bolts (1), and remove cover (2). (Canopy specification)
(Operator's cab specification)
REMARK For the cab specification, disconnect connector (3) on the back side of cover (1).
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50 Disassembly and Assembly
Remove and Install KOMTRAX Terminal Assembly
KOMTRAX terminal assembly 2. Remove connector CK1 (4) and connector CK2 (5). 3.
Remove GPS antenna wiring (6).
4.
Remove communication antenna wiring (7).
5.
Remove mounting bolt (8), and remove KOMTRAX terminal assembly (9).
Install KOMTRAX Terminal Assembly KOMTRAX terminal assembly 1. Install KOMTRAX terminal assembly (9) with mounting bolt (8). 2. Install communication antenna wiring (7). 3.
Install GPS antenna wiring (6).
4.
Install connector CK1 (4) and connector CK2 (5).
Cover 5. Install cover (2), and install it with bolts (1). (Canopy specification)
(Operator's cab specification)
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Remove and Install KOMTRAX Terminal Assembly
50 Disassembly and Assembly
REMARK For the cab specification, connect connector (3) on the back side of cover (1).
50-212
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60 Maintenance Standard
PC45MR-5, PC55MR-5
60-1
Table of Contents
60 Maintenance Standard
Table of Contents Abbreviation List ............................................................................................................................................ 60-3 Engine and Cooling System ........................................................................................................................... 60-9 Maintenance Standard for PTO............................................................................................................... 60-9 Maintenance Standard for Cooling System ........................................................................................... 60-10 Power Train...................................................................................................................................................60-11 Maintenance Standard for Swing Circle .................................................................................................60-11 Maintenance Standard for Swing Machinery ......................................................................................... 60-12 Maintenance Standard for Sprocket ...................................................................................................... 60-14 Undercarriage and Frame ............................................................................................................................ 60-15 Maintenance Standard for Track Frame and Idler Cushion ................................................................... 60-15 Maintenance Standard for Idler ............................................................................................................. 60-16 Maintenance Standard for Track Roller ................................................................................................. 60-18 Maintenance Standard for Carrier Roller ............................................................................................... 60-19 Maintenance Standard for Track Shoes ................................................................................................ 60-20 Maintenance Standard for Triple Shoes ................................................................................................ 60-22 Maintenance Standard for Road Liner................................................................................................... 60-23 Maintenance Standard for Rubber Shoes ............................................................................................. 60-24 Hydraulic System ......................................................................................................................................... 60-25 Maintenance Standard for Hydraulic Tank............................................................................................. 60-25 Maintenance Standard for Main Pump .................................................................................................. 60-26 Maintenance Standard for Main Pump Servo Valve ....................................................................... 60-27 Maintenance Standard for PC-EPC Valve ............................................................................................. 60-28 Maintenance Standard for Swing Motor ................................................................................................ 60-29 Maintenance Standard for Travel Motor ................................................................................................ 60-31 Maintenance Standard for Control Valve ............................................................................................... 60-32 Maintenance Standard for Work Equipment and Swing PPC Valve....................................................... 60-44 Maintenance Standard for Blade PPC Valve ......................................................................................... 60-47 Maintenance Standard for Boom Swing PPC Valve .............................................................................. 60-49 Maintenance Standard for Travel PPC Valve ........................................................................................ 60-51 Maintenance Standard for Attachment PPC Valve ................................................................................ 60-54 Maintenance Standard for Center Swivel Joint...................................................................................... 60-56 Work Equipment .......................................................................................................................................... 60-57 Maintenance Standard for Work Equipment Linkage............................................................................. 60-57 Dimensions of Arm......................................................................................................................... 60-63 Dimensions of Bucket .................................................................................................................... 60-67 Maintenance Standard for Boom Cylinder............................................................................................. 60-68 Maintenance Standard for Arm Cylinder................................................................................................ 60-70 Maintenance Standard for Bucket Cylinder ........................................................................................... 60-72 Maintenance Standard for Blade Cylinder ............................................................................................. 60-74 Maintenance Standard for Boom Swing Cylinder .................................................................................. 60-75
60-2
PC45MR-5, PC55MR-5
60 Maintenance Standard
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
60-3
Abbreviation List
Abbreviation
Actual word spelled out
60 Maintenance Standard
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
60-4
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
60 Maintenance Standard
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
60-5
Abbreviation List
60 Maintenance Standard
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
60-6
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
60 Maintenance Standard
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
60-7
Abbreviation List
60 Maintenance Standard
Abbreviation S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
60-8
Actual word spelled out
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for PTO
Engine and Cooling System Maintenance Standard for PTO
PC45MR-5, PC55MR-5
60-9
Maintenance Standard for Cooling System
60 Maintenance Standard
Maintenance Standard for Cooling System
No.
Item
Judgment criteria
1
Tightening torque of clamp
5.9±0.49 Nm {0.6±0.05 kgfm}
2
Tightening torque of clamp
4.4±0.49 Nm {0.45±0.05 kgfm}
60-10
Remedy Retighten
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Swing Circle
Power Train Maintenance Standard for Swing Circle
Unit: mm No. 1
Item Clearance in bearing
PC45MR-5, PC55MR-5
Judgment criteria
Remedy
Standard clearance
Allowable clearance
0.20 to 0.70
1.7
Replace
60-11
Maintenance Standard for Swing Machinery
60 Maintenance Standard
Maintenance Standard for Swing Machinery
Unit: mm No.
Item
1
Backlash between swing motor shaft and No. 1 sun gear
2
Judgment criteria
Remedy
Standard clearance
Allowable clearance
0.04 to 0.11
-
Backlash between No. 1 sun gear and No. 1 planetary gear
0.12 to 0.28
0.6
3
Backlash between No. 1 planetary gear and swing machinery case
0.14 to 0.38
0.6
4
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.10 to 0.26
-
5
Backlash between No. 2 sun gear and No. 2 planetary gear
0.12 to 0.28
0.6
6
Backlash between No. 2 planetary gear and swing machinery case
0.14 to 0.38
0.6
7
Backlash between No. 2 planetary carrier and swing pinion
0.016 to 0.097
-
8
Backlash between swing pinion and swing circle
0.14 to 0.73
2.0
60-12
Replace
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Swing Machinery
Unit: mm No.
Item
9
Wear of oil seal sliding surface of swing pinion
Judgment criteria Standard dimension
PC45MR-5, PC55MR-5
55
Tolerance 0 -0.074
Remedy Repair limit 54.8
Repair hard chrome plating or replace
60-13
Maintenance Standard for Sprocket
60 Maintenance Standard
Maintenance Standard for Sprocket
Unit: mm No .
Item
1
Wear of tooth bottom diameter
Judgment criteria Standard dimension 380.37
2
Wear of tooth tip diameter
423.99
3
Wear of tooth tip width
26
4
Wear of tooth bottom width
33
5
Thickness of tooth bottom
75.185
60-14
Tolerance +1.0 -2.0 0 -3.0 +0.5 -1.0 +0.492 -1.075
Remedy Repair limit 368 412 24
Repair by build-up welding or replace
30 69
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Track Frame and Idler Cushion
Undercarriage and Frame Maintenance Standard for Track Frame and Idler Cushion
Unit: mm No.
1
2
3
Item
Lateral width of idler guide portion
Repair limit
120
124
118
114
Track frame
161
165
Idler support
160
155
Tightening torque of bolt
Recoil spring
Build-up welding for rebuilding
Repair by buildup welding or replace
98 to 123 Nm {10.0 to 12.5 kgfm}
Retighten
Free height
Installed height
Load at installed height
Free height
Load at installed height
Rubber shoe
302
202.2
42.4 kN {4326 kgf}
294
39.0 kN {3980 kgf}
Steel shoe
302
238.2
27.0 kN {2748 kgf}
294
24.0 kN {2446 kgf}
Tightening torque of bolt
PC45MR-5, PC55MR-5
Remedy
Standard dimension Track Vertical width of frame idler guard Idler support
4
5
Judgment criteria
157 to 196 Nm {16.0 to 20.0 kgfm}
Replace
Retighten
60-15
Maintenance Standard for Idler
60 Maintenance Standard
Maintenance Standard for Idler
60-16
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Idler
Unit: mm No.
Item
1
Outside diameter of protrusion
Standard dimension
Repair limit
377
-
2
Outside diameter of tread
335
327
3
Depth of tread
21
25
4
Thickness of tread
10.3
6.3
5
Width of tread
18
22
6
Overall width
75
-
7
Clearance between shaft and bushing
Judgment criteria
Standard dimension 35
8
Clearance between shaft and support
9
Axial play of idler
PC45MR-5, PC55MR-5
35
Tolerance Shaft
Hole
-0.025
+0.142
-0.064
+0.080
-0.025
+0.060
-0.064
0
Remedy
Repair by build-up welding or replace
Standard clearance
Allowable clearance
0.105 to 0.206
Replace
0.025 to 0.124
-
Standard clearance
Allowable clearance
0.25
-
60-17
Maintenance Standard for Track Roller
60 Maintenance Standard
Maintenance Standard for Track Roller
Unit: mm No.
Item
1
Outside diameter of flange
2
Judgment criteria
Remedy
Standard dimension
Repair limit
123
-
Outside diameter of tread
95
87
3
Thickness of tread
26.5
22.5
4
Width of flange
41
35
5
Width of tread
34.5
-
6
Overall width
110
-
7
Clearance between shaft and bushing
Standard dimension 35
8
Clearance between shaft and collar
9
Axial play of roller
60-18
35
Tolerance Shaft
Hole
-0.025
+0.142
-0.050
+0.080
-0.025
+0.039
-0.050
0
Repair by build-up welding or replace
Standard clearance
Allowable clearance
0.105 to 0.192
Replace
0.025 to 0.089
-
Standard clearance
Allowable clearance
0.17 to 0.40
-
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Carrier Roller
Maintenance Standard for Carrier Roller
Unit: mm No.
Item
1
Outside diameter of tread
2 3
4
Judgment criteria Standard dimension
Repair limit
70
65
Thickness of tread
9
6.5
Width of tread
100
-
Clearance between shaft and support
Standard dimension 30
5
Remedy
Interference between shaft and seal
Standard dimension 30
PC45MR-5, PC55MR-5
Tolerance
Repair by build-up welding or replace
Standard clearance
Allowable clearance -
Shaft
Hole
-0.050
+0.210
-0.100
0
0.050 to 0.310
Shaft
Hole
Standard interference
Allowable interference
0
-0.200
-0.052
-0.400
0.148 to 0.400
-
Tolerance
Replace
60-19
Maintenance Standard for Track Shoes
60 Maintenance Standard
Maintenance Standard for Track Shoes (machine with steel shoe)
REMARK *1: Triple grouser shoe *2: Road liner
60-20
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Track Shoes
Unit: mm No .
Item
Judgment criteria
Remedy
Standard dimension
Turning limit
Repair limit
135
138
143
Outside diameter of bushing
35
32
29
3
Thickness of bushing
6.05
4.55
3.05
4
Height of link
5
Thickness of link (bushing press-fit part)
1
Link pitch
2
Standard dimension
Repair limit
65
59
18.075
12.075 Tolerance
6
Interference between bushing and link
Standard dimension
Shaft
Hole
Shaft: 35
+0.030
+0.040
Hole: 34.85
0
0
Repair by build-up welding or replace
Standard interference
Allowable interference
0.110 to 0.180
-
0.148 to 0.260
-
7
Interference between regular pin and link
Shaft: 22.5
+0.060
+0.052
Hole: 22.3
0
0
8
Interference between master pin and link
Shaft: 22.5
-0.030
+0.052
Hole: 22.3
-0.070
0
0.078 to 0.170
-
Hole
Standard clearance
Allowable clearance
±0.2
0.140 to 0.600
-
±0.2
0.400 to 1.000
-
Tolerance 9
Clearance between regular pin and bushing
Clearance between 10 master pin and bushing Clearance in link con11 tact surface
Standard dimension
Shaft
Shaft: 22.5
+0.060
Hole: 22.9
0
Shaft: 22.5
-0.200
Hole: 22.9
-0.400
Standard clearance (one side)
Standard clearance (both sides)
Allowable clearance (one side)
0.7 to 1.4
1.4 to 2.8
-
12
Protrusion of regular pin
1.5
13
Protrusion of master pin
3.25
14
Tightening torque of shoe bolt
137±19.6 Nm {14±2 kgfm}
PC45MR-5, PC55MR-5
Usable up to turning limit by turning bushing and pin. Replace bushing and pin, or repair link assembly after the repair limit has been reached.
Replace
Adjust
Retighten
60-21
Maintenance Standard for Triple Shoes
60 Maintenance Standard
Maintenance Standard for Triple Shoes
Unit: mm No.
Item
1
Overall height of grouser
2
Overall height of shoe
3
Thickness of plate
4 5
Length of grouser base
6 7 8
60-22
Judgment criteria
Remedy
Standard dimension
Repair limit
14
10
20
16 6 17 13
Repair by build-up welding or replace
13 Length of grouser end
9 17
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Road Liner
Maintenance Standard for Road Liner
Unit: mm No. 1
Item Height
PC45MR-5, PC55MR-5
Judgment criteria
Remedy
Standard dimension
Repair limit
35
17
Replace
60-23
Maintenance Standard for Rubber Shoes
60 Maintenance Standard
Maintenance Standard for Rubber Shoes
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimension
Repair limit
25
5
Wear of roller guide
43
60
3
Wear of meshing portion of sprocket
2
-3
4
Wear of contacting portion of roller
25
19
1
Wear of lug height
2
60-24
Replace
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Hydraulic Tank
Hydraulic System Maintenance Standard for Hydraulic Tank
No.
Item
Judgment criteria
1
Tightening torque of plug
58.8 to 78.5 Nm {6.0 to 8.0 kgfm}
2
Tightening torque of nut
19.6 to 24.5 Nm {2.0 to 2.5 kgfm}
3
Tightening torque of elbow
16.7 to 26.5 Nm {1.7 to 2.7 kgfm}
PC45MR-5, PC55MR-5
Remedy
Retighten
60-25
Maintenance Standard for Main Pump
60 Maintenance Standard
Maintenance Standard for Main Pump
No.
Item
Judgment criteria
1
Tightening torque of bolt
11.8 to 14.7 Nm {1.2 to 1.5 kgfm}
2
Tightening torque of bolt
5.9 to 9.8 Nm {0.6 to 1.0 kgfm}
3
Tightening torque of breather
7.8 to 9.8 Nm {0.8 to 1.0 kgfm}
4
Tightening torque of bolt
27 to 34 Nm {2.8 to 3.5 kgfm}
5
Tightening torque of plug
68.6 to 83.4 Nm {7.0 to 8.5 kgfm}
60-26
Remedy
Retighten
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Main Pump
Maintenance Standard for Main Pump Servo Valve
No.
Item
Judgment criteria
1
Tightening torque of plug
27.4 to 34.3 Nm {2.8 to 3.5 kgfm}
2
Tightening torque of bolt
9.8 to 12.7 Nm {1 to 1.3 kgfm}
PC45MR-5, PC55MR-5
Remedy Retighten
60-27
Maintenance Standard for PC-EPC Valve
60 Maintenance Standard
Maintenance Standard for PC-EPC Valve
No.
Item
Criteria
1
Tightening torque of bolt
0.1 to 0.3 Nm {0.01 to 0.03 kgfm}
2
Tightening torque of bolt
9.8 to 12.7 Nm {1.0 to 1.3 kgfm}
60-28
Remedy Retighten
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Swing Motor
Maintenance Standard for Swing Motor
PC45MR-5, PC55MR-5
60-29
Maintenance Standard for Swing Motor
60 Maintenance Standard
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimension
1
60-30
Check valve spring
Repair limit
Free height x outside diameter
Installed height
Load at installed height
Free height
13.0 x 6.5
7
3.33 N {0.34 kgf}
-
Replace (ReLoad at inplace the spring stalled if damaged or height deformed as well) 2.66 N {0.27 kgf}
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Travel Motor
Maintenance Standard for Travel Motor
PC45MR-5, PC55MR-5
60-31
Maintenance Standard for Control Valve
60 Maintenance Standard
Maintenance Standard for Control Valve 9-Spool Valve
60-32
PC45MR-5, PC55MR-5
60 Maintenance Standard
No.
Item
Maintenance Standard for Control Valve
Judgment criteria
1
Tightening torque of bolt
7.85 to 9.8 Nm {0.8 to 1 kgfm}
2
Tightening torque of bolt
29.4 to 34.3 Nm {3 to 3.5 kgfm}
3
Tightening torque of bolt
9.8 to 12.7 Nm {1 to 1.3 kgfm}
PC45MR-5, PC55MR-5
Remedy
Retighten
60-33
Maintenance Standard for Control Valve
60-34
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Control Valve
Unit: mm No.
Item
Judgment criteria
1
Tightening torque of suction safety valve and suction valve plug
39.2 to 49 Nm {4 to 5 kgfm}
Tightening torque of main relief valve
49 to 58.8 Nm {5 to 6 kgfm}
2
Remedy
Retighten
Standard dimension
3
Suction valve spring
Repair limit
Free height x outside diameter
Installed height
Load at installed height
Free height
Load at installed height
39.2 x 4.45
33.5
5.1 N {0.52 kgf}
-
4.10 N {0.42 kgf}
4
Spool return spring
29 x 17.5
28.5
22.6 N {2.3 kgf}
-
18.1 N {1.84 kgf}
5
Spool return spring
27.2 x 16.6
26.7
30.2 N {3.08 kgf}
-
24.2 N {2.46 kgf}
6
Spool return spring
29 x 17.5
28.5
21.6 N {2.2 kgf}
-
17.3 N {1.76 kgf}
PC45MR-5, PC55MR-5
Replace (Replace spring if damaged or deformed as well)
60-35
Maintenance Standard for Control Valve
60-36
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Control Valve
Unit: mm No.
Item
Judgment criteria
Remedy
1
Tightening torque of plug
117.6 to 161.8 Nm {12 to 16.5 kgfm}
2
Tightening torque of plug
147 to 186.2 Nm {15 to 19 kgfm}
3
Tightening torque of plug
147 to 186.2 Nm {15 to 19 kgfm}
4
Tightening torque of plug
147 to 186.2 Nm {15 to 19 kgfm}
5
Tightening torque of relief valve
39.2 to 49 Nm {4 to 5 kgfm}
6
Tightening torque of plug
19.6 to 27.5 Nm {2 to 2.8 kgfm} Standard dimension
7
Back pressure check valve spring
Retighten
Repair limit
Free height x outside diameter
Installed height
Load at installed height
Free height
Load at installed height
29.06 x 13.3
21
10.9 N {1.11 kgf}
-
8.73 N {0.89 kgf}
8
Merge-divider valve spring
41.07 x 13.8
22
44.3 N {4.52 kgf}
-
35.5 N {3.62 kgf}
9
Cooler check valve spring
27.2 x 13.2
21
78.8 N {8.04 kgf}
-
63.0 N {6.43 kgf}
10
Pressure compensation valve spring
15.4 x 6
8
7.45 N {0.76 kgf}
-
5.96 N {0.61 kgf}
PC45MR-5, PC55MR-5
Replace (Replace spring if damaged or deformed as well)
60-37
Maintenance Standard for Control Valve
60-38
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Control Valve
Unit: mm No.
Item
Judgment criteria
Remedy
1
Tightening torque of plug
65.7 to 82.3 Nm {6.7 to 8.4 kgfm}
2
Tightening torque of relief valve
49 to 58.8 Nm {5 to 6 kgfm}
3
Tightening torque of plug
19.6 to 24.5 Nm {2 to 2.5 kgfm}
4
Tightening torque of unload valve
19.6 to 24.5 Nm {2 to 2.5 kgfm}
5
Tightening torque of relief valve
14.7 to 19.6 Nm {1.5 to 2.0 kgfm}
6
Tightening torque of plug
14.7 to 19.6 Nm {1.5 to 2.0 kgfm} Standard dimension
7
Check valve spring
Retighten
Repair limit
Free height x outside diameter
Installed height
Load at installed height
Free height
Load at installed height
28.5 x 5.4
25
1.96 N {0.2 kgf}
-
1.57 N {0.16 kgf}
8
Check valve spring (boom)
16.4 x 7.5
9.8
1.96 N {0.2 kgf}
-
1.57 N {0.16 kgf}
9
Check valve spring (boom)
21.9 x 5
15.8
1.96 N {0.2 kgf}
-
1.57 N {0.16 kgf}
10
Logic valve spring
10.98 x 6.2
9.5
5.49 N {0.56 kgf}
-
4.41 N {0.45 kgf}
PC45MR-5, PC55MR-5
Replace (Replace spring if damaged or deformed as well)
60-39
Maintenance Standard for Control Valve
60-40
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Control Valve
Unit: mm No.
Item
Judgment criteria
Remedy
1
Tightening torque of plug
15.7 to 20.6 Nm {1.6 to 2.1 kgfm}
2
Tightening torque of plug
24.5 to 34.3 Nm {2.5 to 3.5 kgfm}
3
Tightening torque of plug
98 to 122.5 Nm {10 to 12.5 kgfm}
4
Tightening torque of safety valve
137 to 157 Nm {14 to 16 kgfm}
5
Tightening torque of valve
24.5 to 34.3 Nm {2.5 to 3.5 kgfm}
6
Tightening torque of plug
19.6 to 24.5 Nm {2 to 2.5 kgfm}
7
Tightening torque of plug
117.6 to 161.8 Nm {12 to 16.5 kgfm} Standard dimension
8
Check valve spring
Retighten
Repair limit
Free height x outside diameter
Installed height
Load at installed height
Free height
21.9 x 5
15.8
1.96 N {0.2 kgf}
-
Replace (ReLoad at instal- place spring if led height damaged or deformed as well) 1.57 N {0.16 kgf}
10-Spool Valve REMARK For the standard values other than section AC-AC of 10-spool valve, see the 9-spool valve.
PC45MR-5, PC55MR-5
60-41
Maintenance Standard for Control Valve
60-42
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Control Valve
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimension
1
2
Spool return spring
Pressure compensation valve spring
PC45MR-5, PC55MR-5
Repair limit
Installed height
Load at installed height
29 x 17.5
28.5
22.6 N {2.3 kgf}
-
18.1 N {1.84 kgf}
15.4 x 6
8
7.45 N {0.76 kgf}
-
5.96 N {0.61 kgf}
Free height x outside diameter
Free height
Load at instal- Replace (Reled height place spring if damaged or deformed as well)
60-43
Maintenance Standard for Work Equipment and Swing PPC Valve
60 Maintenance Standard
Maintenance Standard for Work Equipment and Swing PPC Valve
60-44
PC45MR-5, PC55MR-5
60 Maintenance Standard
PC45MR-5, PC55MR-5
Maintenance Standard for Work Equipment and Swing PPC Valve
60-45
Maintenance Standard for Work Equipment and Swing PPC Valve
60 Maintenance Standard
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimension
1
Centering spring (for ports P3, P4)
Free height x outside diameter
Installed height
38.71 x 15.5
34
2
Centering spring (for ports P1, P2)
42.48 x 15.5
34
3
Metering spring
26.53 x 8.15
24.9
60-46
Load at installed height 9.81 N {1.00 kgf} 17.7 N {1.8 kgf} 16.7 N {1.70 kgf}
Repair limit Free height
-
Load at installed height 7.85 N {0.80 kgf} 14.1 N
Replace (Replace the spring if damaged or deformed as well)
{1.44 kgf} 13.3 N {1.36 kgf}
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Blade PPC Valve
Maintenance Standard for Blade PPC Valve
PC45MR-5, PC55MR-5
60-47
Maintenance Standard for Blade PPC Valve
60 Maintenance Standard
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimensions
1
2
60-48
Centering spring
Metering spring
Free height x outside diameter
Installed height
33.88 x 15.3
28.4
22.73 x 8.1
22
Repair limit
Load at installed Free height height 125 N {12.7 kgf} 16.7 N {1.7 kgf}
-
Load at installed Replace (Reheight place spring if damaged or 100 N deformed as {10.2 kgf} well) 13.3 N {1.36 kgf}
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Boom Swing PPC Valve
Maintenance Standard for Boom Swing PPC Valve
PC45MR-5, PC55MR-5
60-49
Maintenance Standard for Boom Swing PPC Valve
60 Maintenance Standard
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimension
1
2
60-50
Centering spring
Metering spring
Repair limit
Free height x Outside diameter
Installed height
Load at installed height
Free height
33.88 x 15.3
28.4
125 N {12.7 kgf}
-
22.73 x 8.1
22
16.7 N {1.7 kgf}
-
Load at inReplace (Restalled place the height spring if dam100 N aged or de{10.2 kgf} formed as well) 13.3 N {1.36 kgf}
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Travel PPC Valve
Maintenance Standard for Travel PPC Valve
PC45MR-5, PC55MR-5
60-51
Maintenance Standard for Travel PPC Valve
60-52
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Travel PPC Valve
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimensions
1
2
Centering spring
Metering spring
PC45MR-5, PC55MR-5
Free height x outside diameter
Installed height
52.06 x 15.5
31.9
24.04 x 8.16
23.05
Load at installed height 135 N {13.8 kgf} 16.7 N {1.7 kgf}
Repair limit Free height
-
Load at installed Replace the height spring if dam108 N aged or de{11.0kgf} formed 13.3 N {1.36 kgf}
60-53
Maintenance Standard for Attachment PPC Valve
60 Maintenance Standard
Maintenance Standard for Attachment PPC Valve
60-54
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Attachment PPC Valve
Unit: mm No.
Item
Judgment criteria
Remedy
Standard dimension
1
2
Centering spring
Metering spring
PC45MR-5, PC55MR-5
Free height x Outside diameter
Installed height
33.88 x 15.3
28.4
22.73 x 8.1
22
Repair limit
Load at installed height 125 N {12.7 kgf} 16.7 N {1.7 kgf}
Free height
-
Load at installed Replace (Reheight place the spring if dam100 N aged or de{10.2 kgf} formed as well) 13.3 N {1.36 kgf}
60-55
Maintenance Standard for Center Swivel Joint
60 Maintenance Standard
Maintenance Standard for Center Swivel Joint
Unit: mm No.
Item
1
Clearance between rotor and shaft
60-56
Judgment criteria
Remedy
Standard dimension
Standard clearance
Allowable clearance
60
0.055 to 0.085
0.090
Replace
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Work Equipment Linkage
Work Equipment Maintenance Standard for Work Equipment Linkage
PC45MR-5, PC55MR-5
60-57
Maintenance Standard for Work Equipment Linkage
60-58
60 Maintenance Standard
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Work Equipment Linkage
PC45MR-5, PC55MR-5 Unit: mm Judgment criteria No .
1
2
3
Item
Standard dimension
Clearance between mounting pin and bushing of revolving frame and boom swing bracket
Revolving frame side Boom swing bracket side
120
Clearance between mounting pin and bushing of boom swing bracket and boom
Boom swing bracket side
50
120
Boom side
50
5
Inside diameter of bushing insertion portion on boom swing bracket side in joint of boom swing bracket and boom
60
6
Clearance between mounting pin and bushing of boom swing bracket and boom cylinder
50
7
Inside diameter of bushing insertion portion on boom side in joint of boom swing bracket and boom
60
8
Clearance between mounting pin and bushing of boom and arm
50
9
Inside diameter of hole to insert bushing on arm side at joint of boom and arm
60
4
PC45MR-5, PC55MR-5
Tolerance Shaft
Hole
-0.036
+0.095
-0.090
+0.034
-0.036
+0.054
-0.090
0
-0.025
+0.039
-0.064
0
-0.025
+0.086
-0.064
+0.035
-
+0.030 0
-0.025
+0.039
-0.087
0
-
-0.030 -0.060
-0.025
+0.089
-0.064
+0.035
-
-0.079 -0.119
Standard clearance
Allowable clearance
Remedy
0.070 to 0.185 1.0
Replace pin and bushing
1.0
Replace pin and bushing
-
-
Machining after build-up welding
0.025 to 0.126
1.0
Replace pin and bushing
-
-
Machining after build-up welding
0.060 to 0.153
1.0
Replace pin and bushing
-
-
Machining after build-up welding
0.036 to 0.144
0.025 to 0.103
0.060 to 0.150
60-59
Maintenance Standard for Work Equipment Linkage
60 Maintenance Standard
Unit: mm Judgment criteria No .
Item
Standard dimension
Clearance between mounting pin and 10 bushing of arm and bucket
45
Inside diameter of hole to insert bush11 ing on arm side at joint of arm and bucket
55
Clearance between mounting pin and 12 bushing of arm and link
45
Inside diameter of hole to insert bush13 ing on arm side at joint of arm and link
55
Clearance between mounting pin and 14 bushing of link and bucket
45
Clearance between 15 mounting pin and bushing of links
45
Clearance between mounting pin and 16 bushing of track frame and blade
35
60-60
Tolerance Shaft
Hole
-0.170
-0.012
-0.230
-0.060
-
-0.030 -0.060
-0.170
-0.012
-0.230
-0.065
-
-0.030 -0.060
-0.170
-0.012
-0.230
-0.065
-0.170
-0.012
-0.230
-0.065
-0.025
+0.142
-0.087
+0.080
Remedy
Standard clearance
Allowable clearance
0.100 to 0.218
1.0
Replace pin and bushing
-
-
Machining after build-up welding
0.105 to 0.218
1.0
Replace pin and bushing
-
-
Machining after build-up welding
0.105 to 0.218
1.0
Replace pin and bushing
0.105 to 0.218
1.0
Replace pin and bushing
0.105 to 0.229
1.0
Replace pin and bushing
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Work Equipment Linkage
Unit: mm Judgment criteria No.
Width of boss
Item
Standard dimension 276 17
Joint of revolving frame and boom swing bracket
Width of hinge
Tolerance 0 -0.5
Standard dimension 278.5
Tolerance +0.5 0
L17: Insert the shims of 0.8 mm thickness (2) and 0.5 mm thickness (2) +0.5
18
+1.5
19
0 60 60 Joint of boom -0.5 swing cylinder and swing bracket L19: R19: Insert the shim of 1.0 mm thickness (1) 60
20
21
0 -0.5
64.5
0
+0.5
+2.0 0
Joint of boom and boom cylinder L22: -
0 -0.5
60.5
+1.5 +0.5
+1.0 0
0.5 to 2.0
Adjust the clearance to Max. 1.0 mm by using shims.
4.5 to 7.0
23
Joint of boom and arm L23: -
-0.3 -1.0
163
+0.5 0
Adjust the clearance to Max. 1.0 mm by using shims.
0.5 to 2.0
Adjust the clearance to Max. 0.5 mm by using shims.
0.3 to 1.5
Adjust the clearance to Max. 0.5 mm by using shims.
0.5 to 2.0
Adjust the clearance to Max. 1.0 mm by using shims.
0.5 to 2.0
Adjust the clearance to Max. 1.0 mm by using shims.
R23: Insert the shim of 0.5 mm thickness (1) 55 24
Joint of boom and arm cylinder L24: -
0 -0.5
55.5
+1.0 0
R24: Insert the shim of 1.0 mm thickness (1) 55
25
0
55.5
-0.5 Joint of arm cylinder and arm L25: Insert the shim of 1.0 mm thickness (2) R25: -
PC45MR-5, PC55MR-5
+1.0 0
Adjust the clearance to Max. 0.5 mm by using shims.
0.5 to 2.0
R22: Insert the shim of 1.0 mm thickness (1) 163
Adjust the clearance to Max. 0.5 mm by using shims.
Adjust the clearance to Max. 0.5 mm by using shims.
R20: Insert the shims of 1.0 mm thickness (4) and 0.5 mm thickness (1)
0 60 60 Joint of boom -0.5 swing bracket and L21: Insert the shim of 1.0 mm thickness (1) boom cylinder R21: -
Remedy
0.5 to 1.5
L20: -
60 22
2.5 to 3.5
U17: Insert the shim of 0.8 mm thickness (1)
-0.5 250 250 Joint of boom -1.0 swing bracket and L18: Insert the shim of 0.5 mm thickness (1) boom R18: -
Joint of revolving frame and boom swing cylinder
Standard clearance
60-61
Maintenance Standard for Work Equipment Linkage
60 Maintenance Standard
Unit: mm Judgment criteria No.
Width of boss
Item
Standard dimension 55 26
Joint of arm and bucket cylinder
Width of hinge
Tolerance 0 -0.5
Standard dimension 55.5
Tolerance +1.0 0
Standard clearance
Remedy
0.5 to 2.0
Adjust the clearance to Max. 1.0 mm by using shims.
L26: Insert the shim of 1.0 mm thickness (2) R26: 168
27
Joint of arm and bucket
+0.7 +0.2
170
±1
0.3 to 2.8 -
L27: R27: 168
28
Joint of link and bucket
+0.7 +0.2
170
±1
0.3 to 2.8 -
L28: R28: -
29
Joint of links
-
-
-
-
Adjust the clearance to Max. 0.5 to 1.5 mm by using shims
-
-
Adjust the clearance to Max. 0.5 to 1.5 mm by using shims
1.5 to 3.5
Adjust the clearance to Max. 1.0 mm by using shims.
1.0 to 2.5
Adjust the clearance to Max. 1.0 mm by using shims.
2.0 to 3.5
Adjust the clearance to Max. 1.0 mm by using shims.
L29: Insert the shim of 1.0 mm thickness (1) R29: 168
30
Joint of arm and link
+0.7 +0.2
-
L30: Insert the shim of 1.0 mm thickness (1) R30: 48
31
Joint of track frame and blade
±0.5
50
+1.0 0
L31: R31: Insert the shim of 1.0 mm thickness (4)
32
Joint of track frame and blade cylinder
65
0 -0.5
66
+1.0 0
L32: Insert the shim of 1.0 mm thickness (4) R32: 65
33
Joint of blade and blade cylinder L33: -
0 -0.5
67
+1.0 0
R33: Insert the shim of 1.0 mm thickness (3)
The number in ( ) after each shim thickness indicates the quantity of shim to be provided.
60-62
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Work Equipment Linkage
Dimensions of Arm PC45MR-5
Unit: mm PC45MR-5 No.
Measuring point
Standard dimension
-
45
1 Arm side
55.5
Cylinder head side
55
2
PC45MR-5, PC55MR-5
Tolerance Shaft
Hole
-0.025
+0.1
-0.064
0 +1 0 0 -0.5
60-63
Maintenance Standard for Work Equipment Linkage
60 Maintenance Standard
Unit: mm PC45MR-5 No.
Measuring point
Standard dimension
-
50
3 Boom side
163
Arm side
163
Tolerance Shaft
Hole
-0.025
+0.039
-0.064
0 +0.5 0
4
-0.3 -1.0
5
-
100.2
±1
6
-
216.7
±1
7
-
312.1
±1
8
-
1695
±3
9
-
1368.8
10
-
193.3
±1
11
-
12.6
±1
12
-
330
±0.5
13
-
303
±0.5
14
-
230.3
±0.5
15
-
870
-
16
-
45
17
Link side
168
Bucket side
170
18
19
20
60-64
-
45
+1 -3
-0.170
-0.050
-0.230
-0.089 +0.7 +0.2 ±1
-0.170
-0.050
-0.230
-0.089 +0.7
Arm side
168
Bucket side
170
±1
Minimum
900
±1.5
Maximum
1480
-
+0.2
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Work Equipment Linkage
PC55MR-5
Unit: mm PC55MR-5 No.
Measuring point
Standard dimension
-
45
1 Arm side
55.5
Cylinder head side
55
2
PC45MR-5, PC55MR-5
Tolerance Shaft
Hole
-0.025
+0.1
-0.064
0 +1 0 0 -0.5
60-65
Maintenance Standard for Work Equipment Linkage
60 Maintenance Standard
Unit: mm PC55MR-5 No.
Measuring point
Standard dimension
-
50
3 Boom side
163
Arm side
163
Tolerance Shaft
Hole
-0.025
+0.039
-0.064
0 +0.5 0
4
-0.3 -1.0
5
-
117
±1
6
-
199.4
±0.5
7
-
375.3
±0.5
8
-
1640
±3
9
-
1364.5
±1
10
-
193.3
±1
11
-
12.8
±1
12
-
330
±0.5
13
-
303
±0.5
14
-
230.3
±0.5
15
-
871
-
16
-
45
17
Link side
168
Bucket side
170
18
19
20
60-66
-
45
-0.170
-0.050
-0.230
-0.089 +0.7 +0.2 ±1
-0.170
-0.050
-0.230
-0.089 +0.7
Arm side
168
Bucket side
170
±1
Minimum
900
±1.5
Maximum
1480
-
+0.2
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Work Equipment Linkage
Dimensions of Bucket
Unit: mm No.
PC45MR-5, PC55MR-5 Measuring point
Standard dimension
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
-
15
-
45
PC45MR-5, PC55MR-5
-0.050 -0.089
60-67
Maintenance Standard for Boom Cylinder
60 Maintenance Standard
Maintenance Standard for Boom Cylinder
PC45MR-5, PC55MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 55
Tolerance Shaft
Hole
-0.030
+0.163
-0.076
+0.006
-0.147
+0.142
-0.209
+0.080
-0.025
+0.142
-0.087
+0.080
Remedy
Standard clearance
Allowable clearance
0.036 to 0.239
0.539
0.227 to 0.351
1.0
0.105 to 0.229
1.0
2
Clearance between piston rod support shaft and bushing
50
3
Clearance between cylinder bottom support shaft and bushing
50
4
Tightening torque of cylinder head
1.13±0.11 kNm {115±11.5 kgfm}
5
Tightening torque of cylinder piston nut
2.65±0.27 kNm {270±27 kgfm} (Width across flats: 65 mm)
Replace the cylinder head
Replace pin and bushing
Retighten
PC45MR-5 (for North America Market (Applicable Serial Numbers: 34639 and up)), PC55MR-5 (for North America Market (Applicable Serial Numbers: 23282 and up)) Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 55
2
Clearance between piston rod support shaft and bushing
50
3
Clearance between cylinder bottom support shaft and bushing
50
60-68
Tolerance Shaft
Hole
-0.030
+0.163
-0.076
+0.006
-0.147
+0.142
-0.209
+0.080
-0.025
+0.142
-0.087
+0.080
Remedy
Standard clearance
Allowable clearance
0.036 to 0.239
0.539
0.227 to 0.351
1.0
0.105 to 0.229
1.0
Replace the cylinder head
Replace pin and bushing
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Boom Cylinder
Unit: mm No.
Item
Judgment criteria
4
Tightening torque of cylinder head
735±73.5 Nm {75±7.5 kgfm}
5
Tightening torque of cylinder piston nut
2.65±0.27 kNm {270±27 kgfm} (Width across flats: 65 mm)
PC45MR-5, PC55MR-5
Remedy
Retighten
60-69
Maintenance Standard for Arm Cylinder
60 Maintenance Standard
Maintenance Standard for Arm Cylinder REMARK The figure shows PC45MR-5.
PC45MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 50
Tolerance Shaft
Hole
-0.025
+0.164
-0.064
+0.007
-0.025
+0.142
-0.064
+0.080
-0.025
+0.142
-0.087
+0.080
Remedy
Standard clearance
Allowable clearance
0.032 to 0.228
0.528
0.105 to 0.206
1.0
0.105 to 0.229
1.0
Clearance between piston rod support shaft and bushing
45
3
Clearance between cylinder bottom support shaft and bushing
45
4
Tightening torque of cylinder head
785±78.5 Nm {80±8.0 kgfm}
5
Tightening torque of cylinder piston nut
2.16±0.22 kNm {220±22 kgfm} (Width across flats: 60 )
2
Replace the bushing
Replace pin and bushing
Retighten
PC55MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 55
2
3
60-70
Clearance between piston rod support shaft and bushing
45
Clearance between cylinder bottom support shaft and bushing
45
Tolerance Shaft
Hole
-0.030
+0.163
-0.076
+0.006
-0.025
+0.142
-0.064
+0.080
-0.025
+0.142
-0.087
+0.080
Remedy
Standard clearance
Allowable clearance
0.036 to 0.239
0.539
0.105 to 0.206
1.0
0.105 to 0.229
1.0
Replace the bushing
Replace pin and bushing
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Arm Cylinder
Unit: mm No.
Item
Judgment criteria
4
Tightening torque of cylinder head
961±96.1 Nm {98±9.8 kgfm}
5
Tightening torque of cylinder piston nut
2.30±0.23 kNm {235±23.5 kgfm} (Width across flats: 65 )
PC45MR-5, PC55MR-5
Remedy
Retighten
60-71
Maintenance Standard for Bucket Cylinder
60 Maintenance Standard
Maintenance Standard for Bucket Cylinder REMARK The figure shows PC45MR-5.
PC45MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 45
Tolerance Shaft
Hole
-0.025
+0.152
-0.087
+0.007
-0.170
+0.142
-0.230
+0.080
-0.025
+0.142
-0.064
+0.080
Remedy
Standard clearance
Allowable clearance
0.032 to 0.239
0.539
0.250 to 0.372
1.0
0.105 to 0.206
1.0
Clearance between piston rod support shaft and bushing
45
3
Clearance between cylinder bottom support shaft and bushing
45
4
Tightening torque of cylinder head
785±78.5 Nm {80±8.0 kgfm}
5
Tightening torque of cylinder piston nut
1.08±0.11 kNm {110±11.0 kgfm} (Width across flats: 50 mm)
2
Replace the bushing
Replace pin and bushing
Retighten
PC55MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 50
2
3
60-72
Clearance between piston rod support shaft and bushing
45
Clearance between cylinder bottom support shaft and bushing
45
Tolerance Shaft
Hole
-0.025
+0.164
-0.064
+0.007
-0.170
+0.142
-0.230
+0.080
-0.025
+0.142
-0.064
+0.080
Remedy
Standard clearance
Allowable clearance
0.032 to 0.228
0.528
0.250 to 0.372
1.0
0.105 to 0.206
1.0
Replace the bushing
Replace pin and bushing
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Bucket Cylinder
Unit: mm No.
Item
Judgment criteria
4
Tightening torque of cylinder head
863±86.5 Nm {88±8.8 kgfm}
5
Tightening torque of cylinder piston nut
1.08±0.11 kNm {110±11.0 kgfm} (Width across flats: 50 mm)
PC45MR-5, PC55MR-5
Remedy
Retighten
60-73
Maintenance Standard for Blade Cylinder
60 Maintenance Standard
Maintenance Standard for Blade Cylinder PC45MR-5, PC55MR-5
Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 50
Tolerance Shaft
Hole
-0.025
+0.164
-0.064
+0.007
-0.030
+0.174
-0.076
+0.100
-0.030
+0.174
-0.076
+0.100
Remedy
Standard clearance
Allowable clearance
0.032 to 0.228
0.528
0.130 to 0.250
1.0
0.130 to 0.250
1.0
2
Clearance between piston rod support shaft and bushing
55
3
Clearance between cylinder bottom support shaft and bushing
55
4
Tightening torque of cylinder head
931±93.1 Nm {95±9.5 kgfm}
5
Tightening torque of cylinder piston nut
1.42±0.14 kNm {145±14.5 kgfm} (Width across flats: 55 mm)
60-74
Replace the bushing
Replace pin and bushing
Retighten
PC45MR-5, PC55MR-5
60 Maintenance Standard
Maintenance Standard for Boom Swing Cylinder
Maintenance Standard for Boom Swing Cylinder REMARK The figure shows PC45MR-5.
PC45MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 50
Tolerance Shaft
Hole
-0.025
+0.164
-0.087
+0.007
-0.025
+0.142
-0.064
+0.080
-0.025
+0.142
-0.064
+0.080
Remedy
Standard clearance
Allowable clearance
0.032 to 0.251
0.551
0.105 to 0.206
1.0
0.105 to 0.206
1.0
Clearance between piston rod support shaft and bushing
50
3
Clearance between cylinder bottom support shaft and bushing
50
4
Tightening torque of cylinder head
676.2±67.6 Nm {69±6.9 kgfm}
5
Tightening torque of cylinder piston nut
1.42±0.14 kNm {145±14.5 kgfm} (Width across flats: 55 )
2
Replace the bushing
Replace pin and bushing
Retighten
PC55MR-5 Unit: mm No.
1
Item
Clearance between piston rod and bushing
Judgment criteria Standard dimension 50
2
3
Clearance between piston rod support shaft and bushing
50
Clearance between cylinder bottom support shaft and bushing
50
PC45MR-5, PC55MR-5
Tolerance Shaft
Hole
-0.025
+0.164
-0.087
+0.007
-0.025
+0.142
-0.064
+0.080
-0.025
+0.142
-0.064
+0.080
Remedy
Standard clearance
Allowable clearance
0.032 to 0.251
0.551
0.105 to 0.206
1.0
0.105 to 0.206
1.0
Replace the bushing
Replace pin and bushing
60-75
Maintenance Standard for Boom Swing Cylinder
60 Maintenance Standard
Unit: mm No.
Item
Judgment criteria
4
Tightening torque of cylinder head
735±73.5 Nm {75±7.5 kgfm}
5
Tightening torque of cylinder piston nut
1.42±0.14 kNm {145±14.5 kgfm} (Width across flats: 55 )
60-76
Remedy
Retighten
PC45MR-5, PC55MR-5
80 Appendix
PC45MR-5, PC55MR-5
80-1
Table of Contents
80 Appendix
Table of Contents Abbreviation List ............................................................................................................................................ 80-3 Precautions Before Work ............................................................................................................................... 80-9 Air Conditioner System ................................................................................................................................ 80-10 Precautions for Refrigerant ................................................................................................................... 80-10 Air Conditioner Component ....................................................................................................................80-11 Specifications of Air Conditioner ........................................................................................................... 80-12 Structure and Function of Refrigeration Cycle ....................................................................................... 80-13 Outline of Refrigeration Cycle ............................................................................................................... 80-14 Component Parts of Air Conditioner System ................................................................................................ 80-16 Air Conditioner Unit ............................................................................................................................... 80-16 Configuration Diagram of Air Conditioner Unit................................................................................ 80-16 Compressor .......................................................................................................................................... 80-18 Structure of Compressor ................................................................................................................ 80-18 Specifications of Compressor......................................................................................................... 80-18 Function of Compressor ................................................................................................................. 80-18 Condenser ............................................................................................................................................ 80-20 Structure of Condenser .................................................................................................................. 80-20 Specifications of Condenser........................................................................................................... 80-20 Function of Condenser................................................................................................................... 80-20 Receiver Drier ....................................................................................................................................... 80-22 Structure of Receiver Dryer............................................................................................................ 80-22 Specifications of Receiver Dryer .................................................................................................... 80-22 Function of Receiver Dryer............................................................................................................. 80-22 Information Shown in Troubleshooting Table................................................................................................ 80-23 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) .................................... 80-24 A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) ........................ 80-27 A-3 Troubleshooting for Temperature Control Function ................................................................................ 80-31 A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System) .................... 80-34 A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems) ............... 80-38 A-6 Troubleshooting for Hot Water Circuit System ....................................................................................... 80-39 A-7 Unusual Noise is Heard from Air Conditioner Related Parts .................................................................. 80-40 A-8 Water Leaks from Air Conditioner Related Parts.................................................................................... 80-41 A-9 Troubleshooting for Fresh/Recirc Air Changeover ................................................................................. 80-42 Precautions for Disconnection and Connection of Air Conditioner Piping ..................................................... 80-43 Handle Compressor Oil................................................................................................................................ 80-45
80-2
PC45MR-5, PC55MR-5
80 Appendix
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
80-3
Abbreviation List
Abbreviation
Actual word spelled out
80 Appendix
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
80-4
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
80 Appendix
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
80-5
Abbreviation List
80 Appendix
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
80-6
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
80 Appendix
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
80-7
Abbreviation List
80 Appendix
Abbreviation S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
80-8
Actual word spelled out
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
80 Appendix
Precautions Before Work
Precautions Before Work Before you start, read the “Safety Notice for Operation” of the “Index and Foreword” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a dan-
ger that you can get caught in the machine. •
Do not wear oversized clothes or accessories.
•
Be sure to tie the long hair that comes out from the helmet.
•
Decide on the work procedure.
•
Obey the specified signal during the work.
k When you work together with more than one person, do the preparation that follows.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange an
observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not to
let the machine move. •
Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
•
Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts, there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.
PC45MR-5, PC55MR-5
80-9
Precautions for Refrigerant
80 Appendix
Air Conditioner System Precautions for Refrigerant
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses. NOTICE • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).
80-10
PC45MR-5, PC55MR-5
80 Appendix
Air Conditioner Component
Air Conditioner Component
A: Vents
C. Fresh air inlet
B: Recirculation air inlet 1: Air conditioner unit
6: Hot water piping
2: Hot water return piping
7: Air conditioner compressor
3: Refrigerant piping
8: FRESH/RECIRC air changeover lever
4: Receiver drier
9: Duct
5: Condenser
10: Air conditioner controlo panel Ass'y
PC45MR-5, PC55MR-5
80-11
Specifications of Air Conditioner
80 Appendix
Specifications of Air Conditioner Refrigerant: R134a Quantity of refrigerant to be refilled: 650±50 g
80-12
PC45MR-5, PC55MR-5
80 Appendix
Structure and Function of Refrigeration Cycle
Structure and Function of Refrigeration Cycle Cycle
Compression
Condensation
Expansion
Evaporation
(component)
(compressor)
(condenser)
(Expansion valve)
(Evaporator)
Location of component
Engine compartment Front part of radiator
Inside of operator's cab
Inside of operator's cab
(built in air conditioner unit)
(built in air conditioner unit)
Function
Circulates refrigerant and increases temperature and pressure of gas refrigerant so that it is liquefied easily in condenser.
Condenses refrigerant Decreases temperature to discharge heat ab- and pressure of refrigersorbed in evaporator. ant with throttle and convert it partially into gas so (condensation of rethat it is evaporated easifrigerant) ly, and controls flow rate.
Absorbs heat from air around evaporator to cool that air by evaporating refrigerant. (Evaporation of refrigerant)
(Throttling of refrigerant)
(Compression of refrigerant) State of refrigerant
Gas → gas
Gas → liquid
Liquid → liquid, gas
Liquid, gas → gas
Adiabatic compression
Isobaric change
Adiabatic expansion
Isobaric change
PC45MR-5, PC55MR-5
80-13
Outline of Refrigeration Cycle
80 Appendix
Outline of Refrigeration Cycle Regeneration cycles are composed of the following 4 processes. Refrigerant circulates around the system repeatedly changing its phase from liquid → gas → liquid.
Compression (Compressor) •
The compressor sucks in the refrigerant which is evaporated in the evaporator and compresses the refrigerant until it can be easily liquefied at the ambient temperature.
•
The gas refrigerant sucked in the compressor cylinder is compressed to make the pressure higher. When the refrigerant is cooled at the ambient temperature, it can be easily liquefied.
Condensation (Condenser) •
The condenser cools and liquefies the high-temperature and high-pressure gas refrigerant sent from the compressor at the ambient temperature.
•
The heat radiation from the condenser to the atmosphere is called the condensation heat.
•
The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the compressor.
•
The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool section to increase the cooling efficiency
•
In the condensation process, gas refrigerant and liquid refrigerant are mixed.
•
The temperature (condensation temperature) and the pressure (condensation pressure) at which the gaseous refrigerant is liquefied are proportional to each other. Reference: The pressure varies depending on the condensation temperature of the refrigerant.
Expansion (Expansion Valve) •
The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily evaporated by the throttle action (*1).
•
The action of reducing the pressure of the liquid refrigerant to a state where it easily evaporates before sending it to the evaporator is called expansion.
•
The expansion valve used for expansion reduces the refrigerant pressure and controls the refrigerant flow simultaneously.
•
The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
•
The expansion valve controls the refrigerant supply rate to prevent too much or too little supply of the liquid refrigerant.
(*1) Throttle action •
If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the flow is generated. When the liquid passes through a narrow section, cross-sectional area suddenly increases. The liquid expansion causes pressure and temperature to decrease.
•
No heat is transferred between inside and outside by the throttle action.
Evaporation (Evaporator) •
The evaporator evaporates the liquid refrigerant (superheated vapor).
•
The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins (air in the cab).
•
The cooled air is sent into the cab by the blower fan, and it decreases the temperature in the cab.
•
In the evaporator, the misty refrigerant sent from the expansion valve and the evaporated gas refrigerant are mixed together.
•
The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrigerant is evaporated are proportional to each other.
80-14
PC45MR-5, PC55MR-5
80 Appendix
•
Outline of Refrigeration Cycle
To evaporate the liquid refrigerant at lower temperature, the pressure in the evaporator must be kept as low as possible. For this purpose, the compressor sucks in the evaporated refrigerant.
Relation Between Refrigerant and Cooling Trouble •
While repeating the refrigeration cycle, the refrigerant circulates in the refrigeration circuit and dissipates the heat in the cab to the outside of the cab.
•
If there is an insufficient quantity of refrigerant, all of it is evaporated while it is passing through the evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
•
If there is excessive refrigerant, not all of it is evaporated and part of it will be sucked into the compressor in liquid form, which causes the compressor to compress the liquid and may damage the components.
•
If water is contained in the refrigerant circuit, it freezes in the small hole of the expansion valve and blocks the refrigerant flow to cause a cooling trouble.
PC45MR-5, PC55MR-5
80-15
Air Conditioner Unit
80 Appendix
Component Parts of Air Conditioner System Air Conditioner Unit Configuration Diagram of Air Conditioner Unit
80-16
PC45MR-5, PC55MR-5
80 Appendix
Air Conditioner Unit
1: Expansion valve
4: Heater core
2: Evaporator temperature sensor
5: FRESH/RECIRC air changeover door
3: Evaporator
6: Blower motor
REMARK “Door” may be expressed as “damper”.
PC45MR-5, PC55MR-5
80-17
Compressor
80 Appendix
Compressor Structure of Compressor General View
A: Refrigerant inlet (from air conditioner unit)
B: Refrigerant outlet (to condenser)
1: Pulley
2: Magnetic clutch
Specifications of Compressor Number of cylinders - Cylinder bore x Stroke: : 7-25.4×28.1 mm Delivery: : 99.8 cc/rev Allowable max. speed: 6500 min-1{6500 rpm} Compressor oil: SANDEN: ND-OIL8 (for R134a) Compressor oil quantity: : 100 cc
Function of Compressor •
The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into a misty refrigerant at high pressure and high temperature so that it is easily regenerated (liquefied) at the normal temperature.
80-18
PC45MR-5, PC55MR-5
80 Appendix
Compressor
•
The air conditioner controller operates magnetic clutch (2) inside the compressor, according to the evaporator temperature and refrigerant pressure.
•
When magnetic clutch (2) is engaged, the compressor shaft is turned together with pulley (1) by the engine power, and the compressor is driven.
PC45MR-5, PC55MR-5
80-19
Condenser
80 Appendix
Condenser Structure of Condenser General View
A: Refrigerant inlet (from compressor)
B: Refrigerant outlet (to receiver drier)
Specifications of Condenser Fin pitch: 9.5 mm Height x Width x thickness: 370.5×283.4×25 mm Max. operating pressure: 3.53 MPa {36 kgf/cm2}
Function of Condenser Condenser cools and liquefies the high-pressure high-temperature misty refrigerant sent from the compressor.
80-20
PC45MR-5, PC55MR-5
80 Appendix
Condenser
NOTICE • If the cooling fins are crushed or clogged with dirt, etc., the heat exchanged efficiency decreases and the refrigerant cannot be completely liquefied. • If the heat exchange efficiency decreases, the circuit pressure in the refrigerant cycle increases resulting in unnecessary load on the engine and poor cooling effect. Be careful not to crush the fins in handling and daily maintenance of the condenser.
PC45MR-5, PC55MR-5
80-21
Receiver Drier
80 Appendix
Receiver Drier Structure of Receiver Dryer General View and Sectional View
A: Refrigerant inlet (from condenser)
B: Refrigerant outlet (to air conditioner unit)
Specifications of Receiver Dryer Effective capacity: : 240 cc Weight of desiccating agent: : 100 g
Function of Receiver Dryer •
The receiver drier temporarily stores the high pressure and high temperature liquid refrigerant from the condenser so that it can be supplied to the evaporator corresponding to the need of cooling.
•
Even if bubbles are mixed in the refrigerant, depending on the heat radiation condition of the condenser, the refrigerant can be liquefied perfectly by sending out the accumulated refrigerant from the bottom to the evaporator.
•
The built-in filter and desiccating agent remove foreign material in the circulation circuit and moisture contained in the refrigerant.
80-22
PC45MR-5, PC55MR-5
80 Appendix
Information Shown in Troubleshooting Table
Information Shown in Troubleshooting Table The following types of information are described in the troubleshooting table and related circuit diagram. Fully understand the description and perform troubleshooting. Failure Related information No.
Cause
1
Probable causes for trouble
2
Problem on machine Information related to the occurred failure and its troubleshooting Procedure, measuring location, criteria, and remarks [Details] •
Procedure
•
Measuring point “Between A and B” denotes measuring values such as voltage and resistance, etc. between A and B.
•
Criteria to judge probable causes (standard value), remarks
[Precautions for troubleshooting] (1) Connector number description sequence and tester lead handling 3
Defective ---
For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as shown below unless otherwise specified. •
Connect the positive (+) lead to pin or wiring harness indicated in the front.
•
Connect the negative (-) lead to a pin or wiring harness indicated in the rear.
(2) Example of troubleshooting by check of multiple items •
Normal in 1 but abnormal in 2 At that time, the description is made as “Defective ---” as shown on the left.
[Failures in wiring harness] •
Open circuit Connection of connector is defective or wiring harness is broken.
•
Ground fault A wiring harness not to be connected to the GND (ground) circuit comes to contact with the GND (ground) circuit or chassis.
•
Hot short circuit A wiring harness not to be connected to the power supply circuit comes to contact with the power supply circuit.
•
Short circuit An independent wire in the wiring harness abnormally comes into contact with one of other wires. (Defective insulation in connector, etc.)
Circuit Diagram This is the excerpted circuit diagram related to troubleshooting •
Connector numbers and pin numbers are shown.
•
Size of wire is shown. When there is a number in front of color, it shows size. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown •
When there are two colors Example) WY: Yellow line on white background
•
When there is a number in front of color, it shows size.
•
NC: Normally closed (Normally ON)
•
[1] and [2] are numbers of unlabeled connectors.
•
Arrow (←→): Roughly indicates their mounting place on the machine.
PC45MR-5, PC55MR-5
80-23
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
80 Appendix
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) Failure
Related
Air conditioner does not operate. •
Check in advance that fuse is not blown out and continuity of wiring harness between each connectors is normal.
•
When air flow selector switch (blower switch) is turned on (position 1, 2, or 3), air conditioner switch is ON.
•
If air does not come out, perform check for “Troubleshooting of blower motor system (air does not come out or air flow is abnormal)” first.
information
No.
1
Cause
Defective air conditioner switch
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector [13].
REMARK There are 2 each of G and L/R, check by referring to circuit diagram. Resistance
Air conditioner switch: ON Between [13] (switch side) Air conditioner switch: G and L/R OFF
Max. 1 Ω Min. 1 MΩ
Be ready with starting switch in OFF position, then perform troubleshooting with 2
3
4
80-24
Open circuit in wiring har- starting switch stayed in OFF position. ness Check the continuity between each connectors by reResistance ferring to circuit diagram. Ground fault in wiring harness (contact with ground circuit) Defective control amplifier
Max. 1 Ω
Be ready with starting switch in OFF position, then perform troubleshooting with starting switch stayed in OFF position. Resistance
Check the insulation between each connector and ground (excluding ground circuit) by referring to circuit diagram.
Min. 1 MΩ
If no failure is found by preceding checks, controller amplifier is defective.
PC45MR-5, PC55MR-5
80 Appendix
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
Circuit Diagram Related to Air Conditioner Power Supply
PC45MR-5, PC55MR-5
80-25
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
80-26
80 Appendix
PC45MR-5, PC55MR-5
A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
80 Appendix
A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) Failure
No air comes out or air flow cannot be selected.
Related information
Check in advance that fuse is not blown out and continuity of wiring harness between each connectors is normal.
No.
Cause
1
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector [13].
Defective air flow selector switch (blower switch) Resistance
2
Between [13] (switch side) Airflow selector switch: B and L/R OFF
Min. 1 MΩ
Between [13] (switch side) Airflow selector switch: B and L/Y OFF
Min. 1 MΩ
Between [13] (switch side) Airflow selector switch: B and L/B OFF
Min. 1 MΩ
Between [13] (switch side) Airflow selector switch: B and L/W OFF
Min. 1 MΩ
Between [13] (switch side) Airflow selector switch: 1 B and L/R
Max. 1 Ω
Between [13] (switch side) Airflow selector switch: 1 B and L/W
Max. 1 Ω
Between terminals other than above
Airflow selector switch: 1
Min. 1 MΩ
Between [13] (switch side) Airflow selector switch: 2 B and L/R
Max. 1 Ω
Between [13] (switch side) Airflow selector switch: 2 B and L/Y
Max. 1 Ω
Between terminals other than above
Airflow selector switch: 2
Min. 1 MΩ
Between [13] (switch side) Airflow selector switch: 3 B and L/R
Max. 1 Ω
Between [13] (switch side) Airflow selector switch: 3 B and L/B
Max. 1 Ω
Between terminals other than above
Min. 1 MΩ
Airflow selector switch: 3
1.
Turn the starting switch to OFF position.
2.
Disconnect connector [12].
Defective resistor
Between [12] (air conditioner unit side) L/W and L/Y
Approx. 1.8 Ω
Between [12] (air conditioner unit side) L/B and L/Y
Approx. 0.7 Ω
Resistance
3
Defective blower motor
PC45MR-5, PC55MR-5
1.
Turn the starting switch to OFF position.
2.
Disconnect connector [12].
Continuity
Between [12] (air conditioner unit side) W/G and L/B
Continuity
Resistance
Between [12] (air conditioner unit side) W/G and ground
Min. 1 MΩ
80-27
A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
No.
Cause
80 Appendix
Procedure, measuring location, criteria and remarks
4
Be ready with starting switch in OFF position, then perform troubleshooting with Open circuit in wiring har- starting switch stayed in OFF position. ness (wire breakage or Check the continuity between each connectors by redefective connector) Max. 1 Ω Resistance ferring to circuit diagram.
5
Ground fault in wiring harness (contact with ground circuit)
6
80-28
Defective control amplifier
Be ready with starting switch in OFF position, then perform troubleshooting with starting switch stayed in OFF position. Resistance
Check the insulation between each connector and ground (excluding ground circuit) by referring to circuit diagram.
Min. 1 MΩ
If no failure is found by preceding checks, controller amplifier is defective.
PC45MR-5, PC55MR-5
80 Appendix
A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
Circuit Diagram of Blower Motor System
PC45MR-5, PC55MR-5
80-29
A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
80-30
80 Appendix
PC45MR-5, PC55MR-5
80 Appendix
A-3 Troubleshooting for Temperature Control Function
A-3 Troubleshooting for Temperature Control Function Failure Related information No.
Vent temperature cannot be adjusted. •
Check in advance that hot water flows to inlet side of hot water cut valve.
•
Check in advance that fuse is not blown out and continuity of wiring harness between each connectors is normal.
Cause
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector [3].
Between [3] (switch side) Y/W and Y/B 1
Defective temperature control switch Resistance
Between [3] (switch side) Y/W and G/W
2
Defective hot water cut valve assembly
Dial control: COOL-MAX → MEDIUM position
Approx. 2.3 kΩ → 1 Ω and below
Dial control: MEDIUM position → HOT-MAX
Max. 1 Ω
Dial control: COOL-MAX → MEDIUM position
Approx. 2.3 kΩ
Dial control: MEDIUM position → HOT-MAX
Approx. 2.3 kΩ → 1 Ω and below
1.
Turn the starting switch to OFF position.
2.
Remove the cover of air conditioner unit, and start the engine.
3.
Turn on the blower switch (any of 1, 2, and 3)
4.
Operate the temperature control switch.
If the rod does not move in accordance with the operation of temperature control switch, hot water cut valve assembly is defective.
3
4
5
Be ready with starting switch in OFF position, then perform troubleshooting with Open circuit in wiring har- starting switch stayed in OFF position. ness
Short circuit in wiring harness
Defective control amplifier
PC45MR-5, PC55MR-5
Resistance
Check the continuity between each connectors by referring to circuit diagram.
Max. 1 Ω
Be ready with starting switch in OFF position, then perform troubleshooting with starting switch stayed in OFF position. Resistance
Check the insulation between each connector and ground (excluding ground circuit) by referring to circuit diagram.
Min. 1 MΩ
If no failure is found by preceding checks, controller amplifier is defective.
80-31
A-3 Troubleshooting for Temperature Control Function
80 Appendix
Circuit Diagram Related to Temperature Control Function
80-32
PC45MR-5, PC55MR-5
80 Appendix
PC45MR-5, PC55MR-5
A-3 Troubleshooting for Temperature Control Function
80-33
A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System)
80 Appendix
A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System) Failure Related information No.
1
Air is not cooled or temperature cannot be adjusted. •
When outside air temperature is 2 °C and below, this phenomenon is not abnormal.
•
Check in advance that fuse is not blown out and continuity of wiring harness between each connectors is normal.
Cause
Defective air conditioner switch
Procedure, measuring location, criteria and remarks 1.
Turn the starting switch to OFF position.
2.
Disconnect connector [13].
REMARK There are 2 each of G and L/R, check by referring to circuit diagram. Resistance
2
Defective compressor clutch
1.
Turn the starting switch to OFF position.
2.
Disconnect connector M13.
Voltage 1. 3
Air conditioner switch: ON Between [13] (switch side) Air conditioner switch: G and L/R OFF
Between M13 (male) and ground
Turn the starting switch to OFF position.
Defective refrigerant (du- 2. Disconnect connector [5]. al) pressure switch Resistance [5] Between terminals (switch side terminal) 1.
Turn the starting switch to OFF position.
2.
Disconnect connector [4].
Defective compressor relay Resistance
5
Max. 1 Ω
Approx. 320 Ω
80-34
Between [4] (relay side) R and R/G
When power supply voltage is added between [4] R/B and Br
Max. 1 Ω
Between [4] (relay side) R and R/G
When power supply voltage is not added between [4] R/B and Br
Min. 1 MΩ
1.
Turn the starting switch to OFF position.
2.
Disconnect connector [12].
Defective evaporator temperature sensor Resistance
6
Min. 1 MΩ
10 to 15 V
Between [4] (relay side) R/B and Br 4
Max. 1 Ω
Between [12] (air conditioner unit side) B/W and B/R
0 °C
Approx. 7.2 kΩ
25 °C
Approx. 2.2 kΩ
Be ready with starting switch in OFF position, then perform troubleshooting with Open circuit in wiring har- starting switch stayed in OFF position. ness
Resistance
Check the continuity between each connectors by referring to circuit diagram.
Max. 1 Ω
PC45MR-5, PC55MR-5
A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System)
80 Appendix
No.
7
8
Cause Ground fault in wiring harness (contact with ground circuit) Defective control amplifier
PC45MR-5, PC55MR-5
Procedure, measuring location, criteria and remarks Be ready with starting switch in OFF position, then perform troubleshooting with starting switch stayed in OFF position. Resistance
Check the insulation between each connector and ground (excluding ground circuit) by referring to circuit diagram.
Min. 1 MΩ
If no failure is found by preceding checks, controller amplifier is defective.
80-35
A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System)
80 Appendix
Circuit Diagram Related to Compressor and Refrigerant System
80-36
PC45MR-5, PC55MR-5
80 Appendix
PC45MR-5, PC55MR-5
A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System)
80-37
A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems)
80 Appendix
A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems) Failure
Air is not cooled or temperature cannot be adjusted.
Related information No.
Cause
1
Gas leakage from pipe joint and parts
Check it and if any trouble is found, repair or replace it.
2
Leakage from hose, etc. (refrigerant has not been refilled for long-term)
Check whether refrigerant level is correct, and if it is insufficient, refill with it to the specified level.
3
Insufficient refrigerant
Refill with refrigerant to the specified level.
4
Defective expansion valve
Check it and if any trouble is found, repair or replace it.
5
Clogging of low-pressure Check it and if it is clogged, remove the stuffing or replace it. circuit or evaporator
6
Clogged evaporator fin
Check it and if it is clogged, clean the evaporator.
7
Clogged filter
Check it and clean or replace.
Defective installment of evaporator temperature sensor
Check it and if any trouble is found, repair or replace it.
8
Air leakage from air conditioner unit and duct joint
Check it and repair or replace air leakage part.
9 10
Lack of set air flow
Increase the set air flow.
11
Over-filling with refrigerant
Check whether refrigerant level is correct, and if it is too much, extract it to the specified level.
12
Mixing of air
After evacuation, refill with refrigerant to the specified level, and replace the receiver drier.
13
Clogged condenser fin
Check it and if it is clogged, clean the fin.
14
Defective compression of Check it and if any trouble is found, repair or replace it. compressor
15
Mixing of moisture in refrigerant circuit
80-38
Procedure, measuring location, criteria and remarks
After evacuation, refill with refrigerant to the specified level, and replace the receiver drier.
PC45MR-5, PC55MR-5
80 Appendix
A-6 Troubleshooting for Hot Water Circuit System
A-6 Troubleshooting for Hot Water Circuit System •
Heating trouble
•
Defective temperature control
Related
•
Check the hot water circuit for water leakage.
information
•
Check that air flows out of the vent.
Failure
No.
Cause
Procedure, measuring location, criteria and remarks Check it and if it is clogged, clean the heater core fin.
1
Clogged heater core fins
REMARK If this item is the cause, temperature at hot water inlet and outlet of heater core becomes high. Check it and repair or replace air leakage part.
2
Air leakage from air conditioner unit
3
Defective hot water cut valve (clogging or defective valve)
REMARK If this item is the cause, temperature at hot water inlet and outlet of heater core becomes high. Check it and if it is clogged or valve is defective, remove the stuffing or replace it.
REMARK If this item is the cause, temperature at hot water inlet of heater core becomes high and that at hot water outlet becomes low. Check it and repair or replace clogging part.
4
Clogged heater core inside
REMARK If this item is the cause, temperature at hot water inlet of heater core becomes high and that at hot water outlet becomes low. Check it and repair or replace clogging part.
5
Clogging up to hot water inlet of heater core
PC45MR-5, PC55MR-5
REMARK If this item is the cause, temperature at hot water inlet of heater core becomes low.
80-39
A-7 Unusual Noise is Heard from Air Conditioner Related Parts
80 Appendix
A-7 Unusual Noise is Heard from Air Conditioner Related Parts Failure
Unusual noise is heard.
Related information No.
Cause
1
Defective installment of case related bolt (screw)
Check it and if any trouble is found, repair it.
2
Interference of fan case or broken fan
Check it and if any trouble is found, repair or replace it.
3
Foreign material in blower motor or defective blower motor
Check it and if any trouble is found, remove foreign material and repair or replace it.
4
Defective expansion valve
Check it and if unusual noise (gas leaking sound) is heard, replace it.
5
Looseness or wear of compressor V-belt
Check it and if looseness or wear is found, repair or replace it.
6
Over-filling or short-filling Check whether refrigerant level is correct, and if it is insufficient or too much, adjust with refrigerant it to the specified level.
7
Defective compressor
80-40
Procedure, measuring location, criteria and remarks
Check it and if any trouble is found, repair or replace it.
PC45MR-5, PC55MR-5
80 Appendix
A-8 Water Leaks from Air Conditioner Related Parts
A-8 Water Leaks from Air Conditioner Related Parts Failure
There is water leakage.
Related information No.
Cause
Procedure, measuring location, criteria and remarks
1
Clogged water drainage Check it and if any trouble is found, repair it. port of air conditioner unit
2
Clogging, kinking, holing, Check it and if any trouble is found, repair or replace it. or defective installation of drain hose of air conditioner unit
3
Crack of air conditioner unit case
4
Defective mounting bolt Check it and if any trouble is found, repair or replace it. (screw) related to air conditioner unit case
5
Defective connection of pipe in hot water circuit
Check it and if any trouble is found, repair or replace it.
6
Defective heater core
Check it and if any trouble is found, repair or replace it.
7
Defective hot water cut valve
Check it and if any trouble is found, repair or replace it.
PC45MR-5, PC55MR-5
Check it and if any crack is found, repair it.
80-41
A-9 Troubleshooting for Fresh/Recirc Air Changeover
80 Appendix
A-9 Troubleshooting for Fresh/Recirc Air Changeover Failure
Fresh air and recirculation air cannot be changed over.
Related information No.
Cause Defective FRESH/ RECIRC air changeover lever
Check it and if any trouble is found, clean and repair or replace it.
1
2
Malfunction of intake damper
Check it and if any trouble is found, clean and repair or replace it.
Clogged unit fresh air inlet duct with foreign material
Check it and if any trouble is found, clean it.
3
80-42
Procedure, measuring location, criteria and remarks
PC45MR-5, PC55MR-5
80 Appendix
Precautions for Disconnection and Connection of Air Conditioner Piping
Precautions for Disconnection and Connection of Air Conditioner Piping Precautions for Disconnection k When replacing the air conditioner unit, compressor, condenser or receiver drier, etc., collect the re-
frigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant. NOTICE • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).
1: Engine
4: Receiver drier
2: Compressor
5: Air conditioner unit
3: Condenser •
When loosening the air conditioner hose nut after collecting the refrigerant, be sure to use 2 wrenches. Use one wrench to fix one nut and the other wrench to loosen the other nut.
•
When working on the air conditioner piping, take measures to prevent the entry of dirt, dust, water, etc. into the hoses.
Precautions for Connection •
When connecting the pipes, apply compressor oil(SP-10) for R134a to prevent O-ring from damage and twisting.
PC45MR-5, PC55MR-5
80-43
Precautions for Disconnection and Connection of Air Conditioner Piping
80 Appendix
Do not apply oil to threaded portion of bolt, nut and union. •
Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged.
•
When connecting a pipe, push it into the end and fully finger-tighten the bolt or nut.
•
Be sure to use 2 wrenches (torque wrench for tightening side) to tighten each nut. Use one wrench to fix one nut and the other wrench to tighten the other nut to the specified torque.
REMARK An O-ring is fitted to every joint of the air conditioner piping.
Table of Tightening Torque for Refrigerant Pipe Joint
80-44
Thread size
Tightening torque
M6 x 1.0
8 to 12 Nm {0.8 to 1.2 kgfm}
M8 x 1.25
20 to 25 Nm {2.0 to 2.6 kgfm}
PC45MR-5, PC55MR-5
80 Appendix
Handle Compressor Oil
Handle Compressor Oil Management of Compressor Oil (SANDEN: SP-10 for R134a) The compressor oil does not need to be checked or refilled as frequently as the engine oil. However, if its level is low or too high, it can cause the following troubles. Accordingly, charge the compressor oil by the specified quantity, similarly to the refrigerant. Condition
Content
Lack of oil
Defective lubrication and seizure of compressor
Excess of oil
Defective cooling (Excess oil sticks to each part and decreases heat exchange efficiency)
Add Compressor Oil k Refrigerant is potentially hazardous to health and environment. Before disconnecting air conditioner
hoses, collect refrigerant according to “PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS”.
k If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or
seized. Be sure to use oil for R134a (SANDEN: SP-10).
k Since oil for R134a is extremely hygroscopic, cap the oil container immediately after use in order to
limit contact with air. Store the oil container in a dry and well ventilated place.
k Since the compressor oil may dissolve the plastic and painting surface, do not allow the oil to con-
tact with them. Check in the following cases, and add new oil as necessary. •
The large quantity of leakage of refrigerant occurs and refrigerant is discharged abruptly.
•
The compressor is replaced due to a failure. (See “The quantity of compressor oil when the compressor is replaced”.)
•
Cycle parts such as the condenser, receiver drier, evaporator unit, etc. are replaced.
Quantity of the Compressor Oil When the Compressor is Replaced The following is the explanation of the quantity of compressor oil when the compressor is broken due to seizure, etc. and in other cases. •
When compressor is broken due to seizure, etc. Metal chips circulate in the air conditioner circuit and contaminate the compressor oil remarkably. In such case, clean the air conditioner circuit and replace the compressor and receiver drier. Since all of the compressor oil is drained from the air conditioner circuit by cleaning the circuit, install the new compressor together with the filled oil of the specified quantity (100 cc).
•
In other cases New compressor contains compressor oil of 100 cc in it. 1. Prepare a container to catch the oil, and drain the oil from the removed compressor. 2. Measure the quantity of the drained oil with a measuring cylinder, and write it down. 3. Drain the oil from the new compressor by the following quantity. Quantity to be drained = 100 cc - “Quantity written down” Example: If 30 cc is drained from the removed compressor, the quantity to be drained from the new compressor will be 70 cc (= 100 cc - 30 cc).
PC45MR-5, PC55MR-5
80-45
90 Circuit Diagrams
PC45MR-5, PC55MR-5
90-1
Table of Contents
90 Circuit Diagrams
Table of Contents Abbreviation List ............................................................................................................................................ 90-3 Hydraulic Circuit Diagram............................................................................................................................... 90-9 Symbols Used in Hydraulic Circuit Diagram ............................................................................................ 90-9 Hydraulic Circuit Diagram...................................................................................................................... 90-13 Hydraulic Circuit Diagram (Quick Coupler Specifications) (1/2) ............................................................. 90-15 Hydraulic Circuit Diagram (Quick Coupler Specifications) (2/2) ............................................................. 90-17 Electrical Circuit Diagram ............................................................................................................................. 90-19 Symbols Used in Electric Circuit Diagram ............................................................................................. 90-19 Electrical Circuit Diagram (Canopy Spec) (1/5) ..................................................................................... 90-23 Electrical Circuit Diagram (Canopy Spec) (2/5) ..................................................................................... 90-25 Electrical Circuit Diagram (Canopy Spec) (3/5) ..................................................................................... 90-27 Electrical Circuit Diagram (Canopy Spec) (4/5) ..................................................................................... 90-29 Electrical Circuit Diagram (Canopy Spec) (5/5) ..................................................................................... 90-31 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (1/5) ........................ 90-33 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (2/5) ........................ 90-35 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (3/5) ........................ 90-37 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (4/5) ........................ 90-39 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (5/5) ........................ 90-41 Electrical Circuit Diagram (Cab Spec) (1/6)........................................................................................... 90-43 Electrical Circuit Diagram (Cab Spec) (2/6)........................................................................................... 90-45 Electrical Circuit Diagram (Cab Spec) (3/6)........................................................................................... 90-47 Electrical Circuit Diagram (Cab Spec) (4/6)........................................................................................... 90-49 Electrical Circuit Diagram (Cab Spec) (5/6)........................................................................................... 90-51 Electrical Circuit Diagram (Cab Spec) (6/6)........................................................................................... 90-53 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (1/6) .............................. 90-55 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (2/6) .............................. 90-57 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (3/6) .............................. 90-59 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (4/6) .............................. 90-61 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (5/6) .............................. 90-63 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (6/6) .............................. 90-65
90-2
PC45MR-5, PC55MR-5
90 Circuit Diagrams
Abbreviation List
Abbreviation List •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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 applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Antilock Brake System
AISS
Automatic Idling Setting Engine System
This is a function that automatically sets the idle speed.
Steering AJSS
Advanced Joystick Steering System
This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.
ARAC
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
(WA) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.
This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.
ARSC
Automatic Retarder Speed Control
ASR
Travel and brake Automatic Spin Regulator (HD, HM)
This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.
ATT
Attachment
A function or component that can be added to the standard specification.
BCV
BRAKE Brake cooling oil control valve (HD)
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
PC45MR-5, PC55MR-5
(HD, HM)
Work equipment
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.
90-3
Abbreviation List
Abbreviation
Actual word spelled out
90 Circuit Diagrams
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.
Electronic control system
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)
CRI
Common Rail Injection
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Travel Electronically Controlled Suspension System (WA)
This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.
ECU
Electronic Control Unit
This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.
EMMS
Equipment ManageMachine monitor ment Monitoring System
This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).
EPC
Electromagnetic ProporHydraulic system tional Control
Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.
FOPS
Falling Object Protective Cab and canopy Structure
Transmission (D, HD, WA, etc)
Electronic control system
This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.
This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.
F-N-R
Forward-Neutral-Reverse
GPS
Global Positioning System
GNSS
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
Operation Communication (KOMTRAX, KOMTRAX Plus)
Steering
90-4
(D Series) Transmission (D, WA)
Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.
This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.
PC45MR-5, PC55MR-5
90 Circuit Diagrams
Abbreviation List
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
Explanation
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
IMA
Inlet Metering Actuator
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)
IMU
Inertial Measurement Unit
Engine
This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV
Inlet Metering Valve
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)
KCCV
Komatsu Closed CrankEngine case Ventilation
This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
Engine
Engine
Komatsu Diesel ParticuEngine late Filter
This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.
Travel and brake
This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.
KTCS
Komatsu Traction Control System
(HM)
LCD
Liquid Crystal Display
Machine monitor
This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.
LED
Light Emitting Diode
Electronic parts
This is a semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
LS
Load Sensing
Hydraulic system
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
MAF
Mass Air Flow
PC45MR-5, PC55MR-5
90-5
Abbreviation List
90 Circuit Diagrams
Abbreviation
Actual word spelled out
Purpose of use (major applicable machine (*1), or component/system)
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.
NO
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
PC
Pressure Compensation Hydraulic system
PCCS
Palm command control system
PCV
Pre-stroke Control Valve Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
PTP
Power Tilt and power Pitch dozer
Steering
ROPS
Roll-Over Protective Structure
(D Series)
Hydraulic system Hydraulic system (D, PC, etc)
Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
Piston type hydraulic pump and motor.
Power train system
Power take-off mechanism
Work equipment
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.
(D Series)
Cab and canopy
ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.
SCR
Selective Catalytic Reduction
SI
Le Systeme International d' Unites (Internation- Unit al unit system)
Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.
SOL
Solenoid
This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.
90-6
Urea SCR system
Electrical system
PC45MR-5, PC55MR-5
90 Circuit Diagrams
Abbreviation
TOPS
Abbreviation List
Purpose of use (major applicable machine (*1), or component/system)
Actual word spelled out
Tip-Over Protective Structure
Cab and canopy
Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.
TWV
2-Way Valve
Hydraulic system
This is a solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
Engine control
This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
List of Abbreviations Used in the Circuit Diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
PC45MR-5, PC55MR-5
90-7
Abbreviation List
90 Circuit Diagrams
Abbreviation S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
90-8
Actual word spelled out
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
PC45MR-5, PC55MR-5
90 Circuit Diagrams
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram Symbols Used in Hydraulic Circuit Diagram Symbol
Content
Main piping route
Pilot and drain route
Flexible piping such as hose
Crossing of disconnected route
Connected route
Flow of fluid
Throttle
Variable
Electric
Spring
Pickup port
Pickup port and pressure gauge
PC45MR-5, PC55MR-5
90-9
Symbols Used in Hydraulic Circuit Diagram
Symbol
90 Circuit Diagrams
Content
Check valve
Intake port (with strainer)
Tank and return piping
Filter
Oil cooler G0140128
Stop valve
Drive shaft (1 way)
Drive shaft (reversible)
Hydraulic pump Reference: ▲ in the figure shows outlet
Variable displacement hydraulic pump
Hydraulic motor Reference: ▲ and ▼ in the figure show the direction of oil flow into hydraulic motor, and as direction changes, the rotation of motor is reversed.
Servo piston
PPC valve
90-10
PC45MR-5, PC55MR-5
90 Circuit Diagrams
Symbols Used in Hydraulic Circuit Diagram
Symbol
Content
Control valve
Single acting solenoid valve
Single acting proportional solenoid valve
Hydraulic pilot valve
Hydraulic 2-stage pilot valve
Lock valve
Drain valve
Pressure regulating valve, safety valve, relief valve
Pressure regulating valve, safety valve, relief valve (when the oil pressure is discharged to the low-pressure side)
Bypass valve
Accumulator
Cylinder
Cylinder with piston valve
PC45MR-5, PC55MR-5
90-11
Symbols Used in Hydraulic Circuit Diagram
Symbol
90 Circuit Diagrams
Content
Unit
90-12
PC45MR-5, PC55MR-5
Hydraulic Circuit Diagram PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-13
Hydraulic Circuit Diagram (Quick Coupler Specifications) (1/2) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-15
Hydraulic Circuit Diagram (Quick Coupler Specifications) (2/2) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-17
90 Circuit Diagrams
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram Symbols Used in Electric Circuit Diagram Symbol
Content
Wire
Wire (junction disconnected)
Wire (junction connected)
Combined wire
Terminal
Grounding by chassis ground
Grounding by terminal
Contact, switch
Push button switch (N.O. type) N.O.: Normally Open
Push button switch (N.C. type) N.C.: Normally Closed
Push button switch (N.O. type) N.O.: Normally Open
Push button switch (N.O. type) N.C.: Normally Closed
PC45MR-5, PC55MR-5
90-19
Symbols Used in Electric Circuit Diagram
Symbol
90 Circuit Diagrams
Content
Variable
Resistor
Variable resistor
Diode
Light emitting diode (LED)
Photo diode
Low-voltage diode (Zener diode)
Transistor (PNP type)
Transistor (NPN type)
Electromagnetic coil
Battery
Fuse
90-20
PC45MR-5, PC55MR-5
90 Circuit Diagrams
Symbols Used in Electric Circuit Diagram
Symbol
Content Connector Reference: •
Concave side of contact face (left in the figure): Female
•
Convex side of contact face (right in the figure): Male
REMARK Figure shows the disconnected state. Plug type connector (left: male, right: female)
REMARK Figure shows the connected state. Solenoid
Motor
Lamp
Pressure switch (N.O. type) N.O.: Normally Open
Pressure switch (N.C. type) N.C.: Normally Closed
Potentiometer, fuel control dial
Temperature sensor
Starting switch
Backup alarm
Horn
PC45MR-5, PC55MR-5
90-21
Symbols Used in Electric Circuit Diagram
Symbol
90 Circuit Diagrams
Content
Buzzer
Antenna
90-22
PC45MR-5, PC55MR-5
Electrical Circuit Diagram (Canopy Spec) (1/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-23
Electrical Circuit Diagram (Canopy Spec) (2/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-25
Electrical Circuit Diagram (Canopy Spec) (3/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-27
Electrical Circuit Diagram (Canopy Spec) (4/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-29
Electrical Circuit Diagram (Canopy Spec) (5/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-31
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (1/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-33
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (2/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-35
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (3/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-37
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (4/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-39
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (5/5) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-41
Electrical Circuit Diagram (Cab Spec) (1/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-43
Electrical Circuit Diagram (Cab Spec) (2/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-45
Electrical Circuit Diagram (Cab Spec) (3/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-47
Electrical Circuit Diagram (Cab Spec) (4/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-49
Electrical Circuit Diagram (Cab Spec) (5/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-51
Electrical Circuit Diagram (Cab Spec) (6/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-53
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (1/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-55
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (2/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-57
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (3/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-59
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (4/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-61
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (5/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-63
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (6/6) PC45MR-5, PC55MR-5 REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC45MR-5, PC55MR-5
90-65
Index
Index A A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)................... 80-24 A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)........... 80-27 A-3 Troubleshooting for Temperature Control Function............................................................... 80-31 A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System)......80-34 A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems) 80-38 A-6 Troubleshooting for Hot Water Circuit System...... .....................................................................80-39 A-7 Unusual Noise is Heard from Air Conditioner Related Parts....................................................80-40 A-8 Water Leaks from Air Conditioner Related Parts... .....................................................................80-41 A-9 Troubleshooting for Fresh/Recirc Air Changeover .....................................................................80-42 Abbreviation List........................................................... ...........00-11,01-3,10-4,20-3,30-5,40-6,50-5,60-3, 80-3,90-3 Abnormality Record Menu................................ 30-123 Adjust Alternator Belt Tension.............................30-32 Adjust Blade Relief Pressure.............................. 30-60 Adjust LS Valve...................................................30-71 Adjust Oil Pressure in Control Circuit..................30-64 Adjust Oil Pressure in Pump PC Control Circuit. 30-66 Adjust Oil Pressure in Swing and Blade Circuits 30-60 Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits....................................30-54 Adjust Play of Work Equipment and Swing PPC Valves.......................................................... 30-80 Adjust Valve Clearance.......................................30-23 Adjust Work Equipment, Travel, and Boom Swing Relief Pressure.................................................30-54 Adjustment Menu.............................................. 30-146 Adjustment Menu (Attachment EPC 2 Adjustment)..... ...................................................................30-147 Adjustment Menu (Attachment EPC 3 Adjustment)..... ...................................................................30-148 Adjustment Menu (Pump Absorption Torque)... 30-146 Air Conditioner Component.................................80-11 Air Conditioner System....................................... 80-10 Air Conditioner Unit.............................................80-16 Assemble Carrier Roller Assembly................... 50-105 Assemble Center Swivel Joint Assembly..........50-124 Assemble Idler Assembly....................................50-99 Assemble Recoil Spring Assembly..................... 50-94 Assemble Swing Machinery Assembly............... 50-88 Assemble Track Roller Assembly..................... 50-102 Attachment Oil Flow Adjuster System...............10-125 Attachment Oil Flow Adjuster System Diagram 10-125 Attachment PPC Valve......................................10-132 Auto-Deceleration System.................................. 10-20
Automatic Gear Shift Valve of Travel Motor...... 10-164 Automatic Idle Stop System................................10-24
B Battery Disconnect Switch.................................. 10-14 Bipartite Solenoid Valve.................................... 10-138 Blade PPC Valve...............................................10-134 Bleed Air from Fuel System...................... 30-28,40-46 Bleed Air from Hydraulic System.............. 30-91,40-46 Boom Swing PPC Valve....................................10-136 Boot-up System.................................................. 10-10 Brake Valve of Swing Motor..............................10-146
C CAB Related Parts..................... 10-174,30-95,50-164 Caution Lamps Shown on Machine Monitor....... 10-35 Center Swivel Joint........................................... 10-168 Check Valve Clearance.......................................30-22 Checks Before Troubleshooting..........................40-16 CLSS...................................................................10-50 Coating Materials List......................................... 50-13 Component Parts of Air Conditioner System...... 80-16 Component Parts of Control System.................. 10-32 Component Parts of Engine System...................10-26 Component Parts of Hydraulic System............... 10-56 Component Parts of Swing System.................. 10-144 Component Parts of Travel System.................. 10-158 Component Parts of Work Equipment System. 10-127 Compressor........................................................ 80-18 Condenser.......................................................... 80-20 Configuration Diagram of Air Conditioner Unit....80-16 Connector Contact Identification (For 4D88E-7 Engine).............................................................40-83 Connector List and Layout.................................. 40-67 Control System................................................... 10-29 Control Valve.......................................................10-72 Conversion Table................................................ 00-76 Cooling System...................................................10-27 Counterbalance Valve and Check Valve of Travel Motor...............................................................10-163
D Default Menu.....................................................30-133 Default Setting Menu (Auto Idle Stop Time Fixing)...... ...................................................................30-135 Default Setting Menu (KEY-ON MODE)............30-133 Default Setting Menu (UNIT SELECTION)....... 30-134 Diagnostic Tests Menu......................................30-138 Dimensions of Arm..............................................60-63 Dimensions of Bucket......................................... 60-67 Disassemble and Assemble Carrier Roller Assembly.. ...................................................................50-104
1
Index
Disassemble and Assemble Center Swivel Joint Assembly....................................................... 50-122 Disassemble and Assemble Final Drive Assembly...... .....................................................................50-74 Disassemble and Assemble Idler Assembly....... 50-98 Disassemble and Assemble KDPF Assembly.... 50-69 Disassemble and Assemble Recoil Spring Assembly.. .....................................................................50-93 Disassemble and Assemble Swing Machinery Assembly......................................................... 50-85 Disassemble and Assemble Track Roller Assembly.... ...................................................................50-101 Disassemble and Assemble Travel PPC Valve Assembly....................................................... 50-146 Disassemble and Assemble Work Equipment Cylinder Assembly............................................. 50-155 Disassemble and Assemble Work Equipment PPC Valve Assembly..........................................50-143 Disassemble Carrier Roller Assembly.............. 50-104 Disassemble Center Swivel Joint Assembly..... 50-123 Disassemble Idler Assembly...............................50-98 Disassemble Recoil Spring Assembly................ 50-93 Disassemble Swing Machinery Assembly.......... 50-85 Disassemble Track Roller Assembly.................50-101 Disassemble Travel PPC Valve Assembly........50-146 Disassemble Work Equipment PPC Valve Assembly.. ...................................................................50-143 Disconnect and Connect Connector with Housing to Rotate.......................................................... 00-61 Disconnect and Connect Connector with Lock to Pull. .....................................................................00-58 Disconnect and Connect Connector with Lock to Push.............................................................00-59 Disconnect and Connect Deutsch Connector..... 00-55 Disconnect and Connect Push-Pull Type Coupler....... .....................................................................00-47
E E-1 Engine Does Not Start (Engine Does Not Crank).. ...................................................................40-212 E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum...................................... 40-230 E-11 Display of Fuel Gauge is Different from Actual Fuel Level.................................................. 40-232 E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum............. 40-233 E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature........ 40-234 E-14 Some Areas of Machine Monitor Screen are Not Shown........................................................40-235 E-15 Function Switch Does Not Operate.......... 40-236 E-16 Auto-Decelerator is Not Operated or Canceled with Lever.................................................. 40-237 E-17 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed.40-238 E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change......... 40-239 2
E-19 Alarm Buzzer Does Not Sound................ 40-241 E-2 Engine Does Not Start (Fuel Feed Pump System) ...................................................................40-218 E-20 Alarm Buzzer Cannot be Canceled.......... 40-242 E-21 Service Meter is Not Shown, While Starting Switch is in OFF Position...........................40-243 E-22 Service Mode Cannot be Selected...........40-244 E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move.......................... 40-245 E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock............................40-247 E-25 Alarm Does Not Sound During Travel...... 40-249 E-26 Travel Alarm Does Not Stop When Machine Stops..........................................................40-251 E-27 Horn Does Not Sound.............................. 40-252 E-28 Horn Does Not Sound (For Proportional Lever Spec)......................................................... 40-254 E-29 Horn Does Not Stop................................. 40-256 E-3 Automatic Preheating System Does Not Operate. ...................................................................40-220 E-30 Horn Does Not Stop (For Proportional Lever Spec)......................................................... 40-258 E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec)..................................... 40-260 E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec)......... 40-264 E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate........................... 40-268 E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate................. 40-270 E-35 Travel Indicator is Not Shown Correctly with Monitoring Function................................... 40-272 E-36 Swing or Arm IN is Not Shown Normally in Monitoring Function.......................................... 40-273 E-37 Work Equipment is Not Shown Normally in Monitoring Function.......................................... 40-274 E-38 KOMTRAX System Does Not Operate Normally. ...................................................................40-276 E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing............ 40-222 E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs...................... 40-225 E-6 Charge Level Monitor Comes On in Red While Engine is in Operation............................... 40-226 E-7 Fuel Level Monitor Comes On in Red While Engine Runs...................................................40-227 E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation.......... 40-228 E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation..................... 40-229 Electrical Circuit Diagram....................................90-19 Electrical Circuit Diagram (Cab Spec) (1/6)........ 90-43 Electrical Circuit Diagram (Cab Spec) (2/6)........ 90-45 Electrical Circuit Diagram (Cab Spec) (3/6)........ 90-47 Electrical Circuit Diagram (Cab Spec) (4/6)........ 90-49 Electrical Circuit Diagram (Cab Spec) (5/6)........ 90-51 Electrical Circuit Diagram (Cab Spec) (6/6)........ 90-53
Index
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (1/6)....................... 90-55 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (2/6)....................... 90-57 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (3/6)....................... 90-59 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (4/6)....................... 90-61 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (5/6)....................... 90-63 Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (6/6)....................... 90-65 Electrical Circuit Diagram (Canopy Spec) (1/5).. 90-23 Electrical Circuit Diagram (Canopy Spec) (2/5).. 90-25 Electrical Circuit Diagram (Canopy Spec) (3/5).. 90-27 Electrical Circuit Diagram (Canopy Spec) (4/5).. 90-29 Electrical Circuit Diagram (Canopy Spec) (5/5).. 90-31 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (1/5)............. 90-33 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (2/5)............. 90-35 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (3/5)............. 90-37 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (4/5)............. 90-39 Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (5/5)............. 90-41 Electrical System.................................. 30-105,50-202 Engine and Cooling System............. 30-18,50-24,60-9 Engine and Pump Combined Control System.... 10-53 Engine and Pump Combined Control System Diagram.............................................................10-53 Engine Control System....................................... 10-16 Engine System....................................................10-15 Examine Air Cleaner Clogging............................40-29 Examine and Adjust Air Conditioner Compressor Belt Tension........................................................ 30-33 Examine and Adjust Alternator Belt Tension.......30-32 Examine and Adjust Oil Pressure in Control Circuit..... .....................................................................30-62 Examine and Adjust Oil Pressure in Pump LS Control Circuit...........................................................30-68 Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits.................30-44 Examine and Adjust Swing and Blade Circuit Oil Pressure...................................................... 30-55 Examine and Adjust Track Tension.....................30-36 Examine and Adjust Travel Deviation................. 30-83 Examine and Adjust Valve Clearance.................30-22 Examine Compression Pressure........................ 30-24 Examine Coolant Level (Reservoir Tank)............40-28 Examine Diodes................................................30-161 Examine Diodes by Digital Tester..................... 30-161 Examine Engine Oil Level (Oil Quantity in Oil Pan)..... .....................................................................40-27 Examine Engine Oil Pressure............................. 30-26 Examine Engine Speed...................................... 30-18 Examine Exhaust Gas Color...............................30-20
Examine Fuel Circuit for Leakage.......................30-30 Examine Fuel Level and Type.............................40-20 Examine Fuel Main Filter.................................... 40-24 Examine Fuel Prefilter.........................................40-21 Examine Function by LCD (Liquid Crystal Display)..... ...................................................................30-108 Examine Function of Service Meter.................. 30-108 Examine Hydraulic Oil Filter................................40-44 Examine Hydraulic Oil Level............................... 40-39 Examine Hydraulic Oil Strainer........................... 40-43 Examine KOMTRAX Settings (GPS & Communication State).................................................. 30-152 Examine KOMTRAX Settings (Modem Information).... ...................................................................30-153 Examine KOMTRAX Settings (Terminal State).30-152 Examine LS Differential Pressure by Testing Tool....... .....................................................................30-69 Examine LS Differential Pressure with Machine Monitor.................................................................30-68 Examine Oil Leakage..........................................30-88 Examine Oil Level in Final Drive Case................40-46 Examine Oil Pressure in Control Circuit..............30-62 Examine Outlet Pressure of Solenoid Valve....... 30-72 Examine Parts Which Cause Hydraulic Drift of Work Equipment....................................................30-86 Examine PPC Valve Outlet Pressure..................30-75 Examine Swing Circle Bearing Clearance.......... 30-35 Examine Swing Parking Brake Release Pressure....... .....................................................................30-81 Examine Water Separator, Drain Water and Sediment .....................................................................40-23 Explanation of Terms for Maintenance Standard 00-66
F Failure Code [989L00]...................................... 40-109 Failure Code [989M00]......................................40-110 Failure Code [989N00]...................................... 40-111 Failure Code [AQ20R1].....................................40-112 Failure Code [B@BCNS]...................................40-113 Failure Code [D19JKZ]......................................40-114 Failure Code [D811MC].....................................40-117 Failure Code [D862KA]..................................... 40-118 Failure Code [D8ALKA].....................................40-119 Failure Code [D8ALKB].....................................40-121 Failure Code [D8AQKR]....................................40-123 Failure Code [DAF0KT].....................................40-125 Failure Code [DAF0MB]....................................40-126 Failure Code [DAF0MC]....................................40-127 Failure Code [DAF3KK].................................... 40-128 Failure Code [DAF9KQ].................................... 40-130 Failure Code [DAFGMC]...................................40-131 Failure Code [DAFLKA].................................... 40-132 Failure Code [DAFLKB].................................... 40-134 Failure Code [DAFQKR]................................... 40-136 Failure Code [DB2QKR]....................................40-137 Failure Code [DBH0MC]................................... 40-141 Failure Code [DBH2KK].................................... 40-142 3
Index
Failure Code [DBH5KP]........................40-145,40-147 Failure Code [DBH9KQ]....................................40-149 Failure Code [DBHLKA].................................... 40-151 Failure Code [DBHLKB].................................... 40-153 Failure Code [DBHQKR]................................... 40-155 Failure Code [DDNRKA]................................... 40-160 Failure Code [DDNRKY]................................... 40-162 Failure Code [DDNS00].................................... 40-164 Failure Code [DDWLKA]................................... 40-166 Failure Code [DDWLKB]................................... 40-168 Failure Code [DFB1KZ].....................................40-170 Failure Code [DFB3L8]..................................... 40-172 Failure Code [DFB5KZ].....................................40-174 Failure Code [DHS1MA]................................... 40-176 Failure Code [DHS5MA]................................... 40-178 Failure Code [DKULKA].................................... 40-180 Failure Code [DKULKB].................................... 40-182 Failure Code [DKULKY].................................... 40-184 Failure Code [DV00KB].....................................40-186 Failure Code [DV20KB].....................................40-187 Failure Code [DW43KA]....................................40-189 Failure Code [DW43KB]....................................40-191 Failure Code [DW43KY]....................................40-193 Failure Code [DW4CKY]................................... 40-194 Failure Code [DXA8KA].................................... 40-196 Failure Code [DXA8KB].................................... 40-198 Failure Code [DXE7KA].................................... 40-200 Failure Code [DXE7KB].................................... 40-202 Failure Code [DXE7KY].................................... 40-204 Failure Code [DXEAKA]....................................40-206 Failure Code [DXEAKB]....................................40-208 Failure Code [DXEAKY]....................................40-210 Failure Code Table..............................................40-99 Foreword, Safety, Basic Information................... 00-17 Fuel Control Dial................................................. 10-46 Function of Attachment Oil Flow Adjuster System....... ...................................................................10-126 Function of Auto-Deceleration System............... 10-20 Function of Automatic Idle Stop System............. 10-24 Function of Battery Disconnect Switch............... 10-14 Function of Brake Valve of Swing Motor........... 10-146 Function of Center Swivel Joint........................ 10-168 Function of CLSS................................................10-51 Function of Compressor......................................80-18 Function of Condenser........................................80-20 Function of Engine and Pump Combined Control System...............................................................10-54 Function of Engine Control System.................... 10-17 Function of Fuel Control Dial.............................. 10-46 Function of Hydraulic Tank Breather...................10-59 Function of Hydraulic Tank Oil Filler Cap............10-59 Function of Introduction of LS Pressure in Control Valve............................................................ 10-99 Function of KOMTRAX System.......................... 10-31 Function of KOMTRAX Terminal.........................10-40 Function of Logic Valve of Control Valve...........10-102 Function of LS Bypass Plug of Control Valve... 10-100
4
Function of LS Introduction Throttle of Pressure Compensation Valve of Control Valve................. 10-97 Function of Machine Monitor...............................10-32 Function of Main Pump....................................... 10-63 Function of Main Pump LS Valve........................10-70 Function of Main Pump PC Valve....................... 10-71 Function of Merge-Divider Valve of Control Valve........ ...................................................................10-104 Function of Operation Lamp System.................. 10-12 Function of Overheat Prevention System........... 10-23 Function of Pilot Circuit Accumulator................ 10-142 Function of PPC Lock System.......................... 10-123 Function of Pressure Compensation Valve of Control Valve............................................................ 10-94 Function of PTO..................................................10-26 Function of Receiver Dryer................................. 80-22 Function of ROPS CAB.....................................10-174 Function of Surface Area Ratio of Pressure Compensation Valve of Control Valve....................... 10-96 Function of Swing Circle................................... 10-153 Function of Swing Machinery............................10-152 Function of Swing Modulating Valve of Swing Motor... ...................................................................10-150 Function of Swing Motor................................... 10-146 Function of Tilt Type Floor.................................10-175 Function of Travel Control System....................10-156 Function of Travel Junction Valve of Control Valve...... ...................................................................10-108 Function of Travel Motor................................... 10-160 Function of Travel Pilot Pressure Detection Circuit of Control Valve..............................................10-114 Function of Unload Valve of Control Valve..........10-86 Function of Work Equipment.............................10-172 Function of Work Equipment and Travel Automatic Lock System.............................................. 10-124 Function of Work Equipment Clearance Adjustment Shim...........................................................10-173 Function of Work Equipment Pilot Pressure Detection Circuit of Control Valve...............................10-113 Fuse Location Table............................................40-93
G Gauges and Meters Shown on Machine Monitor10-34 General Troubleshooting Points..........................40-13
H H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate............................................... 40-278 H-10 Unusual Noise is Heard from Around Hydraulic Pump......................................................... 40-287 H-11 Engine Speed Drops Largely or Engine Stops.... ...................................................................40-288 H-12 All Work Equipment Speed or Power is Low....... ...................................................................40-290 H-13 All Work Equipment and Blade Speed or Power is Low.........................................................40-291
Index
H-14 Blade Does Not Operate.......................... 40-292 H-15 All Work Equipment Do Not Operate....... 40-293 H-16 All Work Equipment or Blade Do Not Operate.... ...................................................................40-294 H-17 Speed or Power of Boom is Low..............40-295 H-18 Arm Speed or Power is Low.....................40-297 H-19 Bucket Speed or Power is Low................ 40-298 H-2 All Work Equipment or Travel Does Not Operate.. ...................................................................40-279 H-20 Blade Speed or Power is Low.................. 40-299 H-21 Boom Swing Speed or Power is Low....... 40-301 H-22 Work Equipment Does Not Move in Single Operation........................................................40-302 H-23 Hydraulic Drift of Boom is Large.............. 40-303 H-24 Hydraulic Drift of Arm is Large................. 40-304 H-25 Hydraulic Drift of Bucket is Large.............40-305 H-26 Hydraulic Drift of Blade is Large...............40-306 H-27 Time Lag of Work Equipment is Large..... 40-308 H-28 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower....... ...................................................................40-309 H-29 Machine Does Not Travel Straight........... 40-310 H-3 Travel or Blade Does Not Operate............. 40-280 H-30 Machine Does Not Move Off Straight.......40-312 H-31 Machine is Not Steered Correctly or Steering Power is Low............................................. 40-313 H-32 Travel Speed is Low.................................40-315 H-33 Two Sides of Crawlers Do Not Move....... 40-317 H-34 One of Tracks Does Not Run................... 40-318 H-35 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast......................... 40-320 H-36 Upper Structure Does Not Swing to Right and Left.............................................................40-321 H-37 Upper Structure Swings Only to Right or Left..... ...................................................................40-323 H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions........................... 40-325 H-39 Swing Acceleration or Swing Speed is Low in Only One Direction.................................... 40-327 H-4 Swing or Blade Does Not Operate............. 40-281 H-40 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left).... 40-328 H-41 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)....... ...................................................................40-329 H-42 Shock is Large When Upper Structure Stops Swing Operation........................................ 40-330 H-43 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation.............. 40-331 H-44 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied).......................... 40-332 H-45 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)....................... 40-333 H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low..............................40-282 H-6 All Work Equipment and Travel Speed or Power is Low.........................................................40-283 H-7 Travel and Blade Speed or Power is Low.. 40-284
H-8 Swing and Blade Speed or Power is Low.. 40-285 H-9 Fine Control Performance or Response is Unsatisfactory..................................................... 40-286 Handle Compressor Oil.......................................80-45 Handle Cylinder Cut-out Mode Operation...........30-31 Handle Voltage Circuit of Engine Controller......30-160 How to Adjust Oil Pressure in Pump PC Control Circuit............................................................... 30-66 How to Adjust Play of Work Equipment and Swing PPC Valves.................................................. 30-80 How to Adjust Swing Relief Pressure................. 30-60 How to Adjust Track Tension...............................30-36 How to Adjust Travel Deviation........................... 30-83 How to Assemble Final Drive Assembly............. 50-78 How to Assemble Travel PPC Valve Assembly 50-147 How to Assemble Work Equipment Cylinder Assembly.............................................................. 50-159 How to Assemble Work Equipment PPC Valve Assembly....................................................... 50-144 How to Bleed Air from Fuel System.................... 30-28 How to Bleed Air from Hydraulic System............ 30-92 How to Disassemble Final Drive Assembly........ 50-74 How to Disassemble Work Equipment Cylinder Assembly....................................................... 50-156 How to Disconnect and Connect Slide Lock Type Connector.................................................... 00-56 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................... 00-47 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................... 00-48 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................... 00-49 How to Examine Alternator Belt Tension.............30-32 How to Examine and Adjust Air Conditioner Compressor Belt Tension.................................... 30-33 How to Examine Blade Relief Pressure by Machine Monitor.........................................................30-57 How to Examine Blade Relief Pressure by Testing Tool.............................................................. 30-59 How to Examine Boom Swing Relief Pressure by Machine Monitor............................................... 30-51 How to Examine Boom Swing Relief Pressure by Testing Tools................................................ 30-53 How to Examine Compression Pressure............ 30-24 How to Examine Diodes by Analog Tester........30-161 How to Examine Electric Equipment...................40-46 How to Examine Engine Oil Pressure.................30-26 How to Examine Engine Speed.......................... 30-18 How to Examine Exhaust Gas Color with Smoke Meter.................................................................30-21 How to Examine Exhaust Gas Color with the Handy Smoke Checker........................................... 30-20 How to Examine Fuel System for Leakage.........30-30 How to Examine Oil Leakage from Arm Cylinder30-88 How to Examine Oil Leakage from Blade Cylinder...... .....................................................................30-89 How to Examine Oil Leakage from Boom Cylinder...... .....................................................................30-88 5
Index
How to Examine Oil Leakage from Bucket Cylinder.... .....................................................................30-89 How to Examine Oil Pressure in Swing and Blade Circuits............................................................. 30-55 How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits.................30-44 How to Examine Oil Pressure of Control Circuit by Machine Monitor.......................................... 30-62 How to Examine Oil Pressure of Control Circuit by Testing Tools................................................ 30-63 How to Examine Outlet Pressure of PPC Valve by Testing Tool..................................................30-78 How to Examine Outlet Pressure of PPC Valve with Machine Monitor.......................................... 30-75 How to Examine Outlet Pressure of Solenoid Valve by Machine Monitor..................................... 30-72 How to Examine Outlet Pressure of Solenoid Valve by Testing Tool............................................. 30-73 How to Examine Parts that Cause Hydraulic Drift of PPC Valve....................................................30-87 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder............ 30-86 How to Examine Self-Define Monitor Information........ ................................................................... 30-116 How to Examine Swing Circle Bearing Clearance....... .....................................................................30-35 How to Examine Swing Parking Brake Release Pressure by Testing Tool..................................... 30-81 How to Examine Swing Parking Brake Release Pressure with Machine Monitor...........................30-81 How to Examine Swing Relief Pressure by Testing Tool.............................................................. 30-56 How to Examine Swing Relief Pressure on Machine Monitor.........................................................30-55 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder.................................... 30-86 How to Examine Track Tension...........................30-36 How to Examine Travel Deviation....................... 30-83 How to Examine Travel Relief Pressure by Testing Tool.............................................................. 30-50 How to Examine Travel Relief Pressure on Machine Monitor.........................................................30-48 How to Examine Unload Pressure...................... 30-54 How to Examine Unload Pressure by Testing Tool...... .....................................................................30-45 How to Examine Unload Pressure on Machine Monitor.................................................................30-44 How to Examine Work Equipment Relief Pressure by Testing Tool..................................................30-48 How to Examine Work Equipment Relief Pressure on Machine Monitor.......................................... 30-46 How to Install Accumulator Assembly (EU Specification)............................................................50-140 How to Install Accumulator Assembly (North America Specification, for Machine with Quick Coupler).... ...................................................................50-141 How to Install Hydraulic Oil Cooler Assembly.....50-43 How to Install Hydraulic Tank Assembly........... 50-128 6
How to Install KDPF Assembly........................... 50-67 How to Install Radiator Assembly....................... 50-36 How to Install Seatbelt...................................... 50-201 How to Open and Close Floor Unit..................... 30-95 How to Operate Battery Disconnect Switch Setting..... ...................................................................30-150 How to Operate Service Mode.......................... 30-111 How to Pressurize Hydraulic Tank...................... 30-94 How to Read the Codes for Electric Cable......... 00-62 How to Read the Shop Manual........................... 00-17 How to Read This Manual...................................50-12 How to Release Remained Pressure from Hydraulic Tank............................................................. 30-38 How to Release Remained Pressure from Swing Motor Circuit..................................................... 30-43 How to Release Remained Pressure from Travel Motor Circuit..................................................... 30-43 How to Release Remained Pressure in Hydraulic Cylinder Circuit..................................................30-38 How to Release Remained Pressure in PPC Accumulator Circuit...................................................30-38 How to Remove Accumulator Assembly (EU Specification)........................................................ 50-137 How to Remove Accumulator Assembly (North America Specification, for Machine with Quick Coupler)............................................................50-138 How to Remove and Install Seat Belt............... 50-201 How to Remove Hydraulic Oil Cooler Assembly.50-40 How to Remove KDPF Assembly....................... 50-65 How to Remove Radiator Assembly................... 50-33 How to Remove Seat Belt.................................50-201 How to See Abnormality Record (Electrical Systems). ...................................................................30-124 How to See Abnormality Record (Mechanical Systems)..........................................................30-123 How to See Maintenance Record..................... 30-126 How to See Pre-defined Monitoring Information.......... ................................................................... 30-112 How to Set with Default Setting Menu (With/Without Attachment)............................................... 30-134 How to Start Up KOMTRAX Terminal............... 30-156 Hydraulic Circuit Diagram........................... 90-9,90-13 Hydraulic Circuit Diagram (Quick Coupler Specifications) (1/2)....................................................90-15 Hydraulic Circuit Diagram (Quick Coupler Specifications) (2/2)....................................................90-17 Hydraulic Circuit Diagram of Control Valve and Names of Valves.......................................... 10-84 Hydraulic System................10-48,30-38,50-118,60-25 Hydraulic Tank.................................................... 10-56 Hydraulic Tank Breather......................................10-59 Hydraulic Tank Oil Filler Cap...............................10-58
I Idler Cushion.....................................................10-170 Information Shown in Troubleshooting Table............... ...........................................................40-65,80-23
Index
Information Shown in Troubleshooting Table (HMode).........................................................40-277 Information Shown in Troubleshooting Table (SMode).........................................................40-334 Input and Output Signals of KOMTRAX Terminal........ .....................................................................10-40 Input and Output Signals of Machine Controller. 10-42 Input and Output Signals of Machine Monitor.....10-33 Inspection Procedure Before Troubleshooting....40-18 Install Air Conditioner Unit Assembly................50-194 Install Blade Assembly......................................50-150 Install Center Swivel Joint Assembly................ 50-119 Install Counterweight Assembly........................ 50-113 Install Engine and Main Pump Assembly............50-53 Install Engine Controller Assembly................... 50-203 Install Floor Frame Assembly (Canopy Specification). ...................................................................50-174 Install Front Window Assembly.........................50-188 Install Fuel Tank Assembly................................. 50-62 Install KOMTRAX Terminal Assembly...............50-211 Install Machine Controller Assembly.................50-205 Install Machine Monitor Assembly.................... 50-208 Install Main Pump Assembly.............................50-133 Install Operator CAB Assembly (CAB Specification)... ...................................................................50-167 Install Operator CAB Glass (Adhered Glass)....50-179 Install Operator's Seat...................................... 50-199 Install Revolving Frame Assembly....................50-108 Install Starting Motor Assembly.......................... 50-32 Install Supply Pump Assembly............................50-27 Install Swing Circle Assembly............................. 50-92 Install Swing Motor and Swing Machinery Assembly... .....................................................................50-84 Install Track Assembly........................................ 50-96 Install Travel Motor and Final Drive Assembly....50-72 Install Work Equipment Assembly.................... 50-152 Introduction of LS Pressure in Control Valve...... 10-98
K KOMTRAX Settings Menu................................ 30-152 KOMTRAX System............................................. 10-31 KOMTRAX Terminal............................................10-40
L Layout Drawing of Boot-up System.................... 10-10 Layout Drawing of Control System..................... 10-29 Layout Drawing of Cooling System.....................10-27 Layout Drawing of Engine System......................10-15 Layout Drawing of Hydraulic System.................. 10-48 Layout Drawing of Swing System..................... 10-143 Layout Drawing of Travel System..................... 10-154 Layout Drawing of Undercarriage..................... 10-169 Layout Drawing of Work Equipment System.....10-116 Logic Valve of Control Valve............................. 10-102 LS Bypass Plug of Control Valve...................... 10-100
LS Introduction Throttle of Pressure Compensation Valve of Control Valve..................................10-97
M Machine Controller..............................................10-42 Machine Monitor................................................. 10-32 Machine Monitor System.................................... 10-30 Machine Posture and Procedures to Measure Performance......................................................20-37 Main Pump..........................................................10-60 Main Pump LS Valve...........................................10-70 Main Pump PC Valve.......................................... 10-71 Main Pump Servo Valve......................................10-66 Maintenance Mode Setting............................... 30-127 Maintenance Standard for Arm Cylinder.............60-70 Maintenance Standard for Attachment PPC Valve...... .....................................................................60-54 Maintenance Standard for Blade Cylinder.......... 60-74 Maintenance Standard for Blade PPC Valve...... 60-47 Maintenance Standard for Boom Cylinder.......... 60-68 Maintenance Standard for Boom Swing Cylinder........ .....................................................................60-75 Maintenance Standard for Boom Swing PPC Valve.... .....................................................................60-49 Maintenance Standard for Bucket Cylinder........ 60-72 Maintenance Standard for Carrier Roller............ 60-19 Maintenance Standard for Center Swivel Joint...60-56 Maintenance Standard for Control Valve............ 60-32 Maintenance Standard for Cooling System........ 60-10 Maintenance Standard for Hydraulic Tank.......... 60-25 Maintenance Standard for Idler...........................60-16 Maintenance Standard for Main Pump............... 60-26 Maintenance Standard for Main Pump Servo Valve.... .....................................................................60-27 Maintenance Standard for PC-EPC Valve.......... 60-28 Maintenance Standard for PTO............................ 60-9 Maintenance Standard for Road Liner................ 60-23 Maintenance Standard for Rubber Shoes...........60-24 Maintenance Standard for Sprocket................... 60-14 Maintenance Standard for Swing Circle..............60-11 Maintenance Standard for Swing Machinery...... 60-12 Maintenance Standard for Swing Motor..............60-29 Maintenance Standard for Track Frame and Idler Cushion........................................................60-15 Maintenance Standard for Track Roller.............. 60-18 Maintenance Standard for Track Shoes..............60-20 Maintenance Standard for Travel Motor..............60-31 Maintenance Standard for Travel PPC Valve......60-51 Maintenance Standard for Triple Shoes..............60-22 Maintenance Standard for Work Equipment and Swing PPC Valve......................................... 60-44 Maintenance Standard for Work Equipment Linkage... .....................................................................60-57 Merge-Divider Valve of Control Valve............... 10-104 Motor Part of Travel Motor................................ 10-161 Multi-Control Valve............................................10-141
7
Index
O Operating Condition of Solenoid Valve............... 30-74 Operation of Auto-Deceleration System............. 10-21 Operation of Automatic Gear Shift Valve of Travel Motor..........................................................10-164 Operation of Brake Valve of Swing Motor......... 10-147 Operation of Control Relief Valve......................10-140 Operation of Counterbalance Valve and Check Valve of Travel Motor...........................................10-163 Operation of Cyclone Assembly..........................10-58 Operation of Introduction of LS Pressure in Control Valve.......................................................... 10-100 Operation of Lock Lever Automatic Lock System........ ...................................................................10-124 Operation of Logic Valve of Control Valve.........10-103 Operation of LS Bypass Plug of Control Valve. 10-101 Operation of LS Introduction Throttle of Pressure Compensation Valve of Control Valve..........10-98 Operation of Main Pump..................................... 10-64 Operation of Main Pump Servo Valve.................10-67 Operation of Merge-Divider Valve of Control Valve...... ...................................................................10-106 Operation of Motor Part of Travel Motor........... 10-161 Operation of Parking Brake of Travel Motor......10-163 Operation of Pressure Compensation Valve of Control Valve...................................................... 10-95 Operation of Solenoid Valve............................. 10-139 Operation of Swing and Blade Valve of Control Valve. ................................................................... 10-112 Operation of Swing Modulating Relief Valve of Swing Motor..........................................................10-150 Operation of Swing Motor................................. 10-146 Operation of Swing Parking Brake of Swing Motor...... ...................................................................10-148 Operation of Swing Parking Brake Release Circuit of Control Valve..............................................10-113 Operation of Travel Junction Valve of Control Valve.... ...................................................................10-109 Operation of Travel Pilot Pressure Detection Circuit of Control Valve..............................................10-115 Operation of Unload Valve of Control Valve........10-90 Operation of Work Equipment and Swing PPC Valve.. ...................................................................10-130 Operation of Work Equipment Pilot Pressure Detection Circuit of Control Valve........................10-114 Operator Mode..................................................30-108 Operator Mode Function of Machine Monitor..... 10-38 Outline of Refrigeration Cycle............................. 80-14 Overheat Prevention System.............................. 10-22 Overheat Prevention System Diagram............... 10-22
P Parking Brake of Travel Motor.......................... 10-163 Pilot Circuit Accumulator...................................10-142 Pilot Lamps Shown on Machine Monitor.............10-37 Pm Clinic...........................................................30-162 8
Pm Clinic Check Sheet: PC45MR-5................. 30-163 Pm Clinic Check Sheet: PC55MR-5................. 30-170 Pm Clinic Service..............................................30-162 Power Train.....................................30-35,50-70,60-11 PPC Lock System............................................. 10-122 Practical Use of KOMTRAX................................ 00-46 Precautions Before Work........ 30-11,40-12,50-11,80-9 Precautions for Disconnection and Connection of Air Conditioner Piping....................................... 80-43 Precautions for Disconnection and Connection of Connectors.................................................. 00-51 Precautions for Refrigerant................................. 80-10 Precautions to Prevent Fire................................ 00-28 Precautions When You Clean and Replace KDPF (KCSF and KDOC)...................................... 40-97 Precautions When You Discard Waste Materials00-31 Precautions When You Disconnect and Connect Pipings.............................................................. 00-35 Precautions When You Handle Electrical Equipment... .....................................................................00-42 Precautions When You Handle Fuel System Equipment.............................................................00-44 Precautions When You Handle Hydraulic Equipment.. .....................................................................00-32 Precautions When You Handle Intake System Equipment.............................................................00-45 Preparation for Troubleshooting of Electrical System.. .....................................................................40-54 Pressure Compensation Valve of Control Valve. 10-94 Pressurize Hydraulic Tank.................................. 30-94 Procedure for Troubleshooting............................40-58 Procedure to Close Floor Unit...........................30-101 Procedure to Close Floor Unit: CAB Spec........ 30-103 Procedure to Close Floor Unit: Canopy Spec... 30-101 Procedure to Open Floor Unit............................. 30-96 Procedure to Open Floor Unit: CAB Spec.......... 30-99 Procedure to Open Floor Unit: Canopy Spec..... 30-96 Procedures If Fire Occurs................................... 00-30 PTO.....................................................................10-26
R Receiver Drier..................................................... 80-22 Related Information on Disassembly and Assembly.... .....................................................................50-12 Related Information on Testing and Adjusting.... 30-12 Related Information to Troubleshooting.............. 40-13 Release Remained Pressure in Hydraulic Circuit........ .....................................................................30-38 Remove Air Conditioner Unit Assembly............50-190 Remove and Install Accumulator Assembly......50-137 Remove and Install Air Conditioner Unit Assembly...... ...................................................................50-190 Remove and Install Blade Assembly................ 50-149 Remove and Install Center Swivel Joint Assembly...... ................................................................... 50-118 Remove and Install Counterweight Assembly...50-110
Index
Remove and Install Engine and Main Pump Assembly................................................................ 50-47 Remove and Install Engine Controller Assembly......... ...................................................................50-202 Remove and Install Floor Frame Assembly (Canopy Specification)............................................. 50-171 Remove and Install Front Window Assembly... 50-187 Remove and Install Fuel Tank Assembly............ 50-60 Remove and Install Hydraulic Oil Cooler Assembly..... .....................................................................50-40 Remove and Install Hydraulic Tank Assembly.. 50-125 Remove and Install KDPF Assembly.................. 50-65 Remove and Install KOMTRAX Terminal Assembly.... ...................................................................50-210 Remove and Install Machine Controller Assembly....... ...................................................................50-204 Remove and Install Machine Monitor Assembly.......... ...................................................................50-207 Remove and Install Main Pump Assembly....... 50-131 Remove and Install Operator CAB Assembly (CAB Specification)............................................. 50-164 Remove and Install Operator Cab Glass (Adhered Glass)........................................................ 50-177 Remove and Install Operator Seat....................50-199 Remove and Install Radiator Assembly.............. 50-33 Remove and Install Revolving Frame Assembly.......... ...................................................................50-107 Remove and Install Starter Assembly.................50-31 Remove and Install Supply Pump Assembly...... 50-24 Remove and Install Swing Circle Assembly........50-92 Remove and Install Swing Motor and Swing Machinery Assembly............................................. 50-83 Remove and Install Travel Motor and Final Drive Assembly......................................................... 50-70 Remove and Install Work Equipment Assembly.......... ...................................................................50-151 Remove Blade Assembly..................................50-149 Remove Center Swivel Joint Assembly............ 50-118 Remove Counterweight Assembly.................... 50-110 Remove Engine and Main Pump Assembly........50-47 Remove Engine Controller Assembly............... 50-202 Remove Floor Frame Assembly (Canopy Specification)............................................................50-171 Remove Front Window Assembly.....................50-187 Remove Fuel Tank Assembly............................. 50-60 Remove Hydraulic Tank Assembly................... 50-125 Remove KOMTRAX Terminal Assembly...........50-210 Remove Machine Controller Assembly.............50-204 Remove Machine Monitor Assembly................ 50-207 Remove Main Pump Assembly.........................50-131 Remove Operator CAB Assembly (CAB Specification)............................................................50-164 Remove Operator CAB Glass (Adhered Glass)50-178 Remove Operator's Seat.................................. 50-199 Remove Revolving Frame Assembly................50-107 Remove Starting Motor Assembly...................... 50-31 Remove Supply Pump Assembly........................50-24 Remove Swing Circle Assembly......................... 50-92
Remove Swing Motor and Swing Machinery Assembly................................................................ 50-83 Remove Travel Motor and Final Drive Assembly50-70 Remove Work Equipment Assembly................ 50-151 ROPS CAB....................................................... 10-174
S S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position............................. 40-335 S-10 Engine Oil Consumption is Excessive......40-347 S-11 Oil Becomes Dirty Quickly........................ 40-348 S-12 Fuel Consumption is Excessive............... 40-349 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant...................................................... 40-350 S-14 Oil Pressure Drops................................... 40-351 S-15 Fuel Mixes Into Engine Oil....................... 40-353 S-16 Water Mixes Into Engine Oil (Milky)......... 40-354 S-17 Coolant Temperature Increases Too High (Overheating)......................................................40-355 S-18 Unusual Noise is Heard............................40-356 S-19 Vibration is Excessive.............................. 40-357 S-2 Engine Cranks but No Exhaust Smoke Comes Out............................................................. 40-336 S-20 Air Cannot be Bled from Fuel Circuit........40-358 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).....40-337 S-4 Engine Startability is Unsatisfactory........... 40-338 S-5 Engine Does Not Pick Up Smoothly...........40-340 S-6 Engine Stops During Operation..................40-342 S-7 Engine Runs Rough or is Not Stable..........40-343 S-8 Engine Lacks Power...................................40-344 S-9 KDPF Becomes Clogged in a Short Time.. 40-346 Safety Notice for Operation.................................00-19 Separate and Connect Track Assembly..............50-96 Separate Track Assembly................................... 50-96 Sequence of Events in Troubleshooting............. 40-14 Service Mode.....................................................30-111 Service Mode Function of Machine Monitor........10-39 Set and Operate Machine Monitor.................... 30-105 Set Phone Number Entry.................................. 30-131 Show Service Message.................................... 30-154 Sketch of Tools for Testing and Adjusting........... 30-16 Sketches of Special Tools................................... 50-23 Special Tool List.................................................. 50-18 Specification Drawing........................................... 01-9 Specification Drawing: PC45MR-5........................01-9 Specification Drawing: PC55MR-5......................01-11 Specifications..............................................01-9,01-15 Specifications of Air Conditioner......................... 80-12 Specifications of Compressor............................. 80-18 Specifications of Condenser............................... 80-20 Specifications of Cooling System........................10-28 Specifications of Hydraulic Tank......................... 10-57 Specifications of Idler Cushion..........................10-170 Specifications of Pilot Circuit Accumulator........10-142 Specifications of Receiver Dryer.........................80-22 Specifications of Swing Circle...........................10-153 9
Index
Specifications of Swing Machinery................... 10-151 Specifications of Swing Motor...........................10-145 Specifications of Travel Motor...........................10-160 Specifications of Undercarriage........................ 10-169 Specifications: PC45MR-5.................................. 01-15 Specifications: PC55MR-5.................................. 01-19 Standard Tightening Torque Table...................... 00-69 Standard Value Table for Engine.......................... 20-9 Standard Value Table for Engine: PC45MR-5.......20-9 Standard Value Table for Engine: PC55MR-5..... 20-11 Standard Value Table for Machine...................... 20-13 Standard Value Table for Machine: PC45MR-5.. 20-13 Standard Value Table for Machine: PC55MR-5.. 20-25 Structure and Function of Refrigeration Cycle.... 80-13 Structure of Attachment PPC Valve.................. 10-132 Structure of Bipartite Solenoid Valve................ 10-138 Structure of Blade PPC Valve........................... 10-134 Structure of Boom Swing PPC Valve................ 10-136 Structure of Center Swivel Joint........................10-168 Structure of CLSS............................................... 10-50 Structure of Compressor.....................................80-18 Structure of Condenser.......................................80-20 Structure of Control Valve................................... 10-72 Structure of Fuel Control Dial..............................10-46 Structure of Hydraulic Tank.................................10-56 Structure of Hydraulic Tank Breather.................. 10-59 Structure of Hydraulic Tank Oil Filler Cap........... 10-58 Structure of Idler Cushion................................. 10-170 Structure of KOMTRAX Terminal........................ 10-40 Structure of Machine Controller.......................... 10-42 Structure of Main Pump...................................... 10-60 Structure of Main Pump Servo Valve.................. 10-66 Structure of Multi-Control Valve........................ 10-141 Structure of Pilot Circuit Accumulator............... 10-142 Structure of PTO................................................. 10-26 Structure of Receiver Dryer................................ 80-22 Structure of ROPS CAB....................................10-174 Structure of Swing and Blade Valve of Control Valve... ................................................................... 10-111 Structure of Swing Circle.................................. 10-153 Structure of Swing Machinery........................... 10-151 Structure of Swing Motor.................................. 10-144 Structure of Tilt Type Floor................................10-175 Structure of Travel Motor.................................. 10-158 Structure of Travel PPC Valve.......................... 10-166 Structure of Valve Control................................. 10-120 Structure of Work Equipment............................10-171 Structure of Work Equipment and Swing PPC Valve... ...................................................................10-127 Surface Area Ratio of Pressure Compensation Valve of Control Valve............................................10-96 Swing and Blade Valve of Control Valve........... 10-111 Swing Circle...................................................... 10-153 Swing Machinery...............................................10-151 Swing Modulating Valve of Swing Motor...........10-150 Swing Motor...................................................... 10-144 Swing Parking Brake of Swing Motor................10-148
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Swing Parking Brake Release Circuit of Control Valve ................................................................... 10-113 Swing System................................................... 10-143 Symbols Used in Electric Circuit Diagram.......... 90-19 Symbols Used in Hydraulic Circuit Diagram......... 90-9 Symptom and Troubleshooting Numbers............40-61 System Diagram of Auto-Deceleration System...10-20 System Diagram of Automatic Idle Stop System 10-24 System Diagram of Engine Control.....................10-16 System Diagram of KOMTRAX System..............10-31 System Diagram of Machine Monitor System.....10-30 System Diagram of PPC Lock.......................... 10-122 System Diagram of System Operating Lamp System.. .....................................................................10-12 System Diagram of Travel Control System....... 10-156 System Operating Lamp System........................ 10-12
T T-Branch Box and T-Branch Adapter Table........ 40-87 Table of Fuel, Coolant, and Lubricants............... 01-27 Table of Pre-defined Monitoring Items.............. 30-113 Table of Self-Define Monitor Items.................... 30-118 Test in Accordance with Testing Procedure........ 40-20 Testing Menu (Active Regeneration for Service).......... ...................................................................30-139 Testing Menu (Cylinder Cutout Mode Operation)......... ...................................................................30-138 Testing Menu (KDPF Memory Reset)............... 30-141 Testing Menu (Rail Pressure Memory Reset)... 30-143 Tilt Type Floor................................................... 10-175 Tools for Testing and Adjusting........................... 30-12 Travel Junction Valve of Control Valve..............10-108 Travel Motor...................................................... 10-158 Travel Pilot Pressure Detection Circuit of Control Valve.......................................................... 10-114 Travel PPC Valve.............................................. 10-166 Travel System................................................... 10-154 Troubleshooting by Failure Code (Display of Code).... ...................................................................40-109 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)........................................... 40-277 Troubleshooting of Electrical System (E-Mode)40-212 Troubleshooting of Engine (S-Mode)................ 40-334
U Undercarriage and Frame.. 10-169,30-36,50-93,60-15 Unload Valve of Control Valve.............................10-86 Usage Limitation and Maintenance Password Change Function....................................... 30-108
W Weight Table....................................................... 01-23 Weight Table: PC45MR-5................................... 01-23 Weight Table: PC55MR-5................................... 01-25 Work Equipment......................... 10-171,50-149,60-57 Work Equipment and Swing PPC Valve............10-127
Index
Work Equipment and Travel Automatic Lock System.. ...................................................................10-124 Work Equipment Clearance Adjustment Shim..10-173 Work Equipment Pilot Pressure Detection Circuit of Control Valve..............................................10-113 Work Equipment System...................................10-116 Working Range Drawings................................... 01-13 Working Range: PC45MR-5............................... 01-13 Working Range: PC55MR-5............................... 01-14
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PC45MR-5, PC55MR-5 COMPACT HYDRAULIC EXCAVATOR Form No. SEN06574-14
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