Komatsu PC45MR-5 User manual

HYDRAULIC
EXCAVATOR
TEN00763-04
PC45MR-5
PC55MR-5
SERIAL NUMBERS
PC45MR-30403
PC55MR-20398
and up
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
NOTICE
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
WARNING

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some ofits
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and
related accessories contain lead
and lead compounds, chemicals
known to the State of California
to cause cancer, birth defects and
reproductive harm.
Wash hands after handling.
FOREWORD
1-1

READ THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the storing location so that all relevant personnel can
read it at any time.
Keep it in the pocket inside the cover of toolbox under the oper-
ator's seat.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the
latest available information concerning your machine or with questions regarding information contained in this
manual.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.
READ THIS MANUAL FOREWORD
1-2

SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
1-3

INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
•Digging work
• Ditching work
• Loading work
• Leveling work
• Demolition work
For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
DIRECTIONS OF MACHINE
(A) Front
(B) Rear
(C) Left
(D) Right
(E) Operator's seat
(F) Sprocket
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
PROTECTIVE STRUCTURES
This machine is equipped with a structure to protect the operator (ROPS) conforming to ISO3471:2008.
INTRODUCTION FOREWORD
1-4

PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-
AL NO. PLATE
It is located on the front left of revolving frame.
The design of the nameplate varies according to the district.
LOCATION OF ENGINE NUMBER PLATE
This is located on the side of the intake manifold.
FOREWORD PRODUCT INFORMATION
1-5

SERVICE METER LOCATION
This is displayed on the machine monitor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Distributor name
Address
Phone/Fax
Service personnel
PRODUCT INFORMATION FOREWORD
1-6

TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
READ THIS MANUAL............................................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-3
INTRODUCTION ...................................................................................................................................... 1-4
MAIN USE OF MACHINE .................................................................................................................. 1-4
DIRECTIONS OF MACHINE.............................................................................................................. 1-4
PROTECTIVE STRUCTURES........................................................................................................... 1-4
PRODUCT INFORMATION....................................................................................................................... 1-5
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ........ 1-5
LOCATION OF ENGINE NUMBER PLATE ........................................................................................ 1-5
SERVICE METER LOCATION........................................................................................................... 1-6
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................................................. 1-6
SAFETY........................................................................................................................................................... 2-1
SAFETY LABELS ..................................................................................................................................... 2-2
LOCATION OF SAFETY LABELS...................................................................................................... 2-3
CONTENTS OF SAFETY LABELS .................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-13
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-13
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-14
PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-18
DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-19
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-20
PROTECTION AGAINST FALLING, FLYING OR INTRUDING OBJECTS....................................... 2-21
UNAUTHORIZED MODIFICATION .................................................................................................. 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-21
PRECAUTIONS RELATED TO CAB GLASS ................................................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING..................................................... 2-22
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-23
PRECAUTIONS FOR JOBSITE....................................................................................................... 2-23
START ENGINE............................................................................................................................... 2-26
PRECAUTIONS FOR OPERATION ................................................................................................. 2-28
PRECAUTIONS FOR TRANSPORTATION...................................................................................... 2-36
TOWING AND BEING TOWED........................................................................................................ 2-37
LIFTING OPERATION BY USING BUCKET WITH HOOK ............................................................... 2-38
PRECAUTIONS FOR MAINTENANCE................................................................................................... 2-39
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-39
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-43
OPERATION .................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES................................................................................................. 3-4
OTHER EQUIPMENT NAME............................................................................................................. 3-7
EXPLANATION OF COMPONENTS......................................................................................................... 3-9
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................... 3-9
SWITCHES...................................................................................................................................... 3-77
CONTROL LEVERS AND PEDALS................................................................................................. 3-86
OTHER EQUIPMENT ...................................................................................................................... 3-94
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-131
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-131
METHOD FOR STARTING ENGINE.............................................................................................. 3-158
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-161
METHOD FOR STOPPING ENGINE ............................................................................................. 3-169
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MA-
CHINE........................................................................................................................................ 3-170
METHOD FOR STEERING MACHINE........................................................................................... 3-176
FOREWORD TABLE OF CONTENTS
1-7

METHOD FOR SWINGING MACHINE .......................................................................................... 3-178
METHOD FOR OPERATING WORK EQUIPMENT ....................................................................... 3-179
HANDLE WORKING MODE .......................................................................................................... 3-182
PROHIBITED OPERATIONS ......................................................................................................... 3-183
PRECAUTIONS FOR OPERATION ............................................................................................... 3-188
PRECAUTIONS FOR WORKING ON SLOPE ............................................................................... 3-190
METHOD FOR ESCAPING FROM MUD ....................................................................................... 3-192
RECOMMENDED APPLICATIONS................................................................................................ 3-193
METHOD FOR REPLACING BUCKET .......................................................................................... 3-195
METHOD FOR PARKING MACHINE............................................................................................. 3-197
METHOD FOR CHECKING AFTER FINISHING WORK................................................................ 3-199
LOCK............................................................................................................................................. 3-199
HANDLE AIR CONDITIONER............................................................................................................... 3-210
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-210
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-212
HANDLE RUBBER AND ROAD LINERS SHOES................................................................................. 3-214
RECOMMENDED USE OF RUBBER AND ROAD LINERS SHOES.............................................. 3-214
COMPARISON OF RUBBER ,ROAD LINERS SHOES AND STEEL SHOES ................................ 3-214
WARRANTY OF RUBBER AND ROAD LINERS SHOES .............................................................. 3-214
PROHIBITED OPERATIONS WHEN USING RUBBER AND ROAD LINERS SHOES................... 3-215
PRECAUTIONS FOR USING RUBBER AND ROAD LINERS SHOES .......................................... 3-216
TRANSPORTATION.............................................................................................................................. 3-219
PRECAUTIONS FOR TRANSPORTING MACHINE ...................................................................... 3-219
SELECT TRANSPORTATION METHOD........................................................................................ 3-219
LOADING AND UNLOADING WITH TRAILER .............................................................................. 3-220
METHOD FOR LIFTING MACHINE............................................................................................... 3-226
COLD WEATHER OPERATION............................................................................................................ 3-229
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-229
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER................................ 3-231
AFTER COLD WEATHER SEASON .............................................................................................. 3-231
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-232
PREPARATION FOR LONG-TERM STORAGE............................................................................. 3-232
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-233
STARTING MACHINE AFTER LONG-TERM STORAGE............................................................... 3-233
TROUBLES AND ACTIONS ................................................................................................................. 3-234
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-234
PHENOMENA THAT ARE NOT FAILURES ................................................................................... 3-236
PRECAUTIONS FOR TOWING MACHINE.................................................................................... 3-237
PRECAUTIONS FOR SEVERE JOB CONDITION......................................................................... 3-237
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-238
OTHER TROUBLE......................................................................................................................... 3-244
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR WELDING ....................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-2
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
PRECAUTIONS WHEN SWINGING BOOM ...................................................................................... 4-3
PRECAUTIONS WHEN OPENING AND CLOSING COOLING COVER............................................ 4-3
TABLE OF CONTENTS FOREWORD
1-8

BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-4
FIX FLOOR SECURELY .................................................................................................................... 4-4
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
HANDLE HYDRAULIC COMPONENTS........................................................................................... 4-10
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...............................................................4-11
MAINTENANCE SCHEDULE.................................................................................................................. 4-13
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-13
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER ............................................................. 4-14
MAINTENANCE PROCEDURE .............................................................................................................. 4-15
INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) .................................. 4-15
WHEN REQUIRED .......................................................................................................................... 4-16
CHECKS BEFORE STARTING........................................................................................................ 4-63
EVERY 100 HOURS MAINTENANCE ............................................................................................. 4-64
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-67
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-69
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-85
EVERY 1500 HOURS MAINTENANCE ........................................................................................... 4-88
EVERY 2000 HOURS MAINTENANCE ........................................................................................... 4-89
EVERY 3000 HOURS MAINTENANCE ........................................................................................... 4-98
EVERY 4000 HOURS MAINTENANCE ........................................................................................... 4-99
EVERY 6000 HOURS MAINTENANCE ......................................................................................... 4-101
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
SPECIFICATIONS: PC45MR-5.......................................................................................................... 5-2
SPECIFICATIONS: PC55MR-5.......................................................................................................... 5-4
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS.................................................................. 6-2
PRECAUTIONS WHEN SELECTING ................................................................................................ 6-2
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY....................................... 6-2
PRECAUTIONS WHEN REMOVING AND INSTALLING ................................................................... 6-2
PRECAUTIONS FOR USING ............................................................................................................ 6-3
HANDLE BUCKET WITH HOOK............................................................................................................... 6-4
PRECAUTIONS FOR OPERATION ................................................................................................... 6-4
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT .................................................... 6-5
EXPLANATION OF COMPONENTS ON MACHINES WITH ATTACHMENT ..................................... 6-5
METHOD FOR CHANGING OVER AND CONNECTING HYDRAULIC CIRCUIT OF MACHINES
READY FOR INSTALLATION OF ATTACHMENT .......................................................................... 6-9
METHOD FOR OPERATING ATTACHMENT................................................................................... 6-12
LONG-TERM STORAGE ................................................................................................................. 6-18
SPECIFICATIONS ........................................................................................................................... 6-18
OTHER TROUBLE........................................................................................................................... 6-18
BATTERY DISCONNECT SWITCH ........................................................................................................ 6-19
SYSTEM OPERATING LAMP................................................................................................................. 6-21
HANDLE HEATER .................................................................................................................................. 6-22
EXPLANATION OF HEATER COMPONENTS................................................................................. 6-22
METHOD FOR USING HEATER...................................................................................................... 6-23
HANDLE RADIO ..................................................................................................................................... 6-24
EXPLANATION OF RADIO EQUIPMENT ........................................................................................ 6-24
METHOD FOR CONTROLLING RADIO .......................................................................................... 6-27
STOW ANTENNA ............................................................................................................................ 6-29
CONTROL PATTERNS OTHER THAN STANDARD CONTROL METHOD (FOR MACHINES EQUIPPED
WITH OPERATION PATTERN CHANGE-OVER VALVE) .................................................................... 6-30
METHOD FOR CHANGING CONTROL PATTERNS ....................................................................... 6-31
FOREWORD TABLE OF CONTENTS
1-9