Komatsu PC18MR-2 Excavator Shop Manual SEBM038404 PDF

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Komatsu PC18MR-2 Excavator Shop Manual SEBM038404 – PDF DOWNLOAD

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Komatsu PC18MR-2 Excavator Shop Manual SEBM038404 – PDF DOWNLOAD 

Language : English
Pages : 391
Downloadable : Yes
File Type : PDF

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Komatsu PC18MR-2 Excavator Shop Manual SEBM038404 – PDF DOWNLOAD 

Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
Testing and adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu PC18MR-2 Excavator Shop Manual SEBM038404 – PDF DOWNLOAD 

COVER 1
CONTENTS 2
01 GENERAL 27
SPECIFICATION DIMENSION DRAWING 28
WORKING RANGE DRAWING 29
SPECIFICATIONS 30
WEIGHT TABLE 33
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS 35
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD 36
PTO 37
COOLING SYSTEM 38
POWER TRAIN 40
SWING CIRCLE 41
TRACK FRAME 42
IDLER CUSHION 43
IDLER 45
TRACK ROLLER 46
SPROCKET 47
TRACK SHOE 48
HYDRAULIC COMPONENTS LAYOUT DRAWING 50
HYDRAULIC TANK 51
CENTER SWIVEL JOINT 52
TRAVEL MOTOR 53
HYDRAULIC CYLINDER 62
SOLENOID VALVE 65
VARIABLE GAUGE VALVE 68
MULTI-CONTROL VALVE 69
HYDRAULIC PUMP 70
CONTROL VALVE 76
CLSS 88
OPERATION FOR EACH FUNCTION AND VALVE 91
SWING MOTOR 104
PPC VALVE 107
WORK EQUIPMENT 115
DIMENSIONS OF EACH PART OF WORK EQUIPMENT 118
FLOOR 121
ENGINE CONTROL 122
ELECTRIC CONTROL SYSTEM 124
COMPONENT PARTS OF SYSTEM 129
MONITOR SYSTEM 130
MONITOR PANEL 131
SENSORS 133
20 TESTING AND ADJUSTING 135
STANDARD VALUE TABLE FOR ENGING RELATED PARTS 136
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 137
TESTING AND ADJUSTING 146
LIST OF TESTING, ADJUSTING,AND TROUBLESHOOTING TOOLS 147
MEASURING ENGINE SPEED 149
MEASURING OF EXHAUST GAS COLOR 150
ADJUSTING VALVE CLEARANCE 151
TESTING COMPRESSION PRESSURE 153
TESTING ENGINE OIL PRESSURE 154
TESTING AND ADJUSTING FUEL INJECTION TIMING 155
ADJUSTING ENGINE STOP SOLENOID 157
BLEEDING AIR FROM FUEL CIRCUIT 158
TESTING AND ADJUSTING FAN BELT TENSION 159
ADJUSTING FUEL CONTROL LEVER LINKAGE 160
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 161
TESTING AND ADJUSTING TRACK SHOE TENSION 162
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT,TRAVEL,SWING,AND BLADE CIRCUITS 164
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE 167
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE 169
MEASURING SOLENOID VALVE OUTPUT PRESSURE 171
MEASURING PPC VALVE OUTPUT PRESSURE 173
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 175
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE 175
TESTING OIL LEAKAGE FORM CYLINDER 177
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 179
BLEEDING AIR FROM CYLINDER 179
PRESSURIZING HYDRAULIC TANK 180
HOW TO OPEN AND CLOSE(TILT) FLOOR 181
INSPECTION PROCEDURES FOR DIODE 183
TROUBLESHOOTING 184
POINTS TO REMEMBER WHEN TROUBLESHOOTING 185
SEQUENCE OF EVENTS IN TROUBLESHOOTING 186
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 187
CHECKS BEFORE TROUBLESHOOTING 195
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 196
CONNECTORS LIST AND CONNECTORS ARRANGEMENT STEREOGRAM 198
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 202
T-ADAPTER-BOXES AND T-ADAPTER TABLE 225
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 228
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM(E MODE) 229
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 231
E-1 ENGINE DOES NOT START 232
E-2 ENGINE DOES NOT STOP 238
E-3 ENGINE OIL PRESSURE MONITOR DOES NOT INDICATE NORMALLY 240
E-4 CHARGE LEVEL MONITOR DOES NOT INDICATE NORMALLY 243
E-5 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY 246
E-6 SERVICE METER DOES NOT OPERATE NORMALLY 249
E-7 PREHEATING SYSTEM DOES NOT OPERATE NORMALLY 251
E-8 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY 254
E-9 ENGINE COOLANT TEMPERATURE MONITOR DOES NOT INDICATE NORMALLY 258
E-10 LOCK LEVER DOES NOT OPERATE NORMALLY 262
E-11 BLADE/VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE NORMALLY 265
E-12 NIGHT LAMP OF MACHINE MONITOR AND WORKING LAMP DO NOT LIGHT UP 268
E-13 TRAVEL ALARM DOES NOT SOUND OR DOES NOT SOUNDING 271
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 274
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 275
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT,TRAVEL,SWING,AND BLADE IS LOW 276
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS 277
H-3 WHOLE WORK EQUIPMENT,TRAVEL SYSTEM,SWING SYSTEM,AND BLADE DO NOT MOVE 278
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP 279
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW 279
H-6 SPEED OR POWER OF BOOM IS LOW 280
H-7 SPEED OR POWER OF ARM IS LOW 281
H-8 SPEED OR POWER OF BUCKET IS LOW 282
H-9 SPEED OR POWER OF BOOM SWING IS LOW 283
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY 283
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE 284
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE 285
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT,SPEED OF PART LOADED MORE IS LOW 285
H-14 MACHINE DEVIATES DURING TRAVEL 286
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW 288
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 288
H-17 TRAVEL SPEED DOES NOT CHANGE 289
H-18 TRAVEL MOTOR DOES NOT WORK(ONE SIDE ONLY) 289
H-19 SPEED OR POWER OF SWING IS LOW 290
H-20 MACHINE DOES NOT SWING 292
H-21 SWING ACCELERATION PERFORMANCE IS LOW 294
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING 295
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING 296
H-24 WHEN UPPER STRUCTURE STOPS SWINGING,IT MAKES LARGE SOUND 296
H-25 HYDRAULIC DRIFT OF SWING IS LARGE 297
H-26 SPEED OR POWER OF BLADE IS LOW 298
H-27 BLADE DOES NOT MOVE 299
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE 299
H-29 VARIABLE GAUGE DOES NOT MOVE 300
H-30 TROUBLESHOOTING FOR HYDRAULIC BREAKER 301
TROUBLESHOOTING OF ENGINE(S MODE) 304
TROUBLESHOOTING CHART 305
30 DISASSEMBLY AND ASSEMBLY 309
HOW TO READ THIS MANUAL 310
PRECAUTIONS WHEN PERFORMING OPERATION 312
SPECIAL TOOL LIST 314
SKETCH OF SPECIAL TOOLS 316
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 320
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 321
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 323
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY 324
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 328
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 329
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING 330
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 332
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY 333
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 342
REMOVAL AND INSTALLATION OF REVOLVING FRAME 347
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY 350
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY 351
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 360
REMOVAL AND INSTALLATION OF HYDRAULIC SYSTEM AND CENTER SWIVEL JOINT ASSEMBLY 364
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 366
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY 368
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY 369
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 376
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 378
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC BREAKER ASSEMBLY 382
90 OTHERS 389
HYDRAULIC CIRCUIT DIAGRAM 390
ELECTRICAL CIRCUIT DIAGRAM 391

S.V  21/12/24