Komatsu PC18MR-2 Hydraulic Excavator Shop Manual SEBM038402 PDF

Description

Komatsu PC18MR-2 Hydraulic Excavator Shop Manual SEBM038402 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC18MR-2 Hydraulic Excavator Shop Manual SEBM038402 – PDF DOWNLOAD

Language : English
Pages :389
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC18MR-2 Hydraulic Excavator Shop Manual SEBM038402 – PDF DOWNLOAD

Machine model Serial number
PC18MR-2 15001 and up

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 Hydraulic Excavator Shop Manual SEBM038402 – PDF DOWNLOAD

Machine model Serial number
PC18MR-2 15001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWORD 8
GENERAL 8
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
SPECIFICATION DIMENSION DRAWING 27
WORKING RANGE DRAWING 28
SPECIFICATIONS 29
WEIGHT TABLE 32
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 34
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 36
PTO 37
COOLING SYSTEM 39
POWER TRAIN 41
SWING CIRCLE 42
TRACK FRAME 43
IDLER CUSHION 44
IDLER 46
TRACK ROLLER 47
SPROCKET 48
TRACK SHOE 49
HYDRAULIC COMPONENTS LAYOUT DRAWING 51
HYDRAULIC TANK 52
CENTER SWIVEL JOINT 53
TRAVEL MOTOR 54
HYDRAULIC CYLINDER 63
SOLENOID VALVE 66
VARIABLE GAUGE VALVE 69
MULTI-CONTROL VALVE 70
HYDRAULIC PUMP 71
CONTROL VALVE 77
CLSS 89
OPERATION FOR EACH FUNCTION AND VALVE 93
SWING MOTOR107
PPC VALVE111
WORK EQUIPMENT120
DIMENSIONS OF EACH PART OF WORK EQUIPMENT123
FLOOR126
ENGINE CONTROL127
ELECTRIC CONTROL SYSTEM129
COMPONENT PARTS OF SYSTEM134
MONITOR SYSTEM135
MONITOR PANEL136
SENSORS138
20 TESTING AND ADJUSTING140
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS141
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS142
TESTING AND ADJUSTING152
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS153
MEASURING ENGINE SPEED155
MEASUREMENT OF EXHAUST GAS COLOR156
ADJUSTING VALVE CLEARANCE157
TESTING COMPRESSION PRESSURE159
TESTING ENGINE OIL PRESSURE 160
TESTING AND ADJUSTING FUEL INJECTION TIMING161
ADJUSTING ENGINE STOP SOLENOID163
BLEEDING AIR FROM FUEL CIRCUIT164
TESTING AND ADJUSTING FAN BELT TENSION165
ADJUSTING FUEL CONTROL LEVER LINKAGE166
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS167
TESTING AND ADJUSTING TRACK SHOE TENSION168
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, SWING, AND BLADE CIRCUITS170
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE173
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE175
MEASURING SOLENOID VALVE OUTPUT PRESSURE177
MEASURING PPC VALVE OUTPUT PRESSURE179
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES181
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE181
TESTING OIL LEAKAGE FROM CYLINDER183
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT185
BLEEDING AIR FROM CYLINDER185
PRESSURIZING HYDRAULIC TANK186
HOW TO OPEN AND CLOSE (TILT) FLOOR187
INSPECTION PROCEDURES FOR DIODE189
TROUBLESHOOTING190
POINTS TO REMEMBER WHEN TROUBLESHOOTING191
SEQUENCE OF EVENTS IN TROUBLESHOOTING192
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE193
CHECKS BEFORE TROUBLESHOOTING201
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING202
CONNECTORS LIST AND CONNECTORS ARRANGEMENT STEREOGRAM204
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS209
T-ADAPTER – BOXES AND T-ADAPTER TABLE232
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)236
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E MODE)237
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE239
E-1 ENGINE DOES NOT START240
E-2 ENGINE DOES NOT STOP247
E-3 ENGINE OIL PRESSURE MONITOR DOES NOT INDICATE NORMALLY249
E-4 CHARGE LEVEL MONITOR DOES NOT INDICATE NORMALLY252
E-5 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY255
E-6 SERVICE METER DOES NOT OPERATE NORMALLY258
E-7 PREHEATING SYSTEM DOES NOT OPERATE NORMALLY260
E-8 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY263
E-9 ENGINE COOLANT TEMPERATURE MONITOR DOES NOT INDICATE NORMALLY267
E-10 LOCK LEVER DOES NOT OPERATE NORMALLY271
E-11 BLADE/VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE NORMALLY274
E-12 NIGHT LAMP OF MACHINE MONITOR AND WORKING LAMP DO NOT LIGHT UP277
E-13 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING280
TOUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)284
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE285
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW286
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS287
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT MOVE288
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP289
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW289
H-6 SPEED OR POWER OF BOOM IS LOW290
H-7 SPEED OR POWER OF ARM IS LOW291
H-8 SPEED OR POWER OF BUCKET IS LOW292
H-9 SPEED OR POWER OF BOOM SWING IS LOW293
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY293
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE294
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE295
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW295
H-14 MACHINE DEVIATES DURING TRAVEL296
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW298
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW298
H-17 TRAVEL SPEED DOES NOT CHANGE299
H-18 TRAVEL MOTOR DOES NOT WORK (ONE SIDE ONLY)299
H-19 SPEED OR POWER OF SWING IS LOW300
H-20 MACHINE DOES NOT SWING302
H-21 SWING ACCELERATION PERFORMANCE IS LOW304
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING305
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING306
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND306
H-25 HYDRAULIC DRIFT OF SWING IS LARGE307
H-26 SPEED OR POWER OF BLADE IS LOW308
H-27 BLADE DOES NOT MOVE309
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE309
H-29 VARIABLE GAUGE DOES NOT MOVE310
TROUBLESHOOTING OF ENGINE (S MODE)312
TROUBLESHOOTING CHART313
30 DISASSEMBLY AND ASSEMBLY317
HOW TO READ THIS MANUAL318
PRECAUTIONS WHEN PERFORMING OPERATION320
SPECIAL TOOL LIST322
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY324
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY325
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY328
REMOVAL AND INSTALLATION OF HYRAULIC OIL COOLER ASSEMBLY327
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY332
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY333
DISASSEMBLY AND ASSEMBLY OF RECOIIL SPRING334
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY336
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY337
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY346
REMOVAL AND INSTALLATION OF REVOLVING FRAME351
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY354
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY355
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY364
REMOVAL AND INSTALLATION OF HYDRAULIC SYSTEM AND CENTER SWIVEL JOINT ASSEMBLY368
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY370
REMOVAL AND INSTALLATION SWING MOTOR ASSEMBLY 372
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY373
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY380
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY382
90 OTHERS386
HYDRAULIC CIRCUIT DIAGRAM388
ELECTRICAL CIRCUIT DIAGRAM389

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24