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KOMATSU PC18MR-2 SERVICE REPAIR MANUAL (SN:15001 & UP) KOMATSU PC18MR-2 – PDF DOWNLOAD
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- KOMATSU PC18MR-2 SERVICE REPAIR MANUAL
- SERIAL NUMBER:15001 & UP
- PUBLICATION NUMBER:SEBM038404
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Description
KOMATSU PC18MR-2 SERVICE REPAIR MANUAL (SN:15001 & UP) KOMATSU PC18MR-2
KOMATSU PC18MR-2 SERVICE REPAIR MANUAL (SN:15001 & UP) KOMATSU PC18MR-2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC18MR-2 SERVICE REPAIR MANUAL (SN:15001 & UP) KOMATSU PC18MR-2
- 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 SERVICE REPAIR MANUAL (SN:15001 & UP) KOMATSU PC18MR-2
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
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