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Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual
SERIAL NUMBERS : 20001 and up
Book Code: SEN04306-04
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Description
Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC18MR-3
Serial Number: 20001 and up
Book Code: SEN04306-04
Language: English
Pages: 500
File Format: Portable Document Format (PDF)
KOMATSU PC18MR-3 20001 AND UP HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual
COVER .............................................................................................................. 1 00 Index and foreword............................................................................................... 0 100 Index....................................................................................................... 2 Composition of shop manual.................................................................................. 3 Table of contents........................................................................................... 5 200 Foreword and general information............................................................................ 10 Safety notice............................................................................................... 11 How to read the shop manual................................................................................. 16 Explanation of terms for maintenance standard............................................................... 18 Handling of electric equipment and hydraulic component...................................................... 20 Handling of connectors newly used for engines............................................................... 29 How to read electric wire code.............................................................................. 32 Precautions when carrying out operation..................................................................... 35 Method of disassembling and connecting push-pull type coupler............................................... 38 Standard tightening torque table............................................................................ 41 Conversion table............................................................................................ 45 01 Specification.................................................................................................... 0 100 Specification and technical data............................................................................ 52 Specification dimension drawing............................................................................. 53 Working range drawing....................................................................................... 54 Specifications.............................................................................................. 55 Weight table................................................................................................ 58 Table of fuel, coolant and lubricants....................................................................... 60 10 Structure, function and maintenance standard..................................................................... 0 100 Engine and cooling system................................................................................... 62 PTO......................................................................................................... 63 Cooling system.............................................................................................. 65 200 Power train................................................................................................. 68 Power train................................................................................................. 69 Swing circle................................................................................................ 70 300 Undercarriage and frame..................................................................................... 72 Track frame................................................................................................. 73 Idler cushion............................................................................................... 74 Idler....................................................................................................... 76 Track roller................................................................................................ 77 Sprocket.................................................................................................... 78 Track shoe.................................................................................................. 79 410 Hydraulic system, Part 1.................................................................................... 82 Hydraulic components layout drawing......................................................................... 83 Hydraulic tank.............................................................................................. 84 Center swivel joint......................................................................................... 85 Travel motor................................................................................................ 86 Hydraulic cylinder.......................................................................................... 95 Solenoid valve.............................................................................................. 99 Variable gauge valve........................................................................................102 Multi-control valve (If equipped)...........................................................................103 420 Hydraulic system, Part 2....................................................................................106 Hydraulic pump..............................................................................................107 Control valve...............................................................................................113 430 Hydraulic system, Part 3....................................................................................124 CLSS........................................................................................................125 Operation for each function and valve.......................................................................129 Swing motor.................................................................................................143 PPC valve...................................................................................................146 500 Work equipment..............................................................................................156 Work equipment..............................................................................................158 Dimensions of each part of work equipment...................................................................161 600 Cab and its attachments.....................................................................................166 Floor.......................................................................................................167 700 Electrical system...........................................................................................170 Engine control system.......................................................................................171 Electric control system.....................................................................................173 Component parts of system...................................................................................178 KOMTRAX system..............................................................................................179 Monitor system..............................................................................................182 Sensors.....................................................................................................185 20 Standard value table............................................................................................. 0 100 Standard service value table................................................................................188 Standard value table for engine related parts...............................................................189 Standard value table for chassis related parts..............................................................190 30 Testing and adjusting............................................................................................ 0 100 Testing and adjusting.......................................................................................200 List of testing, adjusting, and troubleshooting tools.......................................................202 Measuring engine speed......................................................................................204 Measurement of exhaust gas color............................................................................205 Adjusting valve clearance...................................................................................206 Testing compression pressure................................................................................208 Testing engine oil pressure.................................................................................209 Testing and adjusting fuel injection timing.................................................................210 Adjusting engine stop solenoid..............................................................................212 Bleeding air from fuel circuit..............................................................................213 Testing and adjusting fan belt tension......................................................................214 Adjusting fuel control lever linkage........................................................................215 Measurement of clearance in swing circle bearings...........................................................216 Testing and adjusting track shoe tension....................................................................217 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits....................219 Testing and adjusting control circuit basic pressure........................................................222 Testing and adjusting pump LS differential pressure.........................................................224 Measuring solenoid valve output pressure....................................................................226 Measuring PPC valve output pressure.........................................................................228 Adjusting play of work equipment and swing PPC valves.......................................................230 Measuring swing holding brake release pressure..............................................................230 Testing oil leakage from cylinder...........................................................................232 Releasing residual pressure from hydraulic circuit..........................................................234 Bleeding air from cylinder..................................................................................234 Pressurizing hydraulic tank.................................................................................235 How to open and close (tilt) floor..........................................................................236 Inspection procedures for diode.............................................................................238 How to start operation of KOMTRAX terminal..................................................................239 Lamp display of KOMTRAX terminal............................................................................243 Removal and installation of KOMTRAX terminal................................................................246 Preparation work for troubleshooting of electrical system...................................................247 40 Troubleshooting.................................................................................................. 0 100 General information on troubleshooting......................................................................250 Points to remember when troubleshooting.....................................................................251 Sequence of events in troubleshooting.......................................................................252 Checks before troubleshooting...............................................................................253 Classification and procedures of troubleshooting............................................................254 Connection table for connector pin numbers..................................................................257 T- branch box and T- branch adapter table...................................................................293 200 Troubleshooting of electrical system (E-mode)...............................................................298 Before carrying out troubleshooting for electrical system (E-mode)..........................................299 Information contained in troubleshooting table..............................................................301 E-1 Engine does not start...................................................................................302 E-2 Engine does not stop....................................................................................309 E-3 When starting switch is turned ON, any item does not operate............................................311 E-4 When starting switch is turned ON, some items do not operate............................................313 E-5 Alarm buzzer is abnormal................................................................................314 E-6 Engine oil pressure caution is turned ON................................................................316 E-7 Charge level caution is turned ON.......................................................................317 E-8 Preheating system does not operate or preheater does not become hot.....................................319 E-9 Coolant temperature gauge is abnormal...................................................................321 E-10 Fuel level gauge is abnormal...........................................................................325 E-11 Service meter does not operate while engine is running.................................................329 E-12 2nd travel speed is not selected.......................................................................332 E-13 Working lamp does not light up.........................................................................335 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves....337 E-15 Blade/Variable gauge selector system does not operate normally.........................................340 300 Troubleshooting of hydraulic and mechanical system (H-mode).................................................344 Information contained in troubleshooting table..............................................................346 H-1 Speed or power of whole work equipment, travel, swing, and blade is low.................................347 H-2 Engine speed lowers extremely or engine stalls..........................................................348 H-3 Whole work equipment, travel system, swing system, and blade do not move................................349 H-4 Abnormal sound comes out from around hydraulic pump.....................................................350 H-5 Fine control performance or response is low.............................................................350 H-6 Speed or power of boom is low...........................................................................351 H-7 Speed or power of arm is low............................................................................352 H-8 Speed or power of bucket is low.........................................................................353 H-9 Speed or power of boom swing is low.....................................................................354 H-10 Work equipment does not move singly....................................................................354 H-11 Work equipment hydraulic drift is large................................................................355 H-12 Time lag of work equipment is large....................................................................356 H-13 In compound operation of work equipment, speed of part loaded more is low..............................356 H-14 Machine deviates during travel.........................................................................357 H-15 Travel speed or travel power is low....................................................................359 H-16 Machine is not steered well or steering power is low...................................................359 H-17 Travel speed does not change...........................................................................360 H-18 Travel motor does not work (one side only).............................................................360 H-19 Speed or power of swing is low.........................................................................361 H-20 Machine does not swing.................................................................................363 H-21 Swing acceleration performance is low..................................................................365 H-22 Machine overruns when it stops swinging................................................................366 H-23 Large shock is made when machine stops swinging........................................................367 H-24 When upper structure stops swinging, it makes large sound..............................................367 H-25 Hydraulic drift of swing is large......................................................................368 H-26 Speed or power of blade is low.........................................................................369 H-27 Blade does not move....................................................................................370 H-28 Hydraulic drift of blade is large......................................................................370 H-29 Variable gauge does not move...........................................................................371 H-30 Troubleshooting for hydraulic breaker..................................................................372 400 Troubleshooting of engine (S-mode)..........................................................................376 Troubleshooting chart.......................................................................................377 50 Disassembly and assembly......................................................................................... 0 100 General information on disassembly and assembly.............................................................382 How to read this manual.....................................................................................383 Coating materials list......................................................................................385 Special tool list...........................................................................................388 Sketches of special tools...................................................................................390 200 Engine and cooling system...................................................................................394 Removal and installation of fuel injection pump assembly....................................................395 Removal and installation of radiator assembly...............................................................396 Removal and installation of hydraulic oil cooler assembly...................................................398 Removal and installation of engine and hydraulic pump assembly..............................................399 300 Power train.................................................................................................406 Removal and installation of swing circle assembly...........................................................407 400 Undercarriage and frame.....................................................................................410 Removal and installation of track shoe assembly.............................................................411 Disassembly and assembly of idler assembly..................................................................412 Disassembly and assembly of recoil spring...................................................................414 Disassembly and assembly of track roller assembly...........................................................416 Assembly of travel motor assembly...........................................................................418 Removal and installation of floor frame assembly............................................................427 Removal and installation of revolving frame.................................................................431 500 Hydraulic system............................................................................................436 Disassembly and assembly of hydraulic pump assembly.........................................................437 Disassembly and assembly of control valve assembly..........................................................447 Removal and installation of hydraulic system and center swivel joint assembly...............................453 Disassembly and assembly of center swivel joint assembly....................................................455 Removal and installation of swing motor assembly............................................................457 Disassembly and assembly of swing motor assembly............................................................458 Disassembly and assembly of hydraulic cylinder assembly.....................................................465 Disassembly and assembly of hydraulic breaker assembly......................................................469 600 Work equipment..............................................................................................478 Removal and installation of work equipment assembly.........................................................479 700 Cab and its attachments.....................................................................................482 Removal and installation of canopy..........................................................................483 800 Electrical system...........................................................................................486 Removal and installation of KOMTRAX terminal................................................................487 90 Diagrams and drawings............................................................................................ 0 100 Hydraulic diagrams and drawings.............................................................................490 Hydraulic circuit diagram...................................................................................492 200 Electrical diagrams and drawings............................................................................495 Electrical circuit diagram..................................................................................497 Connector list and stereogram...............................................................................498
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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Dennis James –
So far so good. Easy transaction.