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KOMATSU PC18MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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Description
KOMATSU PC18MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC18MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 784
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC18MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
COVER........................................................................................................................... 3 00 INDEX AND FOREWORD.......................................................................................................... 3 INDEX...................................................................................................................... 4 FOREWORD, SAFETY, BASIC INFORMATION........................................................................................ 10 HOW TO READ THE SHOP MANUAL............................................................................................ 10 SAFETY NOTICE FOR OPERATION............................................................................................ 12 PRECAUTIONS TO PREVENT FIRE............................................................................................ 20 ACTIONS IF FIRE OCCURS................................................................................................. 22 PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS........................................................................ 23 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT........................................................................... 24 PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS.................................................................... 27 PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT....................................................................... 34 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT......................................................................... 36 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT....................................................................... 37 PRACTICAL USE OF KOMTRAX............................................................................................... 38 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER.......................................................................... 39 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER.............................................. 39 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER.............................................. 40 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER.............................................. 41 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................................................. 43 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR.............................................................. 47 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...................................................... 48 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL.................................................... 50 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH.................................................... 51 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE............................................... 53 STANDARD TIGHTENING TORQUE TABLE....................................................................................... 54 CONVERSION TABLE....................................................................................................... 61 ABBREVIATION LIST...................................................................................................... 66 01 SPECIFICATION............................................................................................................... 69 CONTENTS................................................................................................................... 70 SPECIFICATIONS............................................................................................................. 71 SPECIFICATION DRAWING.................................................................................................. 71 SPECIFICATION DRAWING: PC18MR-5.................................................................................... 71 WORKING RANGE DRAWINGS................................................................................................. 73 WORKING RANGE DRAWINGS: PC18MR-5................................................................................... 73 SPECIFICATIONS......................................................................................................... 74 SPECIFICATIONS: PC18MR-5........................................................................................... 74 WEIGHT TABLE........................................................................................................... 79 WEIGHT TABLE: PC18MR-5............................................................................................. 79 FUEL, COOLANT, LUBRICANT............................................................................................... 81 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.................................................. 81 10 STRUCTURE AND FUNCTION...................................................................................................... 83 CONTENTS................................................................................................................... 84 BOOT-UP SYSTEM............................................................................................................. 86 LAYOUT DRAWING OF BOOT-UP SYSTEM....................................................................................... 86 SYSTEM OPERATING LAMP SYSTEM........................................................................................... 87 SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP............................................................................ 87 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM........................................................................... 87 OPERATION OF SYSTEM OPERATING LAMP SYSTEM.......................................................................... 87 BATTERY DISCONNECT SWITCH.............................................................................................. 89 FUNCTION OF BATTERY DISCONNECT SWITCH.............................................................................. 89 OPERATION OF BATTERY DISCONNECT SWITCH............................................................................. 89 ENGINE SYSTEM.............................................................................................................. 90 LAYOUT DRAWING OF ENGINE SYSTEM........................................................................................ 90 ENGINE CONTROL SYSTEM.................................................................................................. 91 SYSTEM DIAGRAM OF ENGINE CONTROL................................................................................... 91 OPERATION OF ENGINE CONTROL SYSTEM................................................................................. 91 ENGINE SYSTEM.......................................................................................................... 93 PTO................................................................................................................ 93 COOLING SYSTEM............................................................................................................. 94 LAYOUT DRAWING OF COOLING SYSTEM....................................................................................... 94 SPECIFICATIONS OF COOLING SYSTEM................................................................................... 95 CONTROL SYSTEM............................................................................................................. 96 LAYOUT DRAWING OF CONTROL SYSTEM....................................................................................... 96 MACHINE MONITOR SYSTEM................................................................................................. 97 SYSTEM DIAGRAM OF MACHINE MONITOR.................................................................................. 97 FUNCTION OF MACHINE MONITOR SYSTEM................................................................................. 97 KOMTRAX SYSTEM......................................................................................................... 98 KOMTRAX SYSTEM DIAGRAM............................................................................................. 98 FUNCTION OF KOMTRAX SYSTEM......................................................................................... 98 CONTROL SYSTEM......................................................................................................... 99 MACHINE MONITOR.................................................................................................... 99 KOMTRAX TERMINAL...................................................................................................102 FUEL ADJUSTMENT LEVER..............................................................................................104 HYDRAULIC SYSTEM...........................................................................................................106 LAYOUT DRAWING OF HYDRAULIC SYSTEM.....................................................................................106 CLSS...................................................................................................................107 SYSTEM DIAGRAM OF CLSS.............................................................................................107 FUNCTION OF CLSS...................................................................................................108 HYDRAULIC SYSTEM.......................................................................................................110 HYDRAULIC TANK.....................................................................................................110 MAIN PUMP..........................................................................................................113 CONTROL VALVE......................................................................................................118 WORK EQUIPMENT SYSTEM......................................................................................................149 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM................................................................................149 STRUCTURE OF VALVE CONTROL.............................................................................................151 PPC LOCK SYSTEM........................................................................................................153 SYSTEM DIAGRAM OF PPC LOCK.........................................................................................153 FUNCTION OF PPC LOCK SYSTEM........................................................................................154 WORK EQUIPMENT DOUBLE LOCK SYSTEM......................................................................................155 FUNCTION OF WORK EQUIPMENT DOUBLE LOCK SYSTEM......................................................................155 OPERATION OF WORK EQUIPMENT DOUBLE LOCK SYSTEM.....................................................................155 WORK EQUIPMENT SYSTEM..................................................................................................156 WORK EQUIPMENT AND SWING PPC VALVE.................................................................................156 ATTACHMENT PPC VALVE...............................................................................................161 BLADE PPC VALVE....................................................................................................163 BOOM SWING PPC VALVE...............................................................................................165 BIPARTITE SOLENOID VALVE...........................................................................................167 VARIABLE GAUGE SOLENOID VALVE......................................................................................170 PILOT CIRCUIT ACCUMULATOR..........................................................................................171 SWING SYSTEM...............................................................................................................172 LAYOUT DRAWING OF SWING SYSTEM.........................................................................................172 SWING SYSTEM...........................................................................................................173 SWING MOTOR........................................................................................................173 SWING CIRCLE.......................................................................................................178 TRAVEL SYSTEM..............................................................................................................179 LAYOUT DRAWING OF TRAVEL SYSTEM........................................................................................179 SYSTEM DIAGRAM OF TRAVEL CONTROL.......................................................................................181 FUNCTION OF TRAVEL CONTROL SYSTEM..................................................................................181 TRAVEL SYSTEM..........................................................................................................183 TRAVEL MOTOR.......................................................................................................183 TRAVEL PPC VALVE...................................................................................................194 CENTER SWIVEL JOINT................................................................................................196 UNDERCARRIAGE AND FRAME....................................................................................................197 LAYOUT DRAWING OF UNDERCARRIAGE........................................................................................197 SPECIFICATIONS OF UNDERCARRIAGE........................................................................................198 IDLER CUSHION..........................................................................................................199 STRUCTURE OF IDLER CUSHION.........................................................................................199 SPECIFICATIONS OF IDLER CUSHION....................................................................................200 WORK EQUIPMENT.............................................................................................................201 STRUCTURE OF WORK EQUIPMENT............................................................................................201 FUNCTION OF WORK EQUIPMENT.............................................................................................202 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...............................................................................203 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...............................................................203 20 STANDARD VALUE TABLE........................................................................................................205 CONTENTS...................................................................................................................206 STANDARD VALUE TABLE FOR ENGINE............................................................................................207 STANDARD VALUE TABLE FOR ENGINE: PC18MR-5..............................................................................207 STANDARD VALUE TABLE FOR MACHINE...........................................................................................209 STANDARD VALUE TABLE FOR MACHINE: PC18MR-5.............................................................................209 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE..................................................................219 30 TESTING AND ADJUSTING.......................................................................................................223 CONTENTS...................................................................................................................224 RELATED INFORMATION ON TESTING AND ADJUSTING...............................................................................226 TOOLS FOR TESTING AND ADJUSTING........................................................................................226 ENGINE AND COOLING SYSTEM..................................................................................................230 TEST ENGINE SPEED......................................................................................................230 TEST ENGINE SPEED..................................................................................................230 TEST EXHAUST GAS COLOR.................................................................................................235 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER......................................................................235 TEST EXHAUST GAS COLOR BY SMOKE METER..............................................................................236 CHECK AND ADJUST VALVE CLEARANCE.......................................................................................237 CHECK VALVE CLEARANCE..............................................................................................237 ADJUST VALVE CLEARANCE.............................................................................................240 TEST COMPRESSION PRESSURE..............................................................................................242 TEST COMPRESSION PRESSURE..........................................................................................242 TEST ENGINE OIL PRESSURE...............................................................................................244 TEST ENGINE OIL PRESSURE...........................................................................................244 TEST AND ADJUST FUEL INJECTION TIMING..................................................................................247 TEST FUEL INJECTION TIMING.........................................................................................247 ADJUST FUEL INJECTION TIMING.......................................................................................251 BLEED AIR FROM FUEL SYSTEM.............................................................................................252 BLEED AIR FROM FUEL SYSTEM.........................................................................................252 TEST FUEL SYSTEM FOR LEAKAGE...........................................................................................253 TEST FUEL SYSTEM FOR LEAKAGE.......................................................................................253 TEST AND ADJUST ALTERNATOR BELT TENSION................................................................................254 TEST AND ADJUST ALTERNATOR BELT....................................................................................254 ADJUST FUEL LEVER LINKAGE..............................................................................................257 ADJUST FUEL LEVER LINKAGE..........................................................................................257 POWER TRAIN................................................................................................................258 TEST SWING CIRCLE BEARING CLEARANCE....................................................................................258 TEST SWING CIRCLE BEARING CLEARANCE................................................................................258 UNDERCARRIAGE AND FRAME....................................................................................................260 TEST AND ADJUST TRACK TENSION..........................................................................................260 TEST TRAVEL DEVIATION..............................................................................................260 ADJUST TRACK TENSION...............................................................................................260 HYDRAULIC SYSTEM...........................................................................................................262 RELEASE PRESSURE REMAINED IN HYDRAULIC CIRCUIT.........................................................................262 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.....................................................................262 RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT...........................................................262 RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT................................................................263 RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT...............................................................263 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND SWING CIRCUITS.............................................265 TEST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND SWING CIRCUITS....................................................265 ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND SWING CIRCUITS..................................................270 TEST AND ADJUST OIL PRESSURE IN CONTROL CIRCUIT........................................................................272 TEST OIL PRESSURE OF CONTROL CIRCUIT...............................................................................272 ADJUST OIL PRESSURE IN CONTROL CIRCUIT.............................................................................273 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT................................................................275 TEST LS DIFFERENTIAL PRESSURE......................................................................................275 ADJUST LS VALVE....................................................................................................277 TEST OUTLET PRESSURE IN SOLENOID VALVE.................................................................................278 TEST OUTLET PRESSURE OF IN PPC LOCK SOLENOID VALVE.................................................................278 TEST OUTLET PRESSURE OF TRAVEL SPEED INCREASE SOLENOID VALVE.......................................................279 TEST OUTLET PRESSURE IN PPC VALVE......................................................................................282 TEST OUTLET PRESSURE IN PPC VALVE..................................................................................282 ADJUST PLAY OF WORK EQUIPMENT AND SWING PPC VALVES.....................................................................285 ADJUST PLAY OF WORK EQUIPMENT AND SWING PPC VALVES.................................................................285 TEST RELEASE PRESSURE IN SWING PARKING BRAKE...........................................................................286 TEST RELEASE PRESSURE IN SWING PARKING BRAKE.......................................................................286 TEST TRAVEL DEVIATION..................................................................................................288 TEST PARTS THAT CAUSE HYDRAULIC DRIFT OF BOOM CYLINDER.............................................................288 TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT...........................................................289 TEST PARTS THAT CAUSE HYDRAULIC DRIFT OF BOOM CYLINDER.............................................................289 TEST PARTS THAT CAUSE HYDRAULIC DRIFT OF BUCKET CYLINDER...........................................................289 TEST PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER.................................................................290 TEST PARTS THAT CAUSE HYDRAULIC DRIFT OF BOOM CYLINDER.............................................................290 TEST OIL LEAKAGE.......................................................................................................292 TEST OIL LEAKAGE FROM BOOM CYLINDER................................................................................292 TEST OIL LEAKAGE FROM ARM CYLINDER.................................................................................293 TEST OIL LEAKAGE FROM BUCKET CYLINDER..............................................................................294 TEST OIL LEAKAGE FROM BOOM SWING CYLINDER..........................................................................295 TEST OIL LEAKAGE FROM BLADE CYLINDER...............................................................................296 PRESSURIZE HYDRAULIC TANK..............................................................................................298 PRESSURIZE HYDRAULIC TANK..........................................................................................298 BLEED AIR FROM HYDRAULIC SYSTEM....................................................................................299 FLOOR......................................................................................................................303 TILT OF COVER OF TRAVEL PPC LEVER......................................................................................303 TILT OF COVER OF TRAVEL PPC LEVER..................................................................................303 ELECTRICAL SYSTEM..........................................................................................................306 START UP KOMTRAX TERMINAL..............................................................................................306 STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL).....................................................309 DISPLAY OF KOMTRAX TERMINAL LAMPS......................................................................................312 BATTERY DISCONNECT SWITCH..............................................................................................315 TEST DIODE.............................................................................................................316 TEST DIODES BY DIGITAL TESTER......................................................................................316 TEST DIODES BY ANALOG TESTER.......................................................................................316 Pm-CLINIC..................................................................................................................318 PM CLINIC SERVICE......................................................................................................318 PM CLINIC CHECK SHEET: PC18MR-5....................................................................................319 40 TROUBLESHOOTING.............................................................................................................325 CONTENTS...................................................................................................................326 RELATED INFORMATION TO TROUBLESHOOT........................................................................................329 GENERAL TROUBLESHOOTING POINTS.........................................................................................329 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................330 CHECKS BEFORE TROUBLESHOOTING..........................................................................................332 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING............................................................................334 WALK-AROUND CHECK..................................................................................................334 TEST IN ACCORDANCE WITH TESTING PROCEDURE..............................................................................335 CHECK FUEL LEVEL AND TYPE..........................................................................................335 CHECK FUEL FILTER ELEMENT, DRAIN WATER AND SEDIMENT................................................................336 CHECK FUEL FILTER ELEMENT..........................................................................................337 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).....................................................................339 CHECK COOLANT LEVEL (RESERVOIR TANK)...............................................................................340 CHECK, CLEAN AND REPLACE AIR CLEANER...............................................................................341 CHECK HYDRAULIC OIL LEVEL..........................................................................................349 CHECK HYDRAULIC OIL STRAINER.......................................................................................352 CHECK HYDRAULIC OIL FILTER.........................................................................................354 CHECK OIL LEVEL IN FINAL DRIVE CASE................................................................................356 BLEED AIR FROM FUEL SYSTEM.........................................................................................356 BLEED AIR FROM HYDRAULIC SYSTEM....................................................................................356 CHECK ELECTRIC EQUIPMENT...........................................................................................356 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM..........................................................................364 CONNECT ADAPTER TO TROUBLESHOOT MONITOR............................................................................364 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL...................................................................365 PROCEDURE FOR TROUBLESHOOTING..........................................................................................366 SYMPTOM AND TROUBLESHOOTING NUMBERS....................................................................................367 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.........................................................................370 CONNECTORS LIST AND LAYOUT.............................................................................................372 CONNECTOR CONTACT IDENTIFICATION.......................................................................................376 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE................................................................................418 FUSE LOCATION TABLE....................................................................................................424 TABLE OF FAILURE CODE AND USER CODE....................................................................................425 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)..........................................................................426 USER CODE [EOE]........................................................................................................426 FAILURE CODE [D811MC]..................................................................................................428 FAILURE CODE [D862KA]..................................................................................................429 FAILURE CODE [DAFGMC]..................................................................................................430 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)..............................................................................431 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)..........................................................................431 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM)..........................................................................437 PREHEATING SYSTEM DOES NOT OPERATE.....................................................................................439 WHEN YOU TURN STARTING SWITCH TO ON POSITION, ALL ITEMS OF MACHINE MONITOR DO NOT WORK, OR ONE OF ITEMS DO NOT WORK....441 CHARGE LEVEL CAUTION LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION.......................................................445 FUEL LEVEL MONITOR PILOT LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION...................................................447 ENGINE COOLANT TEMPERATURE MONITOR PILOT LAMP FLASHES WHILE ENGINE IS IN OPERATION.....................................448 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION................................................449 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM.......................................................................450 FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL............................................................................452 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM........................................................453 COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE............................................................455 TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED................................456 ALARM BUZZER DOES NOT MAKE SOUND.......................................................................................460 ALARM BUZZER CANNOT BE STOPPED.........................................................................................462 SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION....................................................463 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS IN OPERATION............................................................464 ALL WORK EQUIPMENT, SWING, TRAVEL DO NOT OPERATE.......................................................................465 ALL WORK EQUIPMENT, SWING, TRAVEL CANNOT BE LOCKED.....................................................................470 TRAVEL ALARM DOES NOT SOUND DURING TRAVEL..............................................................................474 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS..........................................................................477 BLADE AND VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE CORRECTLY (VARIABLE GAUGE MOVES WHILE BLADE IS SELECTED).....479 BLADE AND VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE CORRECTLY (BLADE MOVES WHILE VARIABLE GAUGE IS SELECTED).....481 HORN DOES NOT MAKE SOUND...............................................................................................483 HORN CANNOT BE STOPPED.................................................................................................485 WORKING LAMP DOES NOT LIGHT UP.........................................................................................486 KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY..............................................................................488 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)..............................................................490 INFORMATION SHOWN IN TROUBLESHOOTING TABLE (H-MODE)....................................................................490 ALL WORK EQUIPMENT, TRAVEL, SWING, BLADE DO NOT OPERATE................................................................491 TRAVEL AND BLADE DO NOT OPERATE........................................................................................492 ALL WORK EQUIPMENT, TRAVEL, SWING, BLADE SPEED IS LOW OR POWER IS LOW..................................................493 TRAVEL AND BLADE SPEED IS LOW OR POWER IS LOW..........................................................................494 FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY.................................................................495 THERE IS AN UNUSUAL NOISE FROM AROUND MAIN PUMP........................................................................496 ENGINE SPEED FALLS LARGELY OR ENGINE STOPS.............................................................................497 BLADE DOES NOT OPERATE.................................................................................................498 BOOM SPEED OR POWER IS LOW.............................................................................................499 ARM SPEED IS LOW OR POWER IS LOW.......................................................................................501 BUCKET SPEED OR POWER IS LOW...........................................................................................502 BLADE SPEED IS LOW OR POWER IS LOW.....................................................................................503 BOOM SWING SPEED IS LOW OR POWER IS LOW................................................................................504 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION.......................................................................505 HYDRAULIC DRIFT OF BOOM IS LARGE.......................................................................................507 HYDRAULIC DRIFT OF ARM IS LARGE........................................................................................508 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................................509 HYDRAULIC DRIFT OF BLADE IS LARGE......................................................................................510 TIME LAG OF WORK EQUIPMENT IS LARGE....................................................................................511 IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER.................................512 MACHINE DOES NOT TRAVEL STRAIGHT.......................................................................................513 MACHINE DOES NOT MOVE OFF STRAIGHT.....................................................................................515 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...................................................................516 TRAVEL SPEED IS SLOW...................................................................................................518 ONE OF TRACKS DOES NOT RUN.............................................................................................520 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST......................................................521 MACHINE DOES NOT SWING TO RIGHT OR LEFT................................................................................522 SWINGS ONLY IN ONE DIRECTION...........................................................................................524 SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT...........................................526 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION.........................................................527 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT)....................................528 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION)................................529 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION..............................................................530 THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION..............................................531 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).................................................532 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)................................................533 VARIABLE GAUGE DOES NOT MOVE...........................................................................................534 TROUBLESHOOTING OF ENGINE (S-MODE).........................................................................................535 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (S-MODE)................................................................535 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.................................................536 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT...........................................................................537 FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...............................538 ENGINE STARTABILITY IS UNSATISFACTORY..................................................................................539 ENGINE DOES NOT PICK UP SMOOTHLY.......................................................................................541 ENGINE STOPS DURING OPERATION..........................................................................................542 ENGINE RUNNING IS NOT STABLE...........................................................................................544 OUTPUT POWER IS LOW (POWER IS LOW).....................................................................................545 ENGINE OIL CONSUMPTION IS EXCESSIVE....................................................................................547 ENGINE OIL BECOMES CONTAMINATED QUICKLY................................................................................548 FUEL CONSUMPTION IS EXCESSIVE..........................................................................................549 OIL MIXES INTO COOLANT (OR SPURTS BACK, COOLANT LEVEL FALLS)...........................................................550 ENGINE OIL PRESSURE FALLS..............................................................................................551 FUEL MIXES INTO ENGINE OIL.............................................................................................552 WATER MIXES INTO ENGINE OIL (MILKY)....................................................................................553 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)..........................................................................554 THERE IS AN UNUSUAL NOISE..............................................................................................555 VIBRATION IS EXCESSIVE.................................................................................................556 AIR CANNOT BE BLED FROM FUEL CIRCUIT...................................................................................557 50 DISASSEMBLY AND ASSEMBLY....................................................................................................559 CONTENTS...................................................................................................................560 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY............................................................................562 HOW TO READ THIS MANUAL................................................................................................562 COATING MATERIALS LIST.....................................................................................................564 SPECIAL TOOLS LIST.........................................................................................................568 ENGINE AND COOLING SYSTEM..................................................................................................570 DRAIN AND ADD COOLANT..................................................................................................570 DRAIN COOLANT......................................................................................................570 ADD COOLANT........................................................................................................571 DRAIN AND ADD HYDRAULIC OIL............................................................................................572 DRAIN HYDRAULIC OIL................................................................................................572 ADD HYDRAULIC OIL..................................................................................................573 REMOVE AND INSTALL RADIATOR ASSEMBLY...................................................................................575 REMOVE RADIATOR ASSEMBLY...........................................................................................575 INSTALL RADIATOR ASSEMBLY..........................................................................................578 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.......................................................................581 REMOVE HYDRAULIC OIL COOLER ASSEMBLY...............................................................................581 INSTALL HYDRAULIC OIL COOLER ASSEMBLY..............................................................................583 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY.......................................................................585 REMOVE ENGINE AND MAIN PUMP ASSEMBLY...............................................................................586 INSTALL ENGINE AND MAIN PUMP ASSEMBLY..............................................................................590 REMOVE AND INSTALL FUEL TANK ASSEMBLY..................................................................................595 REMOVE FUEL TANK ASSEMBLY..........................................................................................595 INSTALL FUEL TANK ASSEMBLY.........................................................................................595 REMOVE AND INSTALL ENGINE STOP SOLENOID................................................................................596 REMOVE ENGINE STOP SOLENOID........................................................................................596 INSTALL ENGINE STOP SOLENOID.......................................................................................598 POWER TRAIN................................................................................................................600 REMOVE AND INSTALL TRAVEL MOTOR ASSEMBLY...............................................................................600 REMOVE TRAVEL MOTOR ASSEMBLY.......................................................................................600 INSTALL TRAVEL MOTOR ASSEMBLY......................................................................................602 REMOVE AND INSTALL SWING MOTOR ASSEMBLY................................................................................604 REMOVE SWING MOTOR ASSEMBLY........................................................................................604 INSTALL SWING MOTOR ASSEMBLY.......................................................................................607 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY...............................................................................610 REMOVE SWING CIRCLE ASSEMBLY.......................................................................................610 INSTALL SWING CIRCLE ASSEMBLY......................................................................................611 UNDERCARRIAGE AND FRAME....................................................................................................612 DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY........................................................................612 DISASSEMBLE RECOIL SPRING ASSEMBLY.................................................................................612 ASSEMBLE RECOIL SPRING ASSEMBLY....................................................................................614 REMOVE AND INSTALL TRACK ASSEMBLY......................................................................................616 REMOVE TRACK ASSEMBLY..............................................................................................616 INSTALL TRACK ASSEMBLY.............................................................................................617 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY................................................................................618 DISASSEMBLE IDLER ASSEMBLY.........................................................................................618 ASSEMBLE IDLER ASSEMBLY............................................................................................619 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY.........................................................................621 DISASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................621 ASSEMBLE TRACK ROLLER ASSEMBLY.....................................................................................622 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY............................................................................623 REMOVE REVOLVING FRAME ASSEMBLY....................................................................................623 INSTALL REVOLVING FRAME ASSEMBLY...................................................................................625 REMOVE AND INSTALL COUNTERWEIGHT AND FUEL TANK ASSEMBLY................................................................627 REMOVE COUNTERWEIGHT AND FUEL TANK ASSEMBLY........................................................................627 INSTALL COUNTERWEIGHT AND FUEL TANK ASSEMBLY.......................................................................631 HYDRAULIC SYSTEM...........................................................................................................634 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY........................................................................634 REMOVE CENTER SWIVEL JOINT ASSEMBLY................................................................................634 INSTALL CENTER SWIVEL JOINT ASSEMBLY...............................................................................637 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY.............................................................................641 REMOVE HYDRAULIC TANK ASSEMBLY.....................................................................................641 INSTALL HYDRAULIC TANK ASSEMBLY....................................................................................644 REMOVE AND INSTALL MAIN PUMP ASSEMBLY..................................................................................647 REMOVE MAIN PUMP ASSEMBLY..........................................................................................647 INSTALL MAIN PUMP ASSEMBLY.........................................................................................650 WORK EQUIPMENT.............................................................................................................652 REMOVE AND INSTALL BLADE ASSEMBLY......................................................................................652 REMOVE BLADE ASSEMBLY..............................................................................................652 INSTALL BLADE ASSEMBLY.............................................................................................653 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY.............................................................................655 REMOVE WORK EQUIPMENT ASSEMBLY.....................................................................................655 INSTALL WORK EQUIPMENT ASSEMBLY....................................................................................657 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY..............................................................658 DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................659 ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY..........................................................................661 CAB RELATED PARTS..........................................................................................................666 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY................................................................................666 REMOVE FLOOR FRAME ASSEMBLY........................................................................................667 INSTALL FLOOR FRAME ASSEMBLY.......................................................................................674 REMOVE AND INSTALL OPERATOR'S SEAT.....................................................................................682 REMOVE OPERATOR'S SEAT.............................................................................................682 INSTALL OPERATOR'S SEAT............................................................................................683 REMOVE AND INSTALL SEATBELT............................................................................................685 REMOVE SEATBELT....................................................................................................685 INSTALL SEATBELT...................................................................................................686 ELECTRICAL SYSTEM..........................................................................................................687 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY............................................................................687 REMOVE MACHINE MONITOR ASSEMBLY....................................................................................687 INSTALL MACHINE MONITOR ASSEMBLY...................................................................................689 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...........................................................................691 REMOVE KOMTRAX TERMINAL ASSEMBLY...................................................................................691 INSTALL KOMTRAX TERMINAL ASSEMBLY..................................................................................692 60 MAINTENANCE STANDARD........................................................................................................695 CONTENTS...................................................................................................................696 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD..............................................................................697 ENGINE AND COOLING SYSTEM..................................................................................................699 MAINTENANCE STANDARD OF ENGINE MOUNT...................................................................................699 MAINTENANCE STANDARD OF PTO............................................................................................700 MAINTENANCE STANDARD OF COOLING SYSTEM.................................................................................701 POWER TRAIN................................................................................................................702 MAINTENANCE STANDARD OF SWING CIRCLE...................................................................................702 MAINTENANCE STANDARD OF SPROCKET.......................................................................................703 UNDERCARRIAGE AND FRAME....................................................................................................704 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION..................................................................704 MAINTENANCE STANDARD OF IDLER..........................................................................................706 MAINTENANCE STANDARD OF TRACK ROLLER...................................................................................707 MAINTENANCE STANDARD OF TRACK SHOE.....................................................................................708 MAINTENANCE STANDARD OF DOUBLE SHOE....................................................................................709 MAINTENANCE STANDARD OF RUBBER SHOE....................................................................................710 HYDRAULIC SYSTEM...........................................................................................................711 MAINTENANCE STANDARD OF HYDRAULIC TANK.................................................................................711 MAINTENANCE STANDARD OF MAIN PUMP......................................................................................712 MAINTENANCE STANDARD OF SWING MOTOR....................................................................................713 MAINTENANCE STANDARD OF TRAVEL MOTOR...................................................................................714 MAINTENANCE STANDARD OF CONTROL VALVE..................................................................................716 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE.............................................................725 MAINTENANCE STANDARD OF BLADE PPC VALVE................................................................................728 MAINTENANCE STANDARD OF BOOM SWING PPC VALVE...........................................................................730 MAINTENANCE STANDARD OF TRAVEL PPC VALVE...............................................................................732 MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE...........................................................................735 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT............................................................................737 WORK EQUIPMENT.............................................................................................................738 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE.........................................................................738 DIMENSIONS OF ARM......................................................................................................744 DIMENSIONS OF BUCKET...................................................................................................746 MAINTENANCE STANDARD OF BOOM CYLINDER..................................................................................747 MAINTENANCE STANDARD OF ARM CYLINDER...................................................................................748 MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................................749 MAINTENANCE STANDARD OF BLADE CYLINDER.................................................................................750 MAINTENANCE STANDARD OF BOOM SWING CYLINDER............................................................................751 MAINTENANCE STANDARD OF VARIABLE GAUGE CYLINDER........................................................................752 90 CIRCUIT DIAGRAMS............................................................................................................753 CONTENTS...................................................................................................................754 HOW TO READ THE CODES FOR ELECTRIC CABLE...................................................................................755 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................759 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM..............................................................................759 HYDRAULIC CIRCUIT DIAGRAM..............................................................................................763 HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE OPERATION)....................................................................765 HYDRAULIC CIRCUIT DIAGRAM (AT LEFT SWING OPERATION)....................................................................767 HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE AND LEFT SWING OPERATION).....................................................769 ELECTRICAL CIRCUIT DIAGRAM.................................................................................................771 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM...............................................................................771 ELECTRICAL CIRCUIT DIAGRAM.............................................................................................775 INDEX...........................................................................................................................777
DESCRIPTION:
KOMATSU PC18MR-5 COMPACT HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
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