Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC18MR-2, PC18MR-3, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC18MR-2, PC18MR-3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM038404 – Hydraulic Excavator PC18MR-2 Shop Manual.pdf
SEN04306-04 – Hydraulic Excavator PC18MR-3 Shop Manual.pdf
TEN00052-01 – Hydraulic Excavator GALEO PC18MR-2 Operation & Maintenance Manual.pdf
TEN00292-03 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
TEN00514-01 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
TEN00549-00 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,743 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
SEBM038404 – Hydraulic Excavator PC18MR-2 Shop Manual…2
COVER…2
CONTENTS…3
01 GENERAL…28
SPECIFICATION DIMENSION DRAWING…29
WORKING RANGE DRAWING…30
SPECIFICATIONS…31
WEIGHT TABLE…34
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS…36
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD…37
PTO…38
COOLING SYSTEM…39
POWER TRAIN …41
SWING CIRCLE…42
TRACK FRAME…43
IDLER CUSHION…44
IDLER…46
TRACK ROLLER…47
SPROCKET…48
TRACK SHOE…49
HYDRAULIC COMPONENTS LAYOUT DRAWING…51
HYDRAULIC TANK…52
CENTER SWIVEL JOINT…53
TRAVEL MOTOR…54
HYDRAULIC CYLINDER…63
SOLENOID VALVE…66
VARIABLE GAUGE VALVE…69
MULTI-CONTROL VALVE…70
HYDRAULIC PUMP…71
CONTROL VALVE…77
CLSS…89
OPERATION FOR EACH FUNCTION AND VALVE…92
SWING MOTOR…105
PPC VALVE…108
WORK EQUIPMENT …116
DIMENSIONS OF EACH PART OF WORK EQUIPMENT…119
FLOOR…122
ENGINE CONTROL…123
ELECTRIC CONTROL SYSTEM…125
COMPONENT PARTS OF SYSTEM…130
MONITOR SYSTEM…131
MONITOR PANEL…132
SENSORS…134
20 TESTING AND ADJUSTING…136
STANDARD VALUE TABLE FOR ENGING RELATED PARTS…137
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…138
TESTING AND ADJUSTING…147
LIST OF TESTING, ADJUSTING,AND TROUBLESHOOTING TOOLS…148
MEASURING ENGINE SPEED…150
MEASURING OF EXHAUST GAS COLOR…151
ADJUSTING VALVE CLEARANCE…152
TESTING COMPRESSION PRESSURE…154
TESTING ENGINE OIL PRESSURE…155
TESTING AND ADJUSTING FUEL INJECTION TIMING…156
ADJUSTING ENGINE STOP SOLENOID…158
BLEEDING AIR FROM FUEL CIRCUIT…159
TESTING AND ADJUSTING FAN BELT TENSION…160
ADJUSTING FUEL CONTROL LEVER LINKAGE…161
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…162
TESTING AND ADJUSTING TRACK SHOE TENSION…163
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT,TRAVEL,SWING,AND BLADE CIRCUITS…165
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE…168
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE…170
MEASURING SOLENOID VALVE OUTPUT PRESSURE…172
MEASURING PPC VALVE OUTPUT PRESSURE…174
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…176
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE…176
TESTING OIL LEAKAGE FORM CYLINDER…178
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…180
BLEEDING AIR FROM CYLINDER…180
PRESSURIZING HYDRAULIC TANK…181
HOW TO OPEN AND CLOSE(TILT) FLOOR…182
INSPECTION PROCEDURES FOR DIODE…184
TROUBLESHOOTING…185
POINTS TO REMEMBER WHEN TROUBLESHOOTING…186
SEQUENCE OF EVENTS IN TROUBLESHOOTING…187
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…188
CHECKS BEFORE TROUBLESHOOTING…196
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…197
CONNECTORS LIST AND CONNECTORS ARRANGEMENT STEREOGRAM …199
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…203
T-ADAPTER-BOXES AND T-ADAPTER TABLE…226
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…229
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM(E MODE)…230
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…232
E-1 ENGINE DOES NOT START…233
E-2 ENGINE DOES NOT STOP…239
E-3 ENGINE OIL PRESSURE MONITOR DOES NOT INDICATE NORMALLY…241
E-4 CHARGE LEVEL MONITOR DOES NOT INDICATE NORMALLY…244
E-5 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…247
E-6 SERVICE METER DOES NOT OPERATE NORMALLY…250
E-7 PREHEATING SYSTEM DOES NOT OPERATE NORMALLY…252
E-8 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY…255
E-9 ENGINE COOLANT TEMPERATURE MONITOR DOES NOT INDICATE NORMALLY…259
E-10 LOCK LEVER DOES NOT OPERATE NORMALLY…263
E-11 BLADE/VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE NORMALLY…266
E-12 NIGHT LAMP OF MACHINE MONITOR AND WORKING LAMP DO NOT LIGHT UP…269
E-13 TRAVEL ALARM DOES NOT SOUND OR DOES NOT SOUNDING…272
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…275
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE …276
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT,TRAVEL,SWING,AND BLADE IS LOW…277
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS…278
H-3 WHOLE WORK EQUIPMENT,TRAVEL SYSTEM,SWING SYSTEM,AND BLADE DO NOT MOVE…279
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP…280
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW…280
H-6 SPEED OR POWER OF BOOM IS LOW…281
H-7 SPEED OR POWER OF ARM IS LOW…282
H-8 SPEED OR POWER OF BUCKET IS LOW…283
H-9 SPEED OR POWER OF BOOM SWING IS LOW…284
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY…284
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE…285
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…286
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT,SPEED OF PART LOADED MORE IS LOW…286
H-14 MACHINE DEVIATES DURING TRAVEL…287
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW…289
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…289
H-17 TRAVEL SPEED DOES NOT CHANGE…290
H-18 TRAVEL MOTOR DOES NOT WORK(ONE SIDE ONLY)…290
H-19 SPEED OR POWER OF SWING IS LOW…291
H-20 MACHINE DOES NOT SWING…293
H-21 SWING ACCELERATION PERFORMANCE IS LOW…295
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING…296
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING…297
H-24 WHEN UPPER STRUCTURE STOPS SWINGING,IT MAKES LARGE SOUND…297
H-25 HYDRAULIC DRIFT OF SWING IS LARGE…298
H-26 SPEED OR POWER OF BLADE IS LOW…299
H-27 BLADE DOES NOT MOVE…300
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE…300
H-29 VARIABLE GAUGE DOES NOT MOVE…301
H-30 TROUBLESHOOTING FOR HYDRAULIC BREAKER…302
TROUBLESHOOTING OF ENGINE(S MODE)…305
TROUBLESHOOTING CHART…306
30 DISASSEMBLY AND ASSEMBLY…310
HOW TO READ THIS MANUAL…311
PRECAUTIONS WHEN PERFORMING OPERATION…313
SPECIAL TOOL LIST…315
SKETCH OF SPECIAL TOOLS…317
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…321
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…322
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…324
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…325
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…329
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…330
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING…331
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…333
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY…334
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…343
REMOVAL AND INSTALLATION OF REVOLVING FRAME…348
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…351
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY…352
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…361
REMOVAL AND INSTALLATION OF HYDRAULIC SYSTEM AND CENTER SWIVEL JOINT ASSEMBLY …365
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…367
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY…369
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY…370
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…377
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…379
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC BREAKER ASSEMBLY…383
90 OTHERS…390
HYDRAULIC CIRCUIT DIAGRAM …391
ELECTRICAL CIRCUIT DIAGRAM …392
SEN04306-04 – Hydraulic Excavator PC18MR-3 Shop Manual…393
COVER…393
00 Index and foreword…0
100 Index…394
Composition of shop manual…395
Table of contents…397
200 Foreword and general information…402
Safety notice…403
How to read the shop manual…408
Explanation of terms for maintenance standard…410
Handling of electric equipment and hydraulic component…412
Handling of connectors newly used for engines…421
How to read electric wire code…424
Precautions when carrying out operation…427
Method of disassembling and connecting push-pull type coupler…430
Standard tightening torque table…433
Conversion table…437
01 Specification…0
100 Specification and technical data…444
Specification dimension drawing…445
Working range drawing…446
Specifications…447
Weight table…450
Table of fuel, coolant and lubricants…452
10 Structure, function and maintenance standard…0
100 Engine and cooling system…454
PTO…455
Cooling system…457
200 Power train…460
Power train…461
Swing circle…462
300 Undercarriage and frame…464
Track frame…465
Idler cushion…466
Idler…468
Track roller…469
Sprocket…470
Track shoe…471
410 Hydraulic system, Part 1…474
Hydraulic components layout drawing…475
Hydraulic tank…476
Center swivel joint…477
Travel motor…478
Hydraulic cylinder…487
Solenoid valve…491
Variable gauge valve…494
Multi-control valve (If equipped)…495
420 Hydraulic system, Part 2…498
Hydraulic pump…499
Control valve…505
430 Hydraulic system, Part 3…516
CLSS…517
Operation for each function and valve…521
Swing motor…535
PPC valve…538
500 Work equipment…548
Work equipment…550
Dimensions of each part of work equipment…553
600 Cab and its attachments…558
Floor…559
700 Electrical system…562
Engine control system…563
Electric control system…565
Component parts of system…570
KOMTRAX system…571
Monitor system…574
Sensors…577
20 Standard value table…0
100 Standard service value table…580
Standard value table for engine related parts…581
Standard value table for chassis related parts…582
30 Testing and adjusting…0
100 Testing and adjusting…592
List of testing, adjusting, and troubleshooting tools…594
Measuring engine speed…596
Measurement of exhaust gas color…597
Adjusting valve clearance…598
Testing compression pressure…600
Testing engine oil pressure…601
Testing and adjusting fuel injection timing…602
Adjusting engine stop solenoid…604
Bleeding air from fuel circuit…605
Testing and adjusting fan belt tension…606
Adjusting fuel control lever linkage…607
Measurement of clearance in swing circle bearings…608
Testing and adjusting track shoe tension…609
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits…611
Testing and adjusting control circuit basic pressure…614
Testing and adjusting pump LS differential pressure…616
Measuring solenoid valve output pressure…618
Measuring PPC valve output pressure…620
Adjusting play of work equipment and swing PPC valves…622
Measuring swing holding brake release pressure…622
Testing oil leakage from cylinder…624
Releasing residual pressure from hydraulic circuit…626
Bleeding air from cylinder…626
Pressurizing hydraulic tank…627
How to open and close (tilt) floor…628
Inspection procedures for diode…630
How to start operation of KOMTRAX terminal…631
Lamp display of KOMTRAX terminal…635
Removal and installation of KOMTRAX terminal…638
Preparation work for troubleshooting of electrical system…639
40 Troubleshooting…0
100 General information on troubleshooting…642
Points to remember when troubleshooting…643
Sequence of events in troubleshooting…644
Checks before troubleshooting…645
Classification and procedures of troubleshooting…646
Connection table for connector pin numbers…649
T- branch box and T- branch adapter table…685
200 Troubleshooting of electrical system (E-mode)…690
Before carrying out troubleshooting for electrical system (E-mode)…691
Information contained in troubleshooting table…693
E-1 Engine does not start…694
E-2 Engine does not stop…701
E-3 When starting switch is turned ON, any item does not operate…703
E-4 When starting switch is turned ON, some items do not operate…705
E-5 Alarm buzzer is abnormal…706
E-6 Engine oil pressure caution is turned ON…708
E-7 Charge level caution is turned ON…709
E-8 Preheating system does not operate or preheater does not become hot…711
E-9 Coolant temperature gauge is abnormal…713
E-10 Fuel level gauge is abnormal…717
E-11 Service meter does not operate while engine is running…721
E-12 2nd travel speed is not selected…724
E-13 Working lamp does not light up…727
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves…729
E-15 Blade/Variable gauge selector system does not operate normally…732
300 Troubleshooting of hydraulic and mechanical system (H-mode)…736
Information contained in troubleshooting table…738
H-1 Speed or power of whole work equipment, travel, swing, and blade is low…739
H-2 Engine speed lowers extremely or engine stalls…740
H-3 Whole work equipment, travel system, swing system, and blade do not move…741
H-4 Abnormal sound comes out from around hydraulic pump…742
H-5 Fine control performance or response is low…742
H-6 Speed or power of boom is low…743
H-7 Speed or power of arm is low…744
H-8 Speed or power of bucket is low…745
H-9 Speed or power of boom swing is low…746
H-10 Work equipment does not move singly…746
H-11 Work equipment hydraulic drift is large…747
H-12 Time lag of work equipment is large…748
H-13 In compound operation of work equipment, speed of part loaded more is low…748
H-14 Machine deviates during travel…749
H-15 Travel speed or travel power is low…751
H-16 Machine is not steered well or steering power is low…751
H-17 Travel speed does not change…752
H-18 Travel motor does not work (one side only)…752
H-19 Speed or power of swing is low…753
H-20 Machine does not swing…755
H-21 Swing acceleration performance is low…757
H-22 Machine overruns when it stops swinging…758
H-23 Large shock is made when machine stops swinging…759
H-24 When upper structure stops swinging, it makes large sound…759
H-25 Hydraulic drift of swing is large…760
H-26 Speed or power of blade is low…761
H-27 Blade does not move…762
H-28 Hydraulic drift of blade is large…762
H-29 Variable gauge does not move…763
H-30 Troubleshooting for hydraulic breaker…764
400 Troubleshooting of engine (S-mode)…768
Troubleshooting chart…769
50 Disassembly and assembly…0
100 General information on disassembly and assembly…774
How to read this manual…775
Coating materials list…777
Special tool list…780
Sketches of special tools…782
200 Engine and cooling system…786
Removal and installation of fuel injection pump assembly…787
Removal and installation of radiator assembly…788
Removal and installation of hydraulic oil cooler assembly…790
Removal and installation of engine and hydraulic pump assembly…791
300 Power train…798
Removal and installation of swing circle assembly…799
400 Undercarriage and frame…802
Removal and installation of track shoe assembly…803
Disassembly and assembly of idler assembly…804
Disassembly and assembly of recoil spring…806
Disassembly and assembly of track roller assembly…808
Assembly of travel motor assembly…810
Removal and installation of floor frame assembly…819
Removal and installation of revolving frame…823
500 Hydraulic system…828
Disassembly and assembly of hydraulic pump assembly…829
Disassembly and assembly of control valve assembly…839
Removal and installation of hydraulic system and center swivel joint assembly…845
Disassembly and assembly of center swivel joint assembly…847
Removal and installation of swing motor assembly…849
Disassembly and assembly of swing motor assembly…850
Disassembly and assembly of hydraulic cylinder assembly…857
Disassembly and assembly of hydraulic breaker assembly…861
600 Work equipment…870
Removal and installation of work equipment assembly…871
700 Cab and its attachments…874
Removal and installation of canopy…875
800 Electrical system…878
Removal and installation of KOMTRAX terminal…879
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…882
Hydraulic circuit diagram…884
200 Electrical diagrams and drawings…887
Electrical circuit diagram…889
Connector list and stereogram…890
TEN00052-01 – Hydraulic Excavator GALEO PC18MR-2 Operation & Maintenance Manual…893
COVER…893
FOREWORD…894
FOREWORD…895
SAFETY INFORMATION…898
INTRODUCTION…900
DIRECTIONS OF MACHINE…900
PRODUCT INFORMATION…901
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…901
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…901
EPA NAMEPLATE…902
SERVICE METER LOCATION…902
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…903
CONTENTS…904
SAFETY…908
SAFETY INFORMATION…909
SAFETY LABELS…911
LOCATION OF SAFETY LABELS…911
SAFETY LABELS…912
SAFETY INFORMATION…917
SAFETY MACHINE OPERATION…926
STARTING ENGINE…926
OPERATION…928
TRANSPORTATION…934
BATTERY…935
TOWING…937
LIFTING OBJECTS WITH BUCKET…938
SAFETY MAINTENANCE INFORMATION…939
OPERATION…946
MACHINE VIEW ILLUSTRATIONS…947
OVERALL MACHINE VIEW…947
CONTROLS AND GAUGES…948
DETAILED CONTROLS AND GAUGES…949
MONITORING SYSTEM…949
SWITCHES…955
CONTROL LEVERS AND PEDALS…959
COVER WITH LOCK…964
ENGINE REAR COVER…965
COOLING COVER…966
BATTERY COVER…967
METHOD OF OPENING (TILTING) FLOOR…968
FUSE…972
BLOCK FUSE…972
OPERATION MANUAL STORAGE…973
TOOL BOX…973
MACHINE OPERATIONS AND CONTROLS…974
BEFORE STARTING ENGINE…974
STARTING ENGINE…987
AFTER STARTING ENGINE…991
STOPPING THE ENGINE…994
MACHINE OPERATION…995
STEERING THE MACHINE…1000
SWINGING…1002
WORK EQUIPMENT CONTROLS AND OPERATIONS…1003
PROHIBITED OPERATIONS…1006
GENERAL OPERATION INFORMATION…1008
TRAVELING ON SLOPES…1010
ESCAPE FROM MUD…1012
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1013
BUCKET REPLACEMENT…1015
PARKING MACHINE…1016
MACHINE INSPECTION AFTER DAILY WORK…1017
LOCKING…1018
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1019
TRANSPORTATION…1024
TRANSPORTATION PROCEDURE…1024
LOADING AND UNLOADING WITH TRAILER…1024
LIFTING MACHINE…1030
COLD WEATHER OPERATION…1033
COLD WEATHER OPERATION INFORMATION…1033
AFTER DAILY WORK COMPLETION…1035
AFTER COLD WEATHER SEASON…1035
LONG TERM STORAGE…1036
BEFORE STORAGE…1036
DURING STORAGE…1036
AFTER STORAGE…1036
TROUBLES AND ACTIONS…1037
RUNNING OUT OF FUEL…1037
PHENOMENA THAT ARE NOT FAILURES…1037
TOWING THE MACHINE…1038
SEVERE JOB CONDITION…1038
DISCHARGED BATTERY…1039
OTHER TROUBLE…1043
MAINTENANCE…1046
MAINTENANCE INFORMATION…1047
OUTLINE OF SERVICE…1049
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1049
ELECTRIC SYSTEM MAINTENANCE…1052
HANDLING HYDRAULIC SYSTEM…1052
WEAR PARTS…1053
WEAR PARTS LIST…1053
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1054
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1056
TIGHTENING TORQUE SPECIFICATIONS…1057
TIGHTENING TORQUE LIST…1057
SAFETY CRITICAL PARTS…1058
SAFETY CRITICAL PARTS LIST…1058
MAINTENANCE SCHEDULE…1059
MAINTENANCE SCHEDULE CHART…1059
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1060
MAINTENANCE PROCEDURE…1061
WHEN REQUIRED…1061
CHECK BEFORE STARTING…1083
EVERY 500 HOURS MAINTENANCE…1084
EVERY 1000 HOURS MAINTENANCE…1091
EVERY 2000 HOURS MAINTENANCE…1094
SPECIFICATIONS…1096
SPECIFICATIONS…1097
ATTACHMENTS AND OPTIONS…1100
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1101
SAFETY FIRST…1101
ATTACHMENT INSTALLATION…1102
BUCKET WITH HOOK…1103
PROHIBITED OPERATIONS…1103
MACHINE READY FOR ATTACHMENT…1104
LOCATIONS…1104
HYDRAULIC CIRCUIT…1106
ATTACHMENT OPERATIONS…1108
LONG TERM STORAGE…1109
SPECIFICATIONS…1109
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1110
CONTROL PATTERN CHANGE PROCEDURE…1110
MACHINE CONTROL PATTERNS…1111
ATTACHMENT GUIDE…1112
ATTACHMENT COMBINATIONS…1112
RECOMMENDED ATTACHMENT OPERATIONS…1113
HYDRAULIC BREAKER…1113
INDEX…1118
TEN00292-03 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1122
COVER…1122
FOREWORD…1123
FOREWORD…1124
SAFETY INFORMATION…1125
INTRODUCTION…1127
DIRECTIONS OF MACHINE…1127
PRODUCT INFORMATION…1128
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1128
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1128
EPA NAMEPLATE…1129
SERVICE METER LOCATION…1129
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1130
CONTENTS…1131
SAFETY…1135
SAFETY…1136
SAFETY LABELS…1138
LOCATION OF SAFETY LABELS…1138
SAFETY LABELS…1139
GENERAL PRECAUTIONS…1144
SAFETY MACHINE OPERATION…1153
STARTING ENGINE…1153
OPERATION…1155
TRANSPORTATION…1161
BATTERY…1162
TOWING…1164
LIFTING OBJECTS WITH BUCKET…1165
SAFETY MAINTENANCE INFORMATION…1166
OPERATION…1175
MACHINE VIEW ILLUSTRATIONS…1176
OVERALL MACHINE VIEW…1176
CONTROLS AND GAUGES…1177
DETAILED CONTROLS AND GAUGES…1178
MONITORING SYSTEM…1178
SWITCHES…1184
CONTROL LEVERS AND PEDALS…1187
COVER WITH LOCK…1193
ENGINE REAR COVER…1194
COOLING COVER…1195
BATTERY COVER…1196
METHOD OF OPENING (TILTING) FLOOR…1197
AUXILIARY ELECTRIC POWER…1201
FUSE…1201
BLOCK FUSE…1202
OPERATION MANUAL STORAGE…1202
TOOL BOX…1203
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1204
MACHINE OPERATIONS AND CONTROLS…1205
BEFORE STARTING ENGINE…1205
STARTING ENGINE…1218
AFTER STARTING ENGINE…1222
STOPPING THE ENGINE…1225
MACHINE OPERATION…1226
STEERING THE MACHINE…1231
SWINGING…1233
WORK EQUIPMENT CONTROLS AND OPERATIONS…1234
PROHIBITED OPERATIONS…1237
GENERAL OPERATION INFORMATION…1239
TRAVELING ON SLOPES…1241
ESCAPE FROM MUD…1243
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1244
BUCKET REPLACEMENT…1246
PARKING MACHINE…1247
MACHINE INSPECTION AFTER DAILY WORK…1248
LOCKING…1249
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1250
TRANSPORTATION…1255
TRANSPORTATION PROCEDURE…1255
LOADING AND UNLOADING WITH TRAILER…1256
LIFTING MACHINE…1262
COLD WEATHER OPERATION…1265
COLD WEATHER OPERATION INFORMATION…1265
AFTER DAILY WORK COMPLETION…1267
AFTER COLD WEATHER SEASON…1267
LONG TERM STORAGE…1268
BEFORE STORAGE…1268
DURING STORAGE…1268
AFTER STORAGE…1268
TROUBLES AND ACTIONS…1270
RUNNING OUT OF FUEL…1270
PHENOMENA THAT ARE NOT FAILURES…1270
TOWING THE MACHINE…1271
SEVERE JOB CONDITION…1271
DISCHARGED BATTERY…1272
OTHER TROUBLE…1276
MAINTENANCE…1279
MAINTENANCE INFORMATION…1280
OUTLINE OF SERVICE…1282
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1282
ELECTRIC SYSTEM MAINTENANCE…1286
HANDLING HYDRAULIC SYSTEM…1286
WEAR PARTS…1287
WEAR PARTS LIST…1287
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1288
TIGHTENING TORQUE SPECIFICATIONS…1290
TIGHTENING TORQUE LIST…1290
SAFETY CRITICAL PARTS…1291
SAFETY CRITICAL PARTS LIST…1291
MAINTENANCE SCHEDULE…1292
MAINTENANCE SCHEDULE CHART…1292
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1293
MAINTENANCE PROCEDURE…1294
WHEN REQUIRED…1294
CHECK BEFORE STARTING…1317
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1317
EVERY 500 HOURS MAINTENANCE…1318
EVERY 1000 HOURS MAINTENANCE…1326
EVERY 1500 HOURS MAINTENANCE…1329
EVERY 2000 HOURS MAINTENANCE…1330
SPECIFICATIONS…1335
SPECIFICATIONS…1336
ATTACHMENTS, OPTIONS…1339
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1340
SAFETY FIRST…1340
ATTACHMENT INSTALLATION…1341
BUCKET WITH HOOK…1342
HOOK CONDITION…1342
PROHIBITED OPERATIONS…1342
MACHINE READY FOR ATTACHMENT…1343
LOCATIONS…1343
HYDRAULIC CIRCUIT…1346
ATTACHMENT OPERATIONS…1347
LONG TERM STORAGE…1348
SPECIFICATIONS…1348
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1349
CONTROL PATTERN CHANGE PROCEDURE…1349
MACHINE CONTROL PATTERNS…1350
ATTACHMENT GUIDE…1351
ATTACHMENT COMBINATIONS…1351
HANDLING ARM WITH BUILT-IN BREAKER…1352
REMOVING AND INSTALLING CHISEL…1352
PROCEDURE FOR BREAKER OPERATIONS…1355
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1356
INSTALLATION OF BUCKET…1357
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1359
STOWING CHISEL, DUMMY CHISEL…1359
CHECK BEFORE STARTING…1360
SPECIFICATIONS…1361
RECOMMENDED ATTACHMENT OPERATIONS…1362
HYDRAULIC BREAKER…1362
INDEX…1367
TEN00514-01 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1371
COVER…1371
FOREWORD…1372
FOREWORD…1373
SAFETY INFORMATION…1374
INTRODUCTION…1376
DIRECTIONS OF MACHINE…1376
PROTECTIVE STRUCTURE…1376
PRODUCT INFORMATION…1377
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1377
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1377
EPA NAMEPLATE…1378
SERVICE METER LOCATION…1378
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1379
CONTENTS…1380
SAFETY…1384
SAFETY…1385
SAFETY LABELS…1387
LOCATION OF SAFETY LABELS…1387
SAFETY LABELS…1388
GENERAL PRECAUTIONS…1393
SAFETY MACHINE OPERATION…1402
STARTING ENGINE…1402
OPERATION…1404
TRANSPORTATION…1410
BATTERY…1411
TOWING…1413
LIFTING OBJECTS WITH BUCKET…1414
SAFETY MAINTENANCE INFORMATION…1415
OPERATION…1424
MACHINE VIEW ILLUSTRATIONS…1425
OVERALL MACHINE VIEW…1425
CONTROLS AND GAUGES…1426
DETAILED CONTROLS AND GAUGES…1427
MONITORING SYSTEM…1427
SWITCHES…1433
CONTROL LEVERS AND PEDALS…1436
COVER WITH LOCK…1442
ENGINE REAR COVER…1443
COOLING COVER…1444
BATTERY COVER…1445
METHOD OF OPENING (TILTING) FLOOR…1446
AUXILIARY ELECTRIC POWER…1450
FUSE…1450
OPERATION MANUAL STORAGE…1451
TOOL BOX…1452
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1453
MACHINE OPERATIONS AND CONTROLS…1454
BEFORE STARTING ENGINE…1454
STARTING ENGINE…1467
AFTER STARTING ENGINE…1471
STOPPING THE ENGINE…1474
MACHINE OPERATION…1475
STEERING THE MACHINE…1480
SWINGING…1482
WORK EQUIPMENT CONTROLS AND OPERATIONS…1483
PROHIBITED OPERATIONS…1486
GENERAL OPERATION INFORMATION…1488
TRAVELING ON SLOPES…1490
ESCAPE FROM MUD…1492
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1493
BUCKET REPLACEMENT…1495
PARKING MACHINE…1496
MACHINE INSPECTION AFTER DAILY WORK…1497
LOCKING…1498
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1499
TRANSPORTATION…1504
TRANSPORTATION PROCEDURE…1504
LOADING AND UNLOADING WITH TRAILER…1505
LIFTING MACHINE…1511
COLD WEATHER OPERATION…1514
COLD WEATHER OPERATION INFORMATION…1514
AFTER DAILY WORK COMPLETION…1516
AFTER COLD WEATHER SEASON…1516
LONG TERM STORAGE…1517
BEFORE STORAGE…1517
DURING STORAGE…1517
AFTER STORAGE…1517
TROUBLES AND ACTIONS…1518
RUNNING OUT OF FUEL…1518
PHENOMENA THAT ARE NOT FAILURES…1518
TOWING THE MACHINE…1519
SEVERE JOB CONDITION…1519
DISCHARGED BATTERY…1520
OTHER TROUBLE…1524
MAINTENANCE…1528
MAINTENANCE INFORMATION…1529
OUTLINE OF SERVICE…1531
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1531
ELECTRIC SYSTEM MAINTENANCE…1534
HANDLING HYDRAULIC SYSTEM…1535
WEAR PARTS…1536
WEAR PARTS LIST…1536
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1537
TIGHTENING TORQUE SPECIFICATIONS…1539
TIGHTENING TORQUE LIST…1539
SAFETY CRITICAL PARTS…1540
SAFETY CRITICAL PARTS LIST…1540
MAINTENANCE SCHEDULE…1541
MAINTENANCE SCHEDULE CHART…1541
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1542
MAINTENANCE PROCEDURE…1543
WHEN REQUIRED…1543
CHECK BEFORE STARTING…1565
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1565
EVERY 500 HOURS MAINTENANCE…1566
EVERY 1000 HOURS MAINTENANCE…1574
EVERY 1500 HOURS MAINTENANCE…1577
EVERY 2000 HOURS MAINTENANCE…1578
SPECIFICATIONS…1584
SPECIFICATIONS…1585
ATTACHMENTS, OPTIONS…1588
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1589
SAFETY FIRST…1589
ATTACHMENT INSTALLATION…1590
BUCKET WITH HOOK…1591
HOOK CONDITION…1591
PROHIBITED OPERATIONS…1591
MACHINE READY FOR ATTACHMENT…1592
LOCATIONS…1592
HYDRAULIC CIRCUIT…1595
ATTACHMENT OPERATIONS…1596
LONG TERM STORAGE…1597
SPECIFICATIONS…1597
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1598
CONTROL PATTERN CHANGE PROCEDURE…1598
MACHINE CONTROL PATTERNS…1599
ATTACHMENT GUIDE…1600
ATTACHMENT COMBINATIONS…1600
HANDLING ARM WITH BUILT-IN BREAKER…1601
REMOVING AND INSTALLING CHISEL…1601
PROCEDURE FOR BREAKER OPERATIONS…1604
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1605
INSTALLATION OF BUCKET…1606
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1608
STOWING CHISEL, DUMMY CHISEL…1608
CHECK BEFORE STARTING…1609
SPECIFICATIONS…1610
RECOMMENDED ATTACHMENT OPERATIONS…1611
HYDRAULIC BREAKER…1611
INDEX…1616
TEN00549-00 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1620
COVER…1620
FOREWORD…1621
FOREWORD…1622
SAFETY INFORMATION…1623
INTRODUCTION…1625
DIRECTIONS OF MACHINE…1625
PROTECTIVE STRUCTURE…1625
PRODUCT INFORMATION…1626
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1626
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1626
EPA NAMEPLATE…1627
SERVICE METER LOCATION…1627
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1628
CONTENTS…1629
SAFETY…1633
SAFETY…1634
SAFETY LABELS…1636
LOCATION OF SAFETY LABELS…1636
SAFETY LABELS…1637
GENERAL PRECAUTIONS…1642
SAFETY MACHINE OPERATION…1651
STARTING ENGINE…1651
OPERATION…1653
TRANSPORTATION…1659
BATTERY…1660
TOWING…1662
LIFTING OBJECTS WITH BUCKET…1663
SAFETY MAINTENANCE INFORMATION…1664
OPERATION…1673
MACHINE VIEW ILLUSTRATIONS…1674
OVERALL MACHINE VIEW…1674
CONTROLS AND GAUGES…1675
DETAILED CONTROLS AND GAUGES…1676
MONITORING SYSTEM…1676
SWITCHES…1682
CONTROL LEVERS AND PEDALS…1685
COVER WITH LOCK…1691
ENGINE REAR COVER…1692
COOLING COVER…1693
BATTERY COVER…1694
METHOD OF OPENING (TILTING) FLOOR…1695
AUXILIARY ELECTRIC POWER…1699
FUSE…1699
BLOCK FUSE…1700
OPERATION MANUAL STORAGE…1700
TOOL BOX…1701
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1702
MACHINE OPERATIONS AND CONTROLS…1703
BEFORE STARTING ENGINE…1703
STARTING ENGINE…1716
AFTER STARTING ENGINE…1720
STOPPING THE ENGINE…1723
MACHINE OPERATION…1724
STEERING THE MACHINE…1729
SWINGING…1731
WORK EQUIPMENT CONTROLS AND OPERATIONS…1732
PROHIBITED OPERATIONS…1735
GENERAL OPERATION INFORMATION…1737
TRAVELING ON SLOPES…1739
ESCAPE FROM MUD…1741
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1742
BUCKET REPLACEMENT…1744
PARKING MACHINE…1745
MACHINE INSPECTION AFTER DAILY WORK…1746
LOCKING…1747
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1748
TRANSPORTATION…1753
TRANSPORTATION PROCEDURE…1753
LOADING AND UNLOADING WITH TRAILER…1754
LIFTING MACHINE…1760
COLD WEATHER OPERATION…1763
COLD WEATHER OPERATION INFORMATION…1763
AFTER DAILY WORK COMPLETION…1765
AFTER COLD WEATHER SEASON…1765
LONG TERM STORAGE…1766
BEFORE STORAGE…1766
DURING STORAGE…1766
AFTER STORAGE…1766
TROUBLES AND ACTIONS…1767
RUNNING OUT OF FUEL…1767
PHENOMENA THAT ARE NOT FAILURES…1767
TOWING THE MACHINE…1768
SEVERE JOB CONDITION…1768
DISCHARGED BATTERY…1769
OTHER TROUBLE…1773
MAINTENANCE…1777
MAINTENANCE INFORMATION…1778
OUTLINE OF SERVICE…1780
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1780
ELECTRIC SYSTEM MAINTENANCE…1783
HANDLING HYDRAULIC SYSTEM…1784
WEAR PARTS…1785
WEAR PARTS LIST…1785
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1786
TIGHTENING TORQUE SPECIFICATIONS…1788
TIGHTENING TORQUE LIST…1788
SAFETY CRITICAL PARTS…1789
SAFETY CRITICAL PARTS LIST…1789
MAINTENANCE SCHEDULE…1790
MAINTENANCE SCHEDULE CHART…1790
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1791
MAINTENANCE PROCEDURE…1792
WHEN REQUIRED…1792
CHECK BEFORE STARTING…1814
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1814
EVERY 500 HOURS MAINTENANCE…1815
EVERY 1000 HOURS MAINTENANCE…1823
EVERY 1500 HOURS MAINTENANCE…1826
EVERY 2000 HOURS MAINTENANCE…1827
SPECIFICATIONS…1833
SPECIFICATIONS…1834
ATTACHMENTS, OPTIONS…1837
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1838
SAFETY FIRST…1838
ATTACHMENT INSTALLATION…1839
BUCKET WITH HOOK…1840
HOOK CONDITION…1840
PROHIBITED OPERATIONS…1840
MACHINE READY FOR ATTACHMENT…1841
LOCATIONS…1841
HYDRAULIC CIRCUIT…1844
ATTACHMENT OPERATIONS…1845
LONG TERM STORAGE…1846
SPECIFICATIONS…1846
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1847
CONTROL PATTERN CHANGE PROCEDURE…1847
MACHINE CONTROL PATTERNS…1848
ATTACHMENT GUIDE…1849
ATTACHMENT COMBINATIONS…1849
HANDLING ARM WITH BUILT-IN BREAKER…1850
REMOVING AND INSTALLING CHISEL…1850
PROCEDURE FOR BREAKER OPERATIONS…1853
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1854
INSTALLATION OF BUCKET…1855
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1857
STOWING CHISEL, DUMMY CHISEL…1857
CHECK BEFORE STARTING…1858
SPECIFICATIONS…1859
RECOMMENDED ATTACHMENT OPERATIONS…1860
HYDRAULIC BREAKER…1860
INDEX…1865
Komatsu Hydraulic Excavators PC18MR Repair Service Manual