Komatsu PC18MR-3 20001 and up Hydraulic Excavator Shop Manual - PDF DOWNLOAD by www.heydownloads.com

SEN04306-04

HYDRAULIC EXCAVATOR

PC18MR -3 SERIAL NUMBERS

20001

and up

SEN04308-04

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

00 Index and foreword

100 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

PC18MR-3

00-100

100 Index Composition of shop manual

SEN04308-04

Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: â&#x20AC;˘ Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: â&#x20AC;˘ File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title..................................................................................................................................... Form Number Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04306-04 00 Index and foreword .................................................................................................................... SEN04307-04 100 Index .................................................................................................................................. SEN04308-04 q 200 Foreword and general information ..................................................................................... SEN04309-00 01 Specification ............................................................................................................................... SEN04310-01 100 Specification and technical data......................................................................................... SEN04311-01 q 10 Structure, function and maintenance standard........................................................................... SEN04312-01 100 Engine and cooling system ................................................................................................ SEN04313-00 200 Power train......................................................................................................................... SEN04314-01 q 300 Undercarriage and frame ................................................................................................... SEN04315-00 410 Hydraulic system, Part 1 .................................................................................................... SEN04316-00 420 Hydraulic system, Part 2 .................................................................................................... SEN04317-00 430 Hydraulic system, Part 3 .................................................................................................... SEN04318-01 q 500 Work equipment................................................................................................................. SEN04319-00 600 Cab and its attachments .................................................................................................... SEN04320-00 700 Electrical system ................................................................................................................ SEN04321-00 20 Standard value table................................................................................................................... SEN04322-02 100 Standard service value table.............................................................................................. SEN04495-02 q 30 Testing and adjusting ................................................................................................................. SEN04323-00 100 Testing and adjusting ......................................................................................................... SEN04496-00 40 Troubleshooting.......................................................................................................................... SEN04324-00 100 General information on troubleshooting............................................................................. SEN04497-00 200 Troubleshooting of electrical system (E-mode).................................................................. SEN04498-00 300 Troubleshooting of hydraulic and mechanical system (H-mode) ....................................... SEN04499-00 400 Troubleshooting of engine (S-mode).................................................................................. SEN04500-00 50 Disassembly and assembly........................................................................................................ SEN04325-00 100 General information on disassembly and assembly .......................................................... SEN04620-00 200 Engine and cooling system ................................................................................................ SEN04621-00 300 Power train......................................................................................................................... SEN04622-00 00-100

PC18MR-3

100 Index Composition of shop manual

400 500 600 700 800

SEN04308-04

Undercarriage and frame ...................................................................................................SEN04623-00 Hydraulic system ................................................................................................................SEN04624-00 Work equipment .................................................................................................................SEN04625-00 Cab and its attachments.....................................................................................................SEN04626-00 Electrical system ................................................................................................................SEN04627-00

90 Diagrams and drawings ..............................................................................................................SEN04326-01 100 Hydraulic diagrams and drawings ......................................................................................SEN04327-00 200 Electrical diagrams and drawings.......................................................................................SEN04328-01

PC18MR-3

00-100

SEN04308-04

Table of contents

100 Index Table of contents

00 Index and foreword 100 Index SEN04308-04 Composition of shop manual......................................................................................................................... 2 Table of contents ........................................................................................................................................... 4 200 Foreword and general information SEN04309-00 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 Specification 100 Specification and technical data SEN04311-01 Specification dimension drawing ................................................................................................................... 2 Working range drawing ................................................................................................................................. 3 Specifications ................................................................................................................................................ 4 Weight table .................................................................................................................................................. 7 Table of fuel, coolant and lubricants.............................................................................................................. 9 10 Structure, function and maintenance standard 100 Engine and cooling system SEN04313-00 PTO ............................................................................................................................................................... 2 Cooling system.............................................................................................................................................. 4 200 Power train SEN04314-01 Power train .................................................................................................................................................... 2 Swing circle ................................................................................................................................................... 3 300 Undercarriage and frame SEN04315-00 Track frame ................................................................................................................................................... 2 Idler cushion.................................................................................................................................................. 3 Idler ............................................................................................................................................................... 5 Track roller .................................................................................................................................................... 6 Sprocket ........................................................................................................................................................ 7 Track shoe..................................................................................................................................................... 8 410 Hydraulic system, Part 1 SEN04316-00 Hydraulic components layout drawing .......................................................................................................... 2 Hydraulic tank ............................................................................................................................................... 3 Center swivel joint ......................................................................................................................................... 4 Travel motor .................................................................................................................................................. 5 Hydraulic cylinder.......................................................................................................................................... 14 Solenoid valve............................................................................................................................................... 18 Variable gauge valve..................................................................................................................................... 21 Multi-control valve (If equipped) .................................................................................................................... 22 420 Hydraulic system, Part 2 SEN04317-00 Hydraulic pump ............................................................................................................................................. 2 Control valve ................................................................................................................................................. 8

00-100

PC18MR-3

100 Index Table of contents

SEN04308-04

430 Hydraulic system, Part 3 SEN04318-01 CLSS ............................................................................................................................................................. 2 Operation for each function and valve........................................................................................................... 6 Swing motor................................................................................................................................................... 20 PPC valve...................................................................................................................................................... 23 500 Work equipment SEN04319-00 Work equipment ............................................................................................................................................ 3 Dimensions of each part of work equipment ................................................................................................. 6 600 Cab and its attachments SEN04320-00 Floor .............................................................................................................................................................. 2 700 Electrical system SEN04321-00 Engine control system ................................................................................................................................... 2 Electric control system................................................................................................................................... 4 Component parts of system........................................................................................................................... 9 KOMTRAX system ........................................................................................................................................ 10 Monitor system .............................................................................................................................................. 13 Sensors ......................................................................................................................................................... 16 20 Standard value table 100 Standard service value table SEN04495-02 Standard value table for engine related parts ................................................................................................ 2 Standard value table for chassis related parts............................................................................................... 3 30 Testing and adjusting 100 Testing and adjusting SEN04496-00 List of testing, adjusting, and troubleshooting tools....................................................................................... 3 Measuring engine speed ............................................................................................................................... 5 Measurement of exhaust gas color ............................................................................................................... 6 Adjusting valve clearance.............................................................................................................................. 7 Testing compression pressure....................................................................................................................... 9 Testing engine oil pressure............................................................................................................................ 10 Testing and adjusting fuel injection timing ..................................................................................................... 11 Adjusting engine stop solenoid...................................................................................................................... 13 Bleeding air from fuel circuit .......................................................................................................................... 14 Testing and adjusting fan belt tension ........................................................................................................... 15 Adjusting fuel control lever linkage ................................................................................................................ 16 Measurement of clearance in swing circle bearings...................................................................................... 17 Testing and adjusting track shoe tension....................................................................................................... 18 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits ............................. 20 Testing and adjusting control circuit basic pressure ...................................................................................... 23 Testing and adjusting pump LS differential pressure..................................................................................... 25 Measuring solenoid valve output pressure .................................................................................................... 27 Measuring PPC valve output pressure .......................................................................................................... 29 Adjusting play of work equipment and swing PPC valves ............................................................................. 31 Measuring swing holding brake release pressure ......................................................................................... 31 Testing oil leakage from cylinder ................................................................................................................... 33 Releasing residual pressure from hydraulic circuit ........................................................................................ 35 Bleeding air from cylinder .............................................................................................................................. 35 Pressurizing hydraulic tank............................................................................................................................ 36 How to open and close (tilt) floor ................................................................................................................... 37 Inspection procedures for diode .................................................................................................................... 39 How to start operation of KOMTRAX terminal ............................................................................................... 40 Lamp display of KOMTRAX terminal............................................................................................................. 44 Removal and installation of KOMTRAX terminal ........................................................................................... 47 Preparation work for troubleshooting of electrical system ............................................................................. 48

PC18MR-3

00-100

SEN04308-04

100 Index Table of contents

40 Troubleshooting 100 General information on troubleshooting SEN04497-00 Points to remember when troubleshooting.................................................................................................... 2 Sequence of events in troubleshooting ......................................................................................................... 3 Checks before troubleshooting ..................................................................................................................... 4 Classification and procedures of troubleshooting ......................................................................................... 5 Connection table for connector pin numbers ................................................................................................ 8 T- branch box and T- branch adapter table ................................................................................................... 44 200 Troubleshooting of electrical system (E-mode) SEN04498-00 Before carrying out troubleshooting for electrical system (E-mode) ............................................................. 2 Information contained in troubleshooting table ............................................................................................. 4 E-1 Engine does not start.............................................................................................................................. 5 E-2 Engine does not stop.............................................................................................................................. 12 E-3 When starting switch is turned ON, any item does not operate.............................................................. 14 E-4 When starting switch is turned ON, some items do not operate............................................................. 16 E-5 Alarm buzzer is abnormal....................................................................................................................... 17 E-6 Engine oil pressure caution is turned ON ............................................................................................... 19 E-7 Charge level caution is turned ON.......................................................................................................... 20 E-8 Preheating system does not operate or preheater does not become hot............................................... 22 E-9 Coolant temperature gauge is abnormal ................................................................................................ 24 E-10 Fuel level gauge is abnormal................................................................................................................ 28 E-11 Service meter does not operate while engine is running ...................................................................... 32 E-12 2nd travel speed is not selected ........................................................................................................... 35 E-13 Working lamp does not light up ............................................................................................................ 38 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves ..................................................................................................................... 40 E-15 Blade/Variable gauge selector system does not operate normally ....................................................... 43 300 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04499-00 Information contained in troubleshooting table ............................................................................................. 3 H-1 Speed or power of whole work equipment, travel, swing, and blade is low............................................ 4 H-2 Engine speed lowers extremely or engine stalls .................................................................................... 5 H-3 Whole work equipment, travel system, swing system, and blade do not move ..................................... 6 H-4 Abnormal sound comes out from around hydraulic pump...................................................................... 7 H-5 Fine control performance or response is low ......................................................................................... 7 H-6 Speed or power of boom is low .............................................................................................................. 8 H-7 Speed or power of arm is low ................................................................................................................. 9 H-8 Speed or power of bucket is low............................................................................................................. 10 H-9 Speed or power of boom swing is low .................................................................................................... 11 H-10 Work equipment does not move singly ................................................................................................ 11 H-11 Work equipment hydraulic drift is large................................................................................................. 12 H-12 Time lag of work equipment is large..................................................................................................... 13 H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 13 H-14 Machine deviates during travel............................................................................................................. 14 H-15 Travel speed or travel power is low ...................................................................................................... 16 H-16 Machine is not steered well or steering power is low ........................................................................... 16 H-17 Travel speed does not change ............................................................................................................. 17 H-18 Travel motor does not work (one side only) ......................................................................................... 17 H-19 Speed or power of swing is low ............................................................................................................ 18 H-20 Machine does not swing....................................................................................................................... 20 H-21 Swing acceleration performance is low ................................................................................................ 22 H-22 Machine overruns when it stops swinging............................................................................................ 23 H-23 Large shock is made when machine stops swinging ........................................................................... 24 H-24 When upper structure stops swinging, it makes large sound ............................................................... 24 H-25 Hydraulic drift of swing is large............................................................................................................. 25 H-26 Speed or power of blade is low ............................................................................................................ 26 H-27 Blade does not move............................................................................................................................ 27 H-28 Hydraulic drift of blade is large ............................................................................................................. 27 H-29 Variable gauge does not move............................................................................................................. 28 00-100

PC18MR-3

100 Index Table of contents

SEN04308-04

H-30 Troubleshooting for hydraulic breaker .................................................................................................. 29 400 Troubleshooting of engine (S-mode) SEN04500-00 Troubleshooting chart .................................................................................................................................... 2 50 Disassembly and assembly 100 General information on disassembly and assembly SEN04620-00 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools ............................................................................................................................... 9 200 Engine and cooling system SEN04621-00 Removal and installation of fuel injection pump assembly ............................................................................ 2 Removal and installation of radiator assembly .............................................................................................. 3 Removal and installation of hydraulic oil cooler assembly ............................................................................ 5 Removal and installation of engine and hydraulic pump assembly ............................................................... 6 300 Power train SEN04622-00 Removal and installation of swing circle assembly........................................................................................ 2 400 Undercarriage and frame SEN04623-00 Removal and installation of track shoe assembly.......................................................................................... 2 Disassembly and assembly of idler assembly ............................................................................................... 3 Disassembly and assembly of recoil spring................................................................................................... 5 Disassembly and assembly of track roller assembly ..................................................................................... 7 Assembly of travel motor assembly............................................................................................................... 9 Removal and installation of floor frame assembly ......................................................................................... 18 Removal and installation of revolving frame.................................................................................................. 22 500 Hydraulic system SEN04624-00 Disassembly and assembly of hydraulic pump assembly ............................................................................. 2 Disassembly and assembly of control valve assembly.................................................................................. 12 Removal and installation of hydraulic system and center swivel joint assembly ........................................... 18 Disassembly and assembly of center swivel joint assembly ......................................................................... 20 Removal and installation of swing motor assembly ....................................................................................... 22 Disassembly and assembly of swing motor assembly .................................................................................. 23 Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 30 Disassembly and assembly of hydraulic breaker assembly .......................................................................... 34 600 Work equipment SEN04625-00 Removal and installation of work equipment assembly................................................................................. 2 700 Cab and its attachments SEN04626-00 Removal and installation of canopy............................................................................................................... 2 800 Electrical system SEN04627-00 Removal and installation of KOMTRAX terminal ........................................................................................... 2 90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN04327-00 Hydraulic circuit diagram ............................................................................................................................... 3 200 Electrical diagrams and drawings SEN04328-01 Electrical circuit diagram................................................................................................................................ 3 Connector list and stereogram ...................................................................................................................... 5

PC18MR-3

00-100

SEN04308-04

PC18MR-3 Hydraulic excavator Form No. SEN04308-04

00-100

SEN04309-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

00 Index and foreword

200 Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36

PC18MR-3

00-200

200 Foreword and general information Safety notice

SEN04309-00

Safety notice

(Rev. 2008/02)1

Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

00-200

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w elding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

Precautions against work which you are not used to or you are used to too much

PC18MR-3

200 Foreword and general information Safety notice

SEN04309-00

Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (â&#x20AC;&#x201C;) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

11)

PC18MR-3

10)

12)

13)

14)

15)

16)

When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

00-200

200 Foreword and general information Safety notice

SEN04309-00 4.

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

00-200

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

PC18MR-3

200 Foreword and general information Safety notice

If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN04309-00 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.

PC18MR-3

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard â&#x20AC;&#x153;Zâ&#x20AC;? twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

00-200

200 Foreword and general information Safety notice

SEN04309-00 8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)

00-200

Example of O-ring (Fitted to every joint of hoses and tubes)

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.

PC18MR-3

200 Foreword and general information How to read the shop manual

How to read the shop manual q q q

SEN04309-00

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.

Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

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Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 â&#x20AC;Ś)

Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

Safety

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Coat

Oil, coolant

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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Explanation of terms for maintenance standard

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.

Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size

Tolerance –0.022 –0.126

120 a

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

Example: Standard size 60

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Tolerance Shaft –0.030 –0.076

Hole +0.046 +0

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Standard clearance and standard value q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

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Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

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Handling of electric equipment and hydraulic component

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

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Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

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Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks

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Disconnection

Connection (Example of incomplete setting of (a))

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Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

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Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.

Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

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Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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Handling of connectors newly used for engines a

Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

Pull lock type (PACKARD-2) 95 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

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Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

114 engine

107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

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95, 125 – 170, 12V140 engine While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)

Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.

Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

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How to read electric wire code a

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type

Symbol

Low-voltage wire for automobile

Thin-cover low-voltage wire for automobile

AVS

Heat-resistant low-voltAEX age wire for automobile

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Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

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Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit

Others

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AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

–

R B R D Y G L

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

– –

–

YW GL

– – – –

Gr Br –

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Precautions when carrying out operation

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

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Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

D 6 8 10 12 14 16 18 20 22 24

07049-02734

Dimensions d L 5 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 30 22.5

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2. q q q q q q q q q q q q q

a 3.

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Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

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SEN04309-00 4)

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200 Foreword and general information Precautions when carrying out operation

Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.

PC18MR-3

200 Foreword and general information Method of disassembling and connecting push-pull type coupler

SEN04309-00

Method of disassembling and connecting push-pull type coupler k k

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

PC18MR-3

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200 Foreword and general information Method of disassembling and connecting push-pull type coupler

Type 2 1.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

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Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

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200 Foreword and general information Standard tightening torque table

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Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 157 – 196 16 – 20 245 – 309 25 – 31.5 343 – 427 35 – 43.5 490 – 608 50 – 62 662 – 829 67.5 – 84.5 824 – 1,030 84 – 105 1,180 – 1,470 120 – 150 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12 a Fig. A

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Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

PC18MR-3

200 Foreword and general information Standard tightening torque table

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

SEN04309-00

Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

PC18MR-3

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

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200 Foreword and general information Standard tightening torque table

SEN04309-00 5.

Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

19 22 24 27 32 36 41 46 55

03 04 05 06 (10) (12) (14)

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42

Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).

Outer diameter of pipe (mm)

Width across flats (mm)

8 10 12 15 (16) 22 (20)

19 22 24 (27) 30 (32) 36

Tightening torque Nm {kgm} Range

Target

14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts

Thread size mm 6 8 10 12 14

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Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

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200 Foreword and general information Standard tightening torque table

Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

SEN04309-00

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1

PC18MR-3

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

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200 Foreword and general information Conversion table

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Conversion table

Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.

Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

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(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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200 Foreword and general information Conversion table

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Millimeters to inches 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

PC18MR-3

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

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Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

7 50.6 123.0 195.3 267.6 340.0

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

00-200

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

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200 Foreword and general information Conversion table

SEN04309-00

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

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200 Foreword and general information Conversion table

SEN04309-00 Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-200

PC18MR-3

200 Foreword and general information Conversion table

PC18MR-3

SEN04309-00

00-200

SEN04309-00

PC18MR-3 Hydraulic excavator Form No. SEN04309-00

00-200

SEN04311-01

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

01 Specification

100 Specification and technical data Specification dimension drawing..................................................................................................................... 2 Working range drawing ................................................................................................................................... 3 Specifications .................................................................................................................................................. 4 Weight table .................................................................................................................................................... 7 Table of fuel, coolant and lubricants................................................................................................................ 9

PC18MR-3

01-100

100 Specification and technical data Specification dimension drawing

SEN04311-01

Specification dimension drawing1

Item Operating weight

Canopy specification

a a

PC18MR-3

1,855 [1,900]

Bucket capacity

Engine model

â&#x20AC;&#x201D;

Rated engine output

Unit

0.044 Komatsu 3D67E-2 Diesel engine

kW{HP}/rpm

11.2 {15} / 2,600

Overall length

3,650

Overall height

2,410

Overall width

Min. 980 / Max. 1,300

Shoe width

230

Tail swing radius

715

Overall length of track

1,555

Distance between tumbler centers

1,212

Minimum ground clearance

170

Travel speed (Low / High)

km/h

2.3 / 4.3

Continuous swing speed

rpm

Canopy specification

8.9 (Serial No.: 20001 - 20993) 9.1 (Serial No.: 20994 and up)

Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.) Values in [ ] are for steel shoe specification. Operating weight of machine with full tank of fuel and a 75 kg operator (ISO 6016).

01-100

PC18MR-3

100 Specification and technical data Working range drawing

Working range drawing

Working range (mm)

SEN04311-01

PC18MR-3

Max. digging radius

4,025

Max. digging depth

2,160

Max. digging height

3,615

Max. vertical wall depth

1,785

Max. dumping height

2,610

Swing radius of work equipment

1,670

(1,355)

Max. reach at ground level

Blade lifting height

280

Blade lowering depth

255

PC18MR-3

3,935

01-100

100 Specification and technical data Specifications

SEN04311-01

Specifications

1 PC18MR-3

Machine model

Canopy specification

Serial number Bucket capacity

20001 and up 0.044

1,855

Performance

Working ranges

Operating weight

[1,900]

Max. digging depth

2,160

Max. vertical wall depth

1,785

Max. digging reach

4,025 3,935

Max. reach at ground level Max. digging height

3,615

2,610

Max. dumping height

465 (L.H.) / 785 (R.H.)

Bucket offset Max. blade lifting height

280

Max. blade lowering depth

250 kN {kg}

15.9 {1,620}

Continuous swing speed

rpm

8.9 (Serial No.: 20001 - 20993)

Swing max. slope angle

deg.

19.0

Travel speed

km/h

2.3 (Lo) / 4.3 (Hi)

Gradeability

deg.

Max. digging force (bucket)

9.1 (Serial No.: 20994 and up)

Ground pressure

kPa {kg/cm }

Min. 980 / Max. 1,300

Overall width

2,410 [2,410]

Dimensions

Overall height (for transport) Ground clearance of counterweight

430 [430]

Min. ground clearance

170 [170] 715

Tail swing radius Min. swing radius of work equipment (at boom swing) Min. swing radius of work equipment

1,670 (1,355) mm 2,705

Overall width (crawler)

Min. 980 / Max. 1,300

Overall length (crawler)

1,555

Length of track on ground Track gauge

a a

30.7 {0.31} [31.4 {0.32}] 3,650

Overall length (for transport)

30 2

1,212 Min. 750 / Max. 1,070

Machine cab height

1,195

Blade width x height

Min.980 / Max.1,300 Ă&#x2014; 250

01-100

PC18MR-3

100 Specification and technical data Specifications

SEN04311-01

1 PC18MR-3

Machine model

Canopy specification

Serial number

20001 and up

Model

3D67E-2

Type

4-cycle, water cooled, in-line direct injection type, swirl chamber type mm

3 – 67 × 73.6

l {cc}

0.778 {778}

kW {HP}/rpm

11.2 {15} / 2,600

Maximum torque

Nm {kgm}/rpm

45.6 {4.65} / 2,000

High idle speed

rpm

2,780

No. of cylinders – bore x stroke

Performance

Engine

Piston displacement Flywheel horsepower

rpm

1,475

g/kWh {g/HPh}

265 {198}

Low idle speed Min. fuel consumption ratio

Starting motor

12 V, 1.2 kW

Alternator

12 V, 40 A

Battery (*1)

12 V, 41 Ah × 1 (44B19L)

Radiator

AL louver type fin 1 on each side

Carrier plate

3 on each side

Track roller

Unit-type rubber crawler

Track shoe (Rubber shoe)

Assembly-type double grouser: 35 each side

Track shoe (Steel shoe) Hydraulic pump

Undercarriage

• Core type

Type x No.

Variable displacement piston type x 1, gear type x 1 3

cm /rev

Theoretical capacity For travel, work equipment, blade For swing

MPa {kg/cm2} 2

MPa {kg/cm }

Control valve

Type x No.

Control method

23.0 {235} 19.1 {195} 9-spool type x 1

Boom, Bucket, Arm Breaker, Swing, Travel Blade

Hydraulic motor

Hydraulic system

16 + 4.9

Set pressure

Hydraulic assist control Direct control

Travel motor

Variable-displacement piston motor (with counterbalance valve, parking brake) x 2

Swing motor

Fixed-displacement Orbit-roll type motor (with brake valve, swing shaft brake) x 1

Hydraulic tank Hydraulic oil filter Hydraulic oil cooler

Box-shaped, open type Tank return side Air cooled (Drawn-cup)

*1: The battery capacity (Ah) is based on 5-hour rate.

PC18MR-3

01-100

100 Specification and technical data Specifications

SEN04311-01

1 PC18MR-3

Machine model

Canopy specification

Serial number

20001 and up Double acting piston

Boom cylinder

Cylinder type

Inside diameter of cylinder Outside diameter of piston rod Stroke

Max. distance between pins

985

Min. distance between pins

630 Double acting piston

Arm cylinder

Cylinder type

Inside diameter of cylinder Outside diameter of piston rod Stroke

Min. distance between pins

706

Bucket cylinder Boom swing cylinder

Work equipment cylinder

Hydraulic system

Cylinder type

Double acting piston

Outside diameter of piston rod Stroke

50 mm

Blade cylinder

30 378

Max. distance between pins

1,027

Min. distance between pins

649 Double acting piston 60

Inside diameter of cylinder Outside diameter of piston rod Stroke

30 282

Max. distance between pins

889

Min. distance between pins

597 Double acting piston

Cylinder type

Variable gauge cylinder

447 1,153

Inside diameter of cylinder

Max. distance between pins Cylinder type

01-100

35 355

Inside diameter of cylinder Outside diameter of piston rod Stroke

35 100

Max. distance between pins

460

Min. distance between pins

360 Double acting piston

Cylinder type

Inside diameter of cylinder Outside diameter of piston rod Stroke

30 293

Max. distance between pins

820

Min. distance between pins

527

PC18MR-3

100 Specification and technical data Weight table

Weight table k

SEN04311-01

This weight table is a guide for use when transporting or handing components. Unit: kg Machine model Serial number

PC18MR-3 Canopy specification 20001 and up

Engine assembly (excluding coolant and oil)

126

• Engine (excluding coolant and oil)

• Engine mount

• PTO

• Hydraulic pump

Cooling assembly (excluding coolant and oil)

Battery

Revolving frame

200

Floor frame

125

Canopy assembly

Handrail

Operator's cab (with floor frame)

—

Operator's seat

Fuel tank (excluding fuel)

Hydraulic tank (excluding hydraulic oil)

Control valve

Counterweight

157

X-weight (Additional counterweight)

122

Swing motor (with brake valve and machinery)

Track frame assembly (excluding track shoe)

362

• Track frame

198

• Idler assembly

20 × 2

• Recoil spring assembly

12 × 2

• Carrier roller assembly (shoe plate)

1×2

• Track roller assembly

3×6

• Travel motor (with reduction gear)

18 × 2

• Sprocket

5×2

• Swing circle

• Center swivel joint

PC18MR-3

01-100

100 Specification and technical data Weight table

SEN04311-01

1 Unit: kg Machine model Serial number

PC18MR-3 Canopy specification 20001 and up

Track shoe assembly • Rubber shoe (230 mm)

51 × 2

• Double grouser shoe (230 mm)

82 × 2

Boom swing bracket assembly

Boom assembly

Arm assembly

Bucket link assembly

Bucket assembly (with side cutter)

Blade assembly

Boom cylinder assembly

Arm cylinder assembly

Bucket cylinder assembly

Boom swing cylinder assembly

Blade cylinder assembly

Variable gauge cylinder assembly

01-100

PC18MR-3

100 Specification and technical data Table of fuel, coolant and lubricants

SEN04311-01

Table of fuel, coolant and lubricants a

For details of notes (Notes 1 and 2 ...) in the table, see "Operation and Maintenance Manual".

Unit: l Reservoir

PC18MR-3 Specified capacity

Refill capacity

Engine oil pan

3.6

3.3

Final drive case (each)

0.3

Idle (each)

0.036

Track roller (each)

0.044

Hydraulic system

23.8

15.2

Fuel tank

â&#x20AC;&#x201D;

Cooling system

3.1

â&#x20AC;&#x201D;

PC18MR-3

01-100

SEN04311-01

PC18MR-3 Hydraulic excavator Form No. SEN04311-01

01-100

SEN04313-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

100 Engine and cooling system PTO................................................................................................................................................................. 2 Cooling system ............................................................................................................................................... 4

PC18MR-3

10-100

100 Engine and cooling system PTO

SEN04313-00

PTO

1. 2. 3. 4. 5.

Boss Spring pin Rubber Cover Hydraulic pump

10-100

PC18MR-3

100 Engine and cooling system PTO

PC18MR-3

SEN04313-00

10-100

100 Engine and cooling system Cooling system

SEN04313-00

Cooling system

1. 2. 3. 4. 5. 6.

Radiator cap Fan guard Shroud Oil cooler inlet Radiator Oil cooler outlet

10-100

7. 8. 9. 10. 11.

Oil cooler Reservoir tank Drain valve Radiator inlet hose Radiator outlet hose

PC18MR-3

100 Engine and cooling system Cooling system

SEN04313-00

Specifications

Core type

Radiator

Oil cooler

AL louver type fin

AL drawn-cup

Fin pitch

3.0 / 2

4.0 / 2

Total heat dissipation surface

3.12

1.05

Pressure valve cracking pressure

kPa {kg/cm2}

88.3 ± 14.7 {0.9 ± 0.15}

—

Vacuum valve cracking pressure

kPa {kg/cm2}

4.9 {0.05}

—

PC18MR-3

10-100

SEN04313-00

PC18MR-3 Hydraulic excavator Form No. SEN04313-00

10-100

SEN04314-01

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

200 Power train Power train...................................................................................................................................................... 2 Swing circle..................................................................................................................................................... 3

PC18MR-3

10-200

200 Power train Power train

SEN04314-01

Power train

1. 2. 3. 4. 5. 6.

Idler Swing motor Center swivel joint Right travel motor Engine Hydraulic pump (For work equipment, travel, swing, blade and variable gauge)

10-200

7. 8. 9. 10. 11. 12.

Hydraulic pump (For PPC control) Left travel motor Control valve Travel Hi-Lo speed selector valve PPC lock solenoid valve Swing circle

PC18MR-3

200 Power train Swing circle

SEN04314-01

Swing circle

Unit: mm No.

2. 3. 4. 5. 6. 7.

Check item

Clearance between bearing

Swing circle bearing lubricator Swing circle pinion lubricator Outer race Inner race Ball Seal

Criteria Standard clearance

Clearance limit

0.03 â&#x20AC;&#x201C; 0.15

0.25

Replace

Specifications

Reduction ratio

Grease

PC18MR-3

Remedy

110 /17 = 6.47 (Serial No.: 20001 - 20993) 82/13 = 6.31 (Serial No.: 20994 and up) G2-LI

10-200

SEN04314-01

PC18MR-3 Hydraulic excavator Form No. SEN04314-01

10-200

SEN04315-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

300 Undercarriage and frame Track frame ..................................................................................................................................................... 2 Idler cushion.................................................................................................................................................... 3 Idler ................................................................................................................................................................. 5 Track roller ...................................................................................................................................................... 6 Sprocket .......................................................................................................................................................... 7 Track shoe ...................................................................................................................................................... 8

PC18MR-3

10-300

300 Undercarriage and frame Track frame

SEN04315-00

Track frame

1. 2. 3. 4. 5.

Idler Track frame Carrier plate Travel motor Sprocket

10-300

6. 7. 8. 9.

Track roller Track shoe Idler cushion Idler guard (Steel shoe and road liner spec.)

PC18MR-3

300 Undercarriage and frame Idler cushion

SEN04315-00

Idler cushion

Steel shoe spec.

Unit: mm No.

Check item

Criteria Standard size

2. 3. 4. 5. 6. 7.

Recoil spring

Front support Recoil spring Cylinder Rear support Rod Lubricator

PC18MR-3

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

200

168

6.9 kN {700 kg}

195.6

6.0 kN {612 kg}

Replace

Specifications Grease Amount of grease

G2-LI cc

10-300

300 Undercarriage and frame Idler cushion

SEN04315-00

1 Rubber shoe spec.

1. 2. 3.

Cylinder Rod Lubricator

10-300

Specifications Grease Amount of grease

G2-LI cc

PC18MR-3

300 Undercarriage and frame Idler

SEN04315-00

Idler

Unit: mm No.

Check item

Criteria

Remedy

Standard clearance

Repair limit

266

259.5

Outside diameter of protruding portion

Outside diameter of tread

227

221

Width of protruding portion

Overall width

Width of tread

18.5

21.5

Clearance between idler and bearing

Clearance between shaft and support

PC18MR-3

Standard size

Tolerance

Rebuild or replace

Standard clearance

Clearance limit

Shaft

Hole

+0.030 +0.030

0 – 0.030

1.5

–0.025 –0.025

+0.039 +0.030

0 – 0.064

1.5

Replace bushing

Replace

10-300

300 Undercarriage and frame Track roller

SEN04315-00

Track roller

Unit: mm No.

Check item

Criteria

Remedy

Standard clearance

Repair limit

Outside diameter of protruding portion

Outside diameter of tread

Width of tread

Width of protruding portion

Interference between shaft and bearing

Interference between roller and bearing

10-300

Standard size

Tolerance

Rebuild or replace

Standard clearance

Shaft

Hole

–0.025 –0.021

–0.20 –0.40

0.179 – 0.40

+0.40 +0.20

+0.039 +0.030

0.161 – 0.40

Replace bushing

PC18MR-3

300 Undercarriage and frame Sprocket

SEN04315-00

Sprocket

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

255

+1.0 –2.0

251

Wear of root circle diameter

Wear of tip circle diameter

290

±1.5

278

Wear of tip width

—

Wear of bottom width

+1.0 –2.0

Thickness of bottom

57.5

+1.0 –2.0

55.5

PC18MR-3

Repair by overlaying welding or replace

10-300

300 Undercarriage and frame Track shoe

SEN04315-00

Track shoe

Rubber shoe

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

Wear of lug height

Wear of roller guide

Wear of meshing parts of sprocket

10-300

Replace

PC18MR-3

300 Undercarriage and frame Track shoe

SEN04315-00

1 Steel shoe

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

Link pitch

Height of grouser

Height of link

Outside diameter of bushing

Interference between link and regular pin

Interference between link and bushing

Clearance between master pin and bushing

Shaft

Hole

Standard interference

+0.155 +0.150

+0.050 +0.150

0.100 – 0.105

—

+0.154 +0.150

+0.050 +0.150

0.100 – 0.104

—

Standard size

Standard size 14

PC18MR-3

Tolerance

Replace bushing and pin or link assembly

Tolerance

Interference limit Replace

Shaft

Hole

Standard clearance

Clearance limit

–0.020 –0.050

+0.050 +0.150

0.020 – 0.100

0.8

10-300

SEN04315-00

PC18MR-3 Hydraulic excavator Form No. SEN04315-00

10-300

SEN04316-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

410 Hydraulic system, Part 1 Hydraulic components layout drawing ............................................................................................................ 2 Hydraulic tank ................................................................................................................................................. 3 Center swivel joint........................................................................................................................................... 4 Travel motor .................................................................................................................................................... 5 Hydraulic cylinder.......................................................................................................................................... 14 Solenoid valve............................................................................................................................................... 18 Variable gauge valve..................................................................................................................................... 21 Multi-control valve (If equipped).................................................................................................................... 22

PC18MR-3

10-410

410 Hydraulic system, Part 1 Hydraulic components layout drawing

SEN04316-00

Hydraulic components layout drawing

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Variable gauge valve Boom swing PPC valve Multi-control valve (If equipped) Swing motor 2-spool solenoid valve Right work equipment PPC valve Blade PPC valve Right travel motor Left travel motor Hydraulic pump Left work equipment PPC valve Hydraulic tank

10-410

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Control valve Attachment PPC valve (If equipped) Travel PPC valve Arm cylinder Boom cylinder Oil cooler Center swivel joint Variable gauge cylinder Boom swing cylinder Blade cylinder Bucket cylinder

PC18MR-3

410 Hydraulic system, Part 1 Hydraulic tank

Hydraulic tank

1. 2. 3. 4. 5. 6. 7.

Filler cap Hydraulic tank Sight gauge Drain plug Bypass valve Filter Strainer

PC18MR-3

SEN04316-00

Specifications Item

Unit

Standard

Tank capacity

18.5

Oil amount

Bypass valve set pressure Pressure valve cracking pressure Vacuum valve cracking pressure

kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}

15.2 150 ± 30 {1.53 ± 0.31} 70 ± 15 {0.71 ± 0.15} 0–5 {0 – 0.05}

10-410

410 Hydraulic system, Part 1 Center swivel joint

SEN04316-00

Center swivel joint

A1 : A2 : B1 : B2 : C1 : C2 : D1 : D2 : E1 : E2 : F1 : F2 : G1 : G2 : H1 : H2 : I1 : I2 : J1 : J2 :

From R.H. travel control valve To R.H. travel motor From L.H. travel control valve To L.H. travel motor From R.H. travel control valve To R.H. travel motor From L.H. travel control valve To L.H. travel motor From variable gauge solenoid valve To blade cylinder head From variable gauge solenoid valve To blade cylinder bottom From variable gauge solenoid valve To variable gauge cylinder bottom From variable gauge solenoid valve To variable gauge cylinder head To hydraulic tank From travel motor drain port From solenoid valve B To 2nd travel speed selector valve

1. 2. 3. 4.

Cover Rotor Slipper seal Shaft

Unit: mm No.

Check item

Clearance between rotor and shaft

10-410

Criteria

Remedy

Standard size

Standard clearance

Clearance limit

0.055 â&#x20AC;&#x201C; 0.085

0.090

Replace

PC18MR-3

410 Hydraulic system, Part 1 Travel motor

Travel motor

SEN04316-00

Model: PHV-1B-12B-PT-8517A

A : B : PP : DR :

From travel control valve From travel control valve From 2nd travel speed selector solenoid valve To tank

PC18MR-3

Specifications Model: PHV-1B-12B-PT-8517A Delivery of motor: (1st) 12.4 / (2nd) 6.2 cm3/rev Max. output speed: (1st) 1,683 / (2nd) 3,367 rpm Max. flow rate: 21.3 l/min

10-410

410 Hydraulic system, Part 1 Travel motor

SEN04316-00

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Cover No. 2 planetary gear No. 2 sun gear Ring gear No. 2 planetary carrier Housing Piston Cylinder Valve plate Brake valve Brake piston Plate

10-410

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Disc Shaft Rocker cam Control piston No. 1 planetary gear No. 1 sun gear Drain plug Oil level plug Check valve Counterbalance valve Check valve Automatic speed changing valve

PC18MR-3

410 Hydraulic system, Part 1 Travel motor

SEN04316-00

Principle of operation q The PHV Series travel motor consists of the fixed part which consists of hydraulic motor (2) and hydraulic valve and the rotary part which consists of simple planetary reduction gear unit (1).

(b1) consists of 4 planetary gears and (b2) consists of 3 planetary gears.

1. 2. 3. 4. 5.

PC18MR-3

Simple planetary reduction gear unit (Double reduction) Hydraulic motor Automatic 1st valve Counterbalance valve Carrier 2 10-410

410 Hydraulic system, Part 1 Travel motor

SEN04316-00

1. Reduction gear unit Function q The reduction gear unit consists of 2 stages of simple planetary gears. It converts the highspeed revolution from the hydraulic motor into low-speed higher torque to obtain revolution of the case. Operation q In the following figure, gear (s2) is coupled with the hydraulic motor output shaft by spline (or by a shaft). The revolution of gear (s2) is reduced through gears (s2), (b2), and (a2). q The reduced revolution is further reduced through gears (s1), (b1), and (a1) coupled with carrier 2 (5) by spline. q This revolution is transmitted through internal gears (a1) and (a2) to the rotary part and used for travel.

10-410

The reduction ratio of the 2 stages of the simple planetary gears is generally given by the following expression. R = Zs1 (Zs1 + Za1) x Zs2 (Zs2 + Za2) Zs1, Zs2: Number of teeth of gears (s1) and (s2) Za1, Za2: Number of teeth of gears (a1) and (a2) Since the body of the PHV Series travel motor revolves, the above reduction ratio is given by the following expression. R' = 1/(1-1/R)

PC18MR-3

410 Hydraulic system, Part 1 Travel motor

SEN04316-00

2. Hydraulic motor

Function q This hydraulic motor is an axial piston motor (rotary cylinder swash plate type). It converts the hydraulic energy from the pump into rotary movement. Operation q The hydraulic oil flowing in through the hydraulic valve is supplied to valve plate (3). q The hydraulic oil supplied to port (A) flows into the cylinder port in cylinder barrel (2) corresponding to port (A) and pushes piston (1). q The pushing force of the above hydraulic oil is converted through rocker cam (4) into rotary force and output to shaft (5) coupled with cylinder barrel (2). q The return oil in the cylinder port flows out through port (B) of valve plate (3). q When the motor revolves in reverse, the hydraulic oil flows in through port (B) and the return oil flows out through port (A).

PC18MR-3

10-410

410 Hydraulic system, Part 1 Travel motor

SEN04316-00 Operation of 2nd motor q Rocker cam (4) has 2 faces of (A) and (B) on the opposite side to the face on which shoe (6) slides. It is supported on 2 balls (7) fixed to body (8). q Balls (7) are installed a little higher than the axis. Accordingly, in the 1st gear speed, face (A) is pressed against body (8) by the hydraulic force applied to piston (1) and the force of spring (9), and swash plate angle is set to (a) and the delivery of the motor is increased.

10-410

If the 2nd gear lever is set, hydraulic oil (P) is led through the 2nd spool into control chamber (10). Control piston (11) moves until face (B) of rocker cam (4) reaches body (8), and then rocker cam (4) is fixed at swash plate angle (b). At this time, the delivery of the motor is reduced.

While the engine is stopped, control chamber (10) is connected through the 2nd spool to the drain port. As a result, rocker cam (4) is returned to the 1st gear speed position by spring (9), thus the 1st gear speed is always selected when the machine starts travel.

PC18MR-3

410 Hydraulic system, Part 1 Travel motor

SEN04316-00

3. Hydraulic valve 1) Counterbalance valve

Operation q If the hydraulic oil is supplied through port (A), it pushes check valve (2) open and flows in port (A') on the inlet side of the hydraulic motor. q On the other hand, the hydraulic oil flows through choke (C) into chamber (D) and moves spool (3) to the right against spring (4). q As a result, the oil on the return side of the hydraulic motor flows in through port (B') and returns through body (1) and opening (E) of spool (3) to port (B) to rotate the hydraulic motor. q If the hydraulic oil is supplied through port (B), each part operates in the opposite direction and the hydraulic motor revolves in reverse. q If the hydraulic oil from port (A) is stopped, spool (3) moved to the right is returned to the left by the force of spring (4). q At this time, the oil in chamber (D) controls the speed of spool (3) returning to the left with choke (C).

PC18MR-3

Even if the hydraulic oil from port (A) is stopped, the hydraulic motor continues revolution by inertia. At this time, the return oil is controlled gradually by the changing speed and shape of the cut of spool (3) to stop the hydraulic motor smoothly.

10-410

410 Hydraulic system, Part 1 Travel motor

SEN04316-00

2) Automatic 1st valve

Operation q If the 2nd pilot switch is turned ON, the 2nd pilot pressure is led through port (PP) into hydraulic pressure pilot (1) and force (F1) is generated. q Force (F1) moves automatic 1st valve (5) to the right against force (F4) and sets the system in the 2nd gear speed. q On the other hand, the drive pressure is led into pilots (2) and (3) to generate forces (F2) and (F3). q Since the pressure receiving area of hydraulic pilot (3) is larger than that of (2), force (F3) is larger than force (F2). As the drive pressure is increased, the difference between forces (F2) and (F3) is increased.

10-410

If the drive pressure is increased from the 2nd gear speed level to the set pressure of the 1st gear speed, the total of rightward forces (F1) and (F2) applied to automatic 1st valve (5) increases the total of leftward forces (F3) and (F4). As a result, automatic 1st valve (5) moves to the left and sets the system in the 1st gear speed. If the drive pressure lowers from the 1st gear speed level to the set pressure of the 2nd gear speed, the total of rightward forces (F1) and (F2) applied to automatic 1st valve (5) decreases the total of leftward forces (F3) and (F4). As a result, automatic 1st valve (5) moves to the right and sets the system in the 2nd gear speed.

PC18MR-3

410 Hydraulic system, Part 1 Travel motor

4. Parking brake Function q When the travel motor is stopped, the parking brake fixes the hydraulic motor output shaft mechanically.

SEN04316-00

Operation q While the hydraulic oil is not supplied to port (A) or (B), spring (7) presses brake piston (6) to the left. q At this time, disc plate (3) fixed by the semi lunar groove of cylinder barrel (1) is fixed between steel plate (4) which is also fixed to body (2). q As a result, cylinder barrel (1) cannot revolve because of the friction force of disc plate (3) and steel plate (4) and the hydraulic motor output shaft is fixed.

PC18MR-3

If the hydraulic oil is supplied to port (A) or (B), hydraulic oil (P) is led into chamber (5). Hydraulic oil (P) moves brake piston (6) to the right against the force of spring (7). As a result, disc plate (3) and steel plate (4) is released and the friction force is lost and cylinder barrel (1) can revolve.

10-410

SEN04316-00

Hydraulic cylinder

410 Hydraulic system, Part 1 Hydraulic cylinder

Boom cylinder

Arm cylinder

Bucket cylinder

10-410

PC18MR-3

410 Hydraulic system, Part 1 Hydraulic cylinder

SEN04316-00

Boom swing cylinder

Blade cylinder

Variable gauge cylinder

PC18MR-3

10-410

410 Hydraulic system, Part 1 Hydraulic cylinder

SEN04316-00

Unit: mm No.

Check item Cylinder name

Standard clearance

Clearance limit

–0.025 –0.064

+0.039 +0.080

0.025 – 0.103

0.403

–0.025 –0.064

+0.132 +0.006

0.031 – 0.196

0.496

–0.020 –0.053

+0.133 –0.007

0.013 – 0.186

0.486

Boom swing

–0.020 –0.053

+0.133 –0.007

0.013 – 0.186

0.486

Blade

–0.025 –0.064

+0.132 +0.006

0.031– 0.196

0.496

Variable gauge

–0.020 –0.053

+0.133 –0.007

0.013 – 0.186

0.486

Boom

–0.025 –0.064

+0.134 +0.072

0.097 – 0.198

1.0

Arm

–0.010 –0.050

+0.111 +0.036

0.046 – 0.161

1.0

–0.090 –0.130

+0.099 +0.040

0.130 – 0.229

1.0

–0.010 –0.050

+0.111 +0.036

0.046 – 0.161

1.0

Blade

–0.010 –0.050

+0.134 +0.072

0.082 – 0.184

1.0

Variable gauge

–0.010 –0.050

+0.111 +0.036

0.046 – 0.161

1.0

Boom

–0.025 –0.064

+0.134 +0.072

0.097 – 0.198

1.0

Arm

–0.025 –0.064

+0.111 +0.036

0.061 – 0.175

1.0

–0.090 –0.130

+0.099 +0.040

0.130 – 0.229

1.0

–0.010 –0.050

+0.111 +0.036

0.046 – 0.161

1.0

Blade

–0.010 –0.050

+0.134 +0.072

0.082 – 0.184

1.0

Variable gauge

–0.010 –0.050

+0.111 +0.036

0.046 – 0.161

1.0

Clearance between piston Bucket rod supporting shaft and bush- Boom swing ing

Clearance between cylin- Bucket der bottom supporting shaft Boom swing and bushing

10-410

Tolerance Hole

Arm Clearance between piston rod and bush- Bucket ing

Standard size

Remedy

Shaft

Boom

Criteria

Replace bushing

Replace pin and bushing

PC18MR-3

410 Hydraulic system, Part 1 Hydraulic cylinder

No.

Check item

Tightening torque of cylinder head

Tightening torque of cylinder piston

PC18MR-3

SEN04316-00

Criteria

Boom

785 ± 78.5 Nm {80 ± 8.0 kgm}

Arm

569 ± 57.0 Nm {58 ± 5.8 kgm}

Bucket

539 ± 54.0 Nm {55 ± 5.0 kgm}

Boom swing

441 ± 44.0 Nm {45 ± 4.5 kgm}

Blade

490 ± 49.0 Nm {50 ± 5.0 kgm}

Variable gauge

539 ± 54.0 Nm {55 ± 5.0 kgm}

Remedy

Retighten

Boom

422 ± 42.0 Nm {43 ± 4.3 kgm} (Width across flats: 36 mm)

Arm

618 ± 62.0 Nm {63 ± 6.3 kgm} (Width across flats: 41 mm)

Bucket

324 ± 32.5 Nm {33 ± 3.3 kgm} (Width across flats: 32 mm)

Boom swing

343 ± 34.0 Nm {35 ± 3.5 kgm} (Width across flats: 32 mm)

Blade

412 ± 41.0 Nm {42 ± 4.2 kgm} (Width across flats: 36 mm)

Variable gauge

324 ± 32.5 Nm {33 ± 3.3 kgm} (Width across flats: 32 mm)

10-410

410 Hydraulic system, Part 1 Solenoid valve

SEN04316-00

Solenoid valve

A B P T 1. 2. 3.

: : : :

To PPC valve To 2nd travel speed selector valve From hydraulic pump To hydraulic tank PPC lock solenoid valve 2nd travel speed selector solenoid valve Control relief valve

Solenoid valve 4. Coil (ON/OFF type) 5. Push pin 6. Valve spool 7. Return spring 8. Valve body

10-410

Control relief valve 9. Adjustment screw 10. Locknut 11. Plug 12. Return spring 13. Cover 14. Plunger

PC18MR-3

410 Hydraulic system, Part 1 Solenoid valve

SEN04316-00

2nd travel speed selector solenoid valve PPC lock solenoid valve Operation When solenoid is turned OFF (When circuit is shut off) q While the signal current is not flowing from the PPC lock solenoid valve or travel speed selector switch, solenoid (1) is turned OFF. Accordingly, spool (2) is pressed up by spring (3). q As a result, ports (P) and (A) are shut off from each other and the pilot pressure does not flow into the actuator. At the same time, the oil from the actuator flows through ports (A) and (T) to the hydraulic tank.

PC18MR-3

When solenoid is turned ON (When circuit is connected) q While the signal current is flowing from the PPC lock solenoid valve or travel speed selector switch to solenoid (1), solenoid (1) is turned ON. q Accordingly, spool (2) is pressed down by push pin (4). q As a result, ports (P) and (A) are connected to each other and the pilot pressure flows into the actuator. At the same time, port (T) is closed and the oil does not flow to the hydraulic tank.

10-410

SEN04316-00

410 Hydraulic system, Part 1 Solenoid valve

Control relief valve Operation q If the oil pressure from the hydraulic pump increases, the oil in port (P) pushes plunger (1) and its reaction force compresses spring (2) and moves up plunger (1), and then the oil is relieved through ports (P) and (T). Set pressure: 3.14 MPa {32 kg/cm2}

10-410

PC18MR-3

410 Hydraulic system, Part 1 Variable gauge valve

Variable gauge valve

SEN04316-00

P1: Control valve port (B7) P2: Control valve port (A7) C1: Swivel F (Blade cylinder bottom) C2: Swivel H (Variable gauge cylinder head) C3: Swivel G (Variable gauge cylinder bottom) C4: Swivel E (Blade cylinder head)

PC18MR-3

10-410

410 Hydraulic system, Part 1 Multi-control valve (If equipped)

SEN04316-00

Multi-control valve (If equipped)

(1) JIS pattern

(2) BACKHOE pattern

Operation pattern selection drawing (The port names correspond to the symbols in the drawing).

10-410

PC18MR-3

410 Hydraulic system, Part 1 Multi-control valve (If equipped)

PC18MR-3

SEN04316-00

10-410

SEN04316-00

PC18MR-3 Hydraulic excavator Form No. SEN04316-00

10-410

SEN04317-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

420 Hydraulic system, Part 2 Hydraulic pump ............................................................................................................................................... 2 Control valve ................................................................................................................................................... 8

PC18MR-3

10-420

420 Hydraulic system, Part 2 Hydraulic pump

SEN04317-00

Hydraulic pump

Main pump Model: PVK-OB-163-K-4827Z

P1 P2 PLS S1

: : : :

10-420

Main pump discharge Gear pump discharge LS pressure inlet Pump suction

1. 2. 3.

Main pump (piston pump) Gear pump LS valve

PC18MR-3

420 Hydraulic system, Part 2 Hydraulic pump

1. 2. 3. 4. 5. 6. 7. 8.

SEN04317-00

Input shaft Rocker pin Swash plate Piston Cylinder block Valve plate Spring Control piston

PC18MR-3

10-420

SEN04317-00 Function q This pump converts the engine torque transmitted to its shaft into hydraulic pressure and supplies the hydraulic oil according to the load. q The delivery can be changed by changing the swash plate angle. q This pump has the constant-horsepower control function and the load-sensitive control function. Structure Cylinder block (1) has 9 pistons (2) in it and its end is in contact with valve plate (3). Valve plate (3) has suction port (A) and discharge port (B). q Rocker cam (4) is fixed to body (S) at a certain angle. Piston (2) revolves along rocker cam (4). q

420 Hydraulic system, Part 2 Hydraulic pump

Operation q As shaft (5) revolves, cylinder block (1) revolves and pistons (2) in it reciprocate according to the movement of rocker cam (4) to suck and discharge the oil. q Accordingly, 9 pistons (2) perform 1 cycle of suction and discharge each time cylinder block (1) revolves. If shaft (5) revolves continuously, the oil is sucked and discharged continuously. q Since the displacement of pistons (2) depends on the inclination of rocker cam (4), the discharge can be changed by changing the inclination of rocker cam (4).

a: Suction stroke b: Discharge stroke c: Suction d: Discharge

10-420

PC18MR-3

420 Hydraulic system, Part 2 Hydraulic pump

1. Constant-horsepower control q Rocker pin (6) is installed to rocker cam (4) and they are so installed to body (S) that the angle of rocker cam (4) can be changed. q Spring (7) and pistons (2) of cylinder block are so arranged that they will be against each other through rocker cam (4). Discharge pressure (P1) is applied to pistons (2). q While discharge pressure (P1) is lower than the set value of spring (7), the inclination of rocker cam (4) is fixed to the maximum position by spring (7). q If discharge pressure (P1) is larger than the set value of spring (7), the inclination of rocker cam (4) is reduced by combined force (F1) x (a) of the pistons and fixed to the point where discharge pressure (P1) is balanced with the spring force.

SEN04317-00 q q

PC18MR-3

If the discharge pressure increases further, the inclination of rocker cam (4) is decreased. At this time, the length of the arm receiving combined force (F1) of the pistons is reduced from (a) to (a'). Accordingly, larger force (F1) is necessary for the inclination of rocker cam (4).

As a result, the (P) â&#x20AC;&#x201C; (Q) curve is so changed that the engine horsepower will be used efficiently (constant-horsepower control).

10-420

SEN04317-00 2. Load-sensitive control q In the load-sensitive control mode, the signal pressure from the LS valve is transmitted to control piston (9), which presses rocker cam (4). q Rocker cam (4) is slanted to change the discharge until the above pressure, spring force, and combined force (F1) of the pistons are balanced. q Since the load-sensitive control gives the constant-horsepower control priority, the discharge is controlled within the flow range of the constant-horsepower control.

10-420

420 Hydraulic system, Part 2 Hydraulic pump

3. All-horsepower control q Rod (8) is arranged in the position against spring (7) and discharge pressure (P2) is applied to it. q As discharge pressure (P2) is increased, the inclination of rocker cam (4) is reduced. q Accordingly, the horsepower used by the whole pump is kept constant, even if pressure (P2) rises.

PC18MR-3

420 Hydraulic system, Part 2 Hydraulic pump

SEN04317-00

4. LS valve q The LS valve controls the pump discharge according to the stroke of the control lever, or the demand flow for the actuator. q The LS valve detects the demand flow for the actuator from differential pressure (dPLS) between pump discharge pressure (P1L) and control valve outlet pressure (PLS) and controls pump discharge (Q) ((P1L) is called the pump discharge pressure, (PLS) the LS pressure, and (dPLS) the LS differential pressure). q In other words, the pressure loss caused by flowing of oil through the opening of the control valve spool (= LS differential pressure (dPLS) is detected, and then pump discharge (Q) is controlled to keep that pressure loss constant and supply the pump discharge according to the demand of flow for the actuator

PC18MR-3

10-420

420 Hydraulic system, Part 2 Control valve

SEN04317-00

Control valve a

C P S T A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 LS PP PS TS PA1 PA2 PA3 PA4 PA5 PA6 PA8 PA9 PB1 PB2 PB3 PB4 PB5 PB6 PB8 PB9

The control valve is an add-on type where one service valve each can be added, so it is possible to add valves or remove valves if necessary. The service valve is installed additionally between the top cover and lower valve. : Cooler port (To oil cooler) : Pump port (From main pump) : Swing motor suction port [To swing motor port (T)] : Tank port (To hydraulic tank) : To arm cylinder bottom : To swing motor (L.H.) : To left travel motor (FORWARD) : To right travel motor (FORWARD) : To boom cylinder head : To bucket cylinder head : To blade cylinder head or variable gauge cylinder bottom through selector valve : To boom swing cylinder head : To attachment actuator : To arm cylinder head : To swing motor (R.H.) : To left travel motor (REVERSE) : To right travel motor (REVERSE) : To boom cylinder bottom : To bucket cylinder bottom : To blade cylinder bottom or variable gauge cylinder head through selector valve : To boom swing cylinder bottom : To attachment actuator : Port (LS) (To pump LS valve) :â&#x20AC;&#x201D; : To swing brake (Swing holding brake release port) : Seal drain port (To tank) : From arm IN PPC valve : From swing LEFT PPC valve : From left travel FORWARD PPC valve : From right travel FORWARD PPC valve : From boom LOWER PPC valve : From bucket DUMP PPC valve : From boom swing RIGHT PPC valve : From attachment PPC valve : From arm OUT PPC valve : From swing RIGHT PPC valve : From left travel REVERSE PPC valve : From right travel REVERSE PPC valve : From boom RAISE PPC valve : From bucket CURL PPC valve : From boom swing LEFT PPC valve : From attachment PPC valve.

10-420

PC18MR-3

420 Hydraulic system, Part 2 Control valve

SEN04317-00

9-spool valve (1/5)

PC18MR-3

10-420

SEN04317-00

420 Hydraulic system, Part 2 Control valve

(2/5)

10-420

PC18MR-3

420 Hydraulic system, Part 2 Control valve

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

SEN04317-00

Suction safety valve (Attachment) Suction valve (Boom swing) Suction valve (Bucket) Suction valve (Boom) Suction valve (Arm) Suction valve (Boom) Suction safety valve (Attachment) Safety valve Spool (Attachment) Spool (Boom swing) Spool (Blade) Spool (Bucket) Spool (Boom) Spool (R.H. travel) Spool (L.H. travel) Spool (Swing) Spool (Arm) Main relief valve Unit: mm

No.

Check item

Criteria

Remedy

Standard clearance

Spool return spring (Boom swing, bucket, boom, R.H. travel, L.H. travel and arm)

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

29 x 17.5

181 N {18.42 kg}

—

144 N {14.7 kg}

Spool return spring (Swing)

20.25 x 17.6

55.4 N {5.65 kg}

—

44.3 N {4.52 kg}

Spool return spring (Swing)

13.07 x 16.7

8.5

55.4 N {5.65 kg}

—

44.3 N {4.52 kg}

Spool return spring (Blade)

42 x 20

25.4

74.5 N {7.6 kg}

—

59.6 N {6.08 kg}

Suction valve spring

36.3 x 4.45

33.3

2.65 N {0.27 kg}

—

2.16 N {0.22 kg}

Suction valve spring

39.62 x 4.5

33.3

15.9 N {1.626 kg}

—

12.8 N {1.30 kg}

PC18MR-3

Replace spring if damaged or deformed

10-420

SEN04317-00

420 Hydraulic system, Part 2 Control valve

(3/5)

10-420

PC18MR-3

420 Hydraulic system, Part 2 Control valve

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

SEN04317-00

Back pressure check valve Unload valve Pressure compensation valve F (Arm) Pressure compensation valve F (Swing) Pressure compensation valve F (L.H. travel) Pressure compensation valve F (R.H. travel) Pressure compensation valve F (Boom) Pressure compensation valve F (Bucket) Pressure compensation valve F (Blade) Pressure compensation valve F (Boom swing) Pressure compensation valve F (Attachment) Filter (For pump circuit) Pressure compensation valve R (Attachment) Pressure compensation valve R (Boom swing)

15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Pressure compensation valve R (Blade) Pressure compensation valve R (Bucket) Pressure compensation valve R (Boom) Pressure compensation valve R (R.H. travel) Pressure compensation valve R (L.H. travel) Pressure compensation valve R (Swing) Pressure compensation valve R (Arm) LS bypass valve Oil cooler bypass valve Main relief valve

F: R:

Flow control valve Pressure reducing valve Unit: mm

No.

Check item

Criteria Standard clearance

Pressure compensation valve spring (Boom swing, blade, bucket, boom and arm)

Remedy Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

16.4 x 9.4

14.5

7.65 N {0.78 kg}

—

6.08 N {0.62 kg}

22.51 x 8.4

12.5 N {1.27 kg}

—

10.0 N {1.02 kg}

20 x 8.4

6.86 N {0.7 kg}

—

5.49 N {0.56 kg}

Pressure compensation valve spring (R.H. travel and L.H. travel)

Pressure compensation valve spring (Swing)

Unload valve spring

29.1 x 18.7

90.2 N {9.2 kg}

—

72.2 N {7.36 kg}

Oil cooler bypass spring

27.2 x 13.2

78.8 N {8.04 kg}

—

63.1 N {6.43 kg}

Back pressure check valve spring

29 x 13.3

15.3 N {1.56 kg}

—

12.3 N {1.25 kg}

PC18MR-3

Replace spring if damaged or deformed

10-420

SEN04317-00

420 Hydraulic system, Part 2 Control valve

(4/5)

10-420

PC18MR-3

420 Hydraulic system, Part 2 Control valve

SEN04317-00

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Pressure compensation valve F (Arm) Spool (Arm) Check valve Suction valve Pilot check valve Pressure compensation valve R (Arm) Pressure compensation valve F (Swing) Pilot check valve Spool (Swing) Pilot check valve Pressure compensation valve R (Swing) Pressure compensation valve F (L.H. travel) Spool (L.H. travel) Pressure compensation valve R (L.H. travel) Pressure compensation valve F (Boom) Suction valve Spool (Boom) Check valve Suction valve Pressure compensation valve R (Boom)

F: R:

Flow control valve Pressure reducing valve Unit: mm

No.

Check item

Criteria Standard clearance

Check valve spring (Boom and arm)

PC18MR-3

Remedy Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

21.9 x 5

15.8

1.96 N {0.20 kg}

â&#x20AC;&#x201D;

1.57 N {0.16 kg}

Replace spring if damaged or deformed

10-420

SEN04317-00

420 Hydraulic system, Part 2 Control valve

(5/5)

10-420

PC18MR-3

420 Hydraulic system, Part 2 Control valve

SEN04317-00

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Pressure compensation valve F (Bucket) Spool (Bucket) Check valve Suction valve Pressure compensation valve R (Bucket) Pressure compensation valve F (Blade) Spool (Blade) Pressure compensation valve R (Blade) Pressure compensation valve F (Boom swing) Spool (Boom swing) Suction valve Pressure compensation valve R (Boom swing) Suction safety valve Suction safety valve Spool (Attachment) Pressure compensation valve R (Attachment) Pressure compensation valve F (Attachment) Safety valve Air bleeding plug Filter (For safety valve circuit)

F: R:

Flow control valve Pressure reducing valve Unit: mm

No.

Check item

Criteria Standard clearance

Check valve spring (Bucket)

PC18MR-3

Remedy Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

21.9 x 5

15.8

1.96 N {0.20 kg}

â&#x20AC;&#x201D;

1.57 N {0.16 kg}

Replace spring if damaged or deformed

10-420

SEN04317-00

PC18MR-3 Hydraulic excavator Form No. SEN04317-00

10-420

SEN04318-01

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

430 Hydraulic system, Part 3 CLSS............................................................................................................................................................... 2 Operation for each function and valve ............................................................................................................ 6 Swing motor .................................................................................................................................................. 20 PPC valve ..................................................................................................................................................... 23

PC18MR-3

10-430

SEN04318-01

CLSS

430 Hydraulic system, Part 3 CLSS

Outline of CLSS

Features CLSS stands for Closed center Load Sensing System, and has the following features. q Fine control not influenced by load q Control enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q Energy saving using variable pump control

10-430

Structure q The CLSS consists of a variable capacity piston pump, control valve, and actuators. q The hydraulic pump consists of the pump body, TCC valve and LS valve.

PC18MR-3

430 Hydraulic system, Part 3 CLSS

SEN04318-01

Basic principle 1.

Control of pump swash plate angle q The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS) [the difference between pump discharge pressure (PP) and control valve outlet port LS pressure (PLS) (load pressure of actuator)] is constant. q [LS differential pressure (dPLS) = Pump discharge pressure (PP) – LS pressure (PLS)]

If LS differential pressure (dPLS) becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position. If the set pressure becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.

LS differential pressure (dPLS) and pump swash plate angle

PC18MR-3

For details of the operation, see “Hydraulic pump”.

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SEN04318-01 2.

430 Hydraulic system, Part 3 CLSS

Pressure compensation control

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A pressure compensation valve is installed to the outlet port side of the control valve spool to balance the load. When two actuators are operated together, this valve acts to make pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) the same, regardless of the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the area of openings (S1) and (S2) of each valve when it is operated.

PC18MR-3

430 Hydraulic system, Part 3 CLSS

PC18MR-3

SEN04318-01

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SEN04318-01

Operation for each function and valve

430 Hydraulic system, Part 3 Operation for each function and valve

Hydraulic circuit diagram and name of valve

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PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

1. 2. 3. 4. 5. 6. 7. 8.

SEN04318-01

Unload valve Set pressure : LS pressure + 2.9 MPa {30 kg/cm2} Safety valve Set pressure: 27.9 MPa {285 kg/cm2} Pressure compensation valve Port relief valve Set pressure: 17.2 MPa {175 kg/cm2} Main relief valve Set pressure: 23 MPa {235 kg/cm2} Back pressure check valve Set pressure: 0.14 MPa {1.4 kg/cm2} Oil cooler bypass valve Set pressure: 0.4 MPa {4.0 kg/cm2} Check valve (For swing holding brake release system)

PC18MR-3

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SEN04318-01

430 Hydraulic system, Part 3 Operation for each function and valve

Unload valve 1.

When control valve is at neutral

A : To each valve B : To pump LS valve T : Tank circuit PP : Pump circuit PLS : LS circuit 1. 2.

Spool Spring

Function q When the control valve is at neutral, pump delivery (Q) discharged by the minimum swash plate angle is released to the tank circuit. When this happens, pump discharge pressure (PP) is set at 1.9 MPa {19.7 kg/cm2} by spring (2) inside the valve. [LS pressure (PLS) : 0 MPa {0 kg/cm2}].

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Operation q On the left side of spool (1), pump discharge pressure (PP) is applied to the area of (S1). On the right side, pump discharge pressure (PP) is applied to the area of (S2) and LS pressure (PLS) is applied to the area of (S3). q When the control valve is at neutral, LS pressure (PLS) is 0, so only pump discharge pressure (PP) has any effect, and (PP) is set only by the load of spring (2). q Spool (1) moves to the right until pump discharge pressure (PP) rises and (PP) x (S1) = (PP) x (S2) + force of spring (2). Pump circuit (PP) is connected to tank circuit (T) through the hole of spool (1). q In this way, pump discharge pressure (PP) is set to 1.9 MPa {19.7 kg/cm2}.

PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01

When control valve is in fine control

A : To each valve B : To pump LS valve T : Tank circuit PP : Pump circuit PLS : LS circuit 1. 2.

Spool Spring

Function q When the control valve is in the fine control mode, if the demand flow for actuator is less than the value corresponding to the minimum swash plate angle of the pump, pump pressure (PP) is set to LS pressure (PLS) + 1.9 MPa {19.7 kg/cm 2 }. If the difference of pressure between pump pressure (PP) and LS pressure (PLS) becomes equal to the load of spring (2) (1.9 MPa {19.7 kg/cm 2 }), the unload valve opens. Accordingly, LS differential pressure (dPLS) is (1.9 MPa {19.7 kg/cm2}) at this time.

PC18MR-3

Operation q When the control valve is operated finely, LS pressure (PLS) is generated and applied to area (S3) at the right end of spool (1). At this time, difference between LS pressure (PLS) and pump discharge pressure (PP) is large, since the opening area of the control valve spool is narrow. q When the difference between pump discharge pressure (PP) and LS pressure (PLS) reaches the load of spring (2), spool (1) moves to the right and pump circuit (PP) and tank circuit (T) are connected to each other. q In other words, pump discharge pressure (PP) is set to a pressure equal to force of spring (2) (1.9 MPa {19.7 kg/cm2}) + LS pressure (PLS), and LS differential pressure (dPLS) becomes 1.9 MPa {19.7 kg/cm2}.

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430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01 3.

When control valve is being operated (work equipment)

A : To each valve B : To pump LS valve T : Tank circuit PP : Pump circuit PLS : LS circuit 1. 2.

Spool Spring

Function q When the control valve is operated, if the demand flow for actuator exceeds the value corresponding to the minimum swash plate angle of the pump, the outflow to tank circuit (T) is shut off and all of pump delivery (Q) is sent to the actuator circuit.

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Operation q When the control valve is operated large, LS pressure (PLS) is generated and applied to area (S3) at the right end of spool (1). At this time, difference between LS pressure (PLS) and pump discharge pressure (PP) is small, since the opening area of the control valve spool is wide. q For this reason, the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) does not reach the load of spring (2) (1.9 MPa {19.7 kg/cm2}), so spool (1) is pushed to the left by spring (2). q As a result, pump circuit (PP) and tank circuit (T) are shut off, and all the pump delivery (Q) flows to actuator circuit (3).

PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01

Introduction of LS pressure 1.

Work equipment valve (boom, arm, bucket, boom swing, blade, swing)

Function q The LS pressure is the actuator load pressure at the outlet port end of the control valve. q With the control valve, it actually reduces pump pressure (PP) at reducing valve (3) of the pressure compensation valve to the same pressure as actuation circuit pressure (A), and sends it to the LS circuit (PLS).

PC18MR-3

Operation q When spool (1) is operated, pump pressure (PP) flows from flow control valve (2) and notch (a) in spool (1) through bridge passage (b) to actuator circuit (A). q At the same time, reducing valve (3) also moves to the right, so pump pressure (PP) is reduced by the pressure loss at notch (c), and then applied through LS circuit (PLS) to spring chamber (PLS1). q When this happens, LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4) (see the section on the LS bypass valve). q The actuator circuit pressure (PA) = (A) acts on the left end of reducing valve (3). The reduced pump pressure (PP) acts on at the other end.

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SEN04318-01 q

430 Hydraulic system, Part 3 Operation for each function and valve

As a result, reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of spring chamber (PLS1) are the same. Pump pressure (PP) reduced at notch (c) becomes actuator circuit pressure (A) and is taken to LS circuit (PLS).

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PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01

LS bypass valve

T : Tank circuit PP : Pump circuit PLS : LS circuit 1. 2.

LS bypass valve Valve cover

Function q This releases the residual pressure of LS pressure (PLS). q It makes the speed of the rise in pressure of LS pressure (PLS) more gentle. In addition, with this discarded throttled flow, it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effective LS differential pressure.

PC18MR-3

Operation q The pressurized oil for LS circuit (PLS) passes from filter (a) of bypass plug (1) through orifice (b) and flows to tank circuit (T).

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SEN04318-01

430 Hydraulic system, Part 3 Operation for each function and valve

Pressure compensation valve

Function q During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase, compensation is received. [When this happens, the other actuator being used for compound operation (right side) is at a higher load than the actuator on this side (left side).]

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Operation q If the load pressure on the other actuator side (right side) is increased during compound operation, the flow in actuator circuit (A) on this side (left side) is increased. q At this time, LS pressure (PLS) of the other actuator acts on spring chamber (PLS1) and pushes reducing valve (1) and flow control valve (2) to the left. q Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to cause a pressure loss between (PP) and (PPA). q Flow control valve (2) and reducing valve (1) are balanced at a position where the difference between pressures (PA) and (PLS) applied to both ends of reducing valve (1) becomes the same as the pressure loss made between (PP) of flow control valve (2) and (PPA). q Accordingly, the differences between upstream pressure (PPA) and downstream pressure (PA) of both spools used for the compound operation become the same, and then the oil flow is divided in proportion to the open area of cut (a) of each spool.

PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01

Area ratio of pressure compensation valve

Function q The pressure compensation valve finely adjusts the ratio of (left) area (S1) of flow control valve (2) to (right) area (S2) of reducing valve (1) and decides the compensation characteristics according to the characteristics of each actuator. S1: Area of flow control valve (2) – Area of piston (3) S2: Area of reducing valve (1) – Area of piston (3)

PC18MR-3

Area ratio (S1) : (S2) and compensation characteristics q When 1.00: [Pump (discharge) pressure (PP) – Spool cut upstream pressure (PPA)] C [LS circuit pressure (PLS) – Actuator circuit pressure (PA) (= A)] As a result, the oil is divided according to the opening area ratio of the spool. q When above 1.00: (PP) – (PPA) > (PLS) – (PA) (= A) As a result, less oil is supplied to the compensated side by the area ratio of the spool. q When below 1.00: (PP) – (PPA) < (PLS) – (PA) (= A) As a result, more oil is supplied to the compensated side by the area ratio of the spool.

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430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01 2.

LS introduction throttle of pressure compensation valve

Function q If the other actuator is relieved during compound operation, more oil is supplied through LS introduction throttle (b) of reducing valve (1).

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Operation q If the other actuator side (right side) is relieved during compound operation, each circuit press u r e ( P PA ) , ( PA ) o f t h e o t h e r a c t u a t o r becomes the same as the pump circuit pressure [(PP) = Relief pressure)]. q At this time, spring chamber pressure (PLS2) of the other actuator becomes the same as pump circuit pressure (PP) because of balancing of reducing valve (1). q (PLS2) is led through LS introduction throttle (b) of reducing valve (1) and it becomes (PLS). Since (PLS) is connected through LS bypass valve (4) to tank circuit (T), a pressure loss is made in LS introduction throttle (b) [(PLS) < (PLS2)]. q Accordingly, even if the other actuator is relieved, a pressure difference is made between (PP) and (PLS) and more oil flows through actuator circuit (A) on this side (left side).

PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01

L.H., R.H. Travel junction circuit 1.

When traveling in a straight line

Function q To compensate for any difference in the oil flow in the left and right travel circuits when traveling in a straight line, the junction circuit opens when the left and right travel spools are operated. q In this way, the flow of oil to the left and right travel motors is almost the same when traveling in a straight line, so there is no travel deviation. q When steering the machine, the difference in the load pressure returns the reducing valve of the travel valve on the inside of the turn and the opening of the notch in the travel junction valve spool becomes smaller, so the machine can be steered.

PC18MR-3

Operation q When left and right travel spools (1) are operated, the pump discharge flows from pump circuit (PP) and circuits (PA) to actuator circuits (B). q When traveling in a straight line, to make actuator circuits (PA) equal, left and right reducing valves (2) are pushed to the right by the same amount, and notch (a) and the travel junction circuit are opened. q In this way, the left and right travel actuator circuits are interconnected by the travel junction circuit, so if any difference occurs in the flow of oil to the left and right travel motors, the compensation is carried out to prevent any deviation in travel.

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SEN04318-01 2.

430 Hydraulic system, Part 3 Operation for each function and valve

Steering when traveling

Operation q When traveling in a straight line, if left travel spool (L.H. 1) is returned to the neutral position and the steering is operated, a difference (R.H. B) > (L.H. B) is generated in the load pressure of left and right travel actuator circuits (PA), and LS pressure (PLS) becomes the same pressure as (R.H. B). q As a result, flow control valve (3) on the left travel side is pushed to the left by LS circuit (PLS). Because of this, the opening of the left notch (a) is made smaller, so it becomes possible to operate the steering when traveling. q Damper (b) is provided in the circuit to damper any excessive characteristics in the opening or closing of the travel junction circuit if the spool is operated suddenly.

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PC18MR-3

430 Hydraulic system, Part 3 Operation for each function and valve

SEN04318-01

Swing holding brake cancel system

Function q This system resets the swing holding brake by using left and right swing PPC pressures and arm IN PPC pressure as signals.

PC18MR-3

Operation q The left and right swing PPC pressure and the arm IN PPC pressure each pass through check valve (2) inside spring case (1), are output to port (BR) and the swing holding brake is canceled. [The highest pressure is output to port (BR)]. q The arm and swing are connected by the pilot circuit inside the control valve.

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430 Hydraulic system, Part 3 Swing motor

SEN04318-01

Swing motor

A B L P T

: From control valve : From control valve : From control valve (PPC valve pressure signal) : Pilot port : To tank

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Specifications Model : 104-6404-005+V2TD3A (Serial No.: 20001 - 20993) 104-6454-005+V2TD3A (Serial No.: 20994 and up) Delivery of motor : 195 cm3/rev Max. using speed : 57.8 rpm Max. using flow rate : 12.0 l/min Relief valve set pressure: 15.2 MPa {155 kg/cm2} Check valve cracking pressure: 0.02 MPa {0.2 kg/cm2} Pinion gear teeth: 17 (Serial No.: 20001-20993) 13 (Serial No.: 20994 and up)

PC18MR-3

430 Hydraulic system, Part 3 Swing motor

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Pinion gear Front bearing Housing Plate Disc Flange Rear bearing Geroler Valve plate Outer face seal Inner face seal

PC18MR-3

SEN04318-01

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Valve Suction valve Valve drive shaft Spring Piston Ring Drive shaft Safety valve Safety valve Timer valve

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430 Hydraulic system, Part 3 Swing motor

SEN04318-01 Operation

Note) When the motor revolves in the opposite direction, the oil flows in the opposite direction to the above figure. 1. 2. 3. 4.

Output shaft Main drive Geroler Star

5. 6. 7. 8.

Valve plate Valve drive Disc valve Check valve

The oil from the pump through the control valve flows through disc valve (7) to geroler (3), and then star (4) of the geroler makes planetary movements. Only the rotation of the planetary movements is taken out by main drive (2) to rotate output shaft (1). At this time, the positional relationship between the 12 ports of disc valve (7) and 7 ports (a) of valve plate (5) changes in order, and the position of the oil flowing to geroler (3) changes in order accordingly.

In other words, output shaft (1) is rotated by main drive (2). At the same time, rotation of star (4) of geroler (3) is taken out by valve drive (6) and transmitted to disc valve (7), thus the motor is rotated by the oil flowing in the geroler.

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PC18MR-3

430 Hydraulic system, Part 3 PPC valve

PPC valve

SEN04318-01

Work equipment and swing PPC valve

P : From pilot pump through solenoid valve P1 : L.H. PPC valve: arm IN port/ R.H. PPC valve: boom RAISE port P2 : L.H. PPC valve: arm OUT port/ R.H. PPC valve: boom LOWER port P3 : L.H. PPC valve: swing RIGHT port/ R.H. PPC valve: bucket DUMP port

PC18MR-3

P4 : L.H. PPC valve: swing LEFT port / R.H. PPC valve: bucket CURL port T : To tank

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SEN04318-01

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430 Hydraulic system, Part 3 PPC valve

PC18MR-3

430 Hydraulic system, Part 3 PPC valve

1. 2. 3. 4. 5. 6. 7. 8. 9.

SEN04318-01

Spool Piston Disc Nut (for connecting lever) Joint Plate Retainer Body Filter Unit: mm

No.

Check item

Criteria

Remedy

Standard clearance

Centering spring [for port (P3), (P4)]

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

42.48 x 15.5

17.7 N {1.8 kg}

—

14.1 N {1.44 kg}

Centering spring [for port (P1), (P2)]

44.45 x 15.5

29.4 N {3 kg}

—

23.5 N {2.4 kg}

Metering spring

26.53 x 8.15

24.9

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

PC18MR-3

Replace spring if damaged or deformed

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430 Hydraulic system, Part 3 PPC valve

SEN04318-01 Operation 1. At neutral q Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).

q q

When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port (P1). The relationship in the position of spool (1) and body (10) (fine control hole (f) is at a point midway between drain hole (D) and pump pressure chamber (PP)) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever. So the pressure at port (P1) also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber (A) [the same as the pressure at port (P1)] and the force of the control valve spool return spring are balanced.

During fine control (neutral o fine control) q When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. q When this happens, fine control hole (f) is shut off from drain chamber (D), and at almost the same time, it is connected to pump pressure chamber (PP). q So pilot pressure oil from the control pump passes through fine control hole (f) and goes from port (P1) to port (A). q When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1).

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PC18MR-3

430 Hydraulic system, Part 3 PPC valve

During fine control (when control lever is returned) q When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). q When this happens, fine control hole (f) is connected to drain chamber (D) and the pressure oil at port (P1) is released. q If the pressure at port (P1) drops too far, spool (1) is pushed down by metering spring (2). q Fine control hole (f) is shut off from drain chamber (D). At almost the same time, it is connected to pump pressure chamber (PP). q The pump pressure is supplied until the pressure at port (P1) recovers to a pressure that corresponds to the lever position. q When the spool of the control valve returns, oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to fill the chamber with oil.

PC18MR-3

SEN04318-01 4.

At full stroke q When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). q Fine control hole (f) is shut off from drain chamber (D), and is connected with pump pressure chamber (PP). q Therefore, the pilot pressure from the solenoid valve passes through fine control hole (f) and flows to chamber (A) from port (P1), and pushes the control valve spool. q The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).

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SEN04318-01

430 Hydraulic system, Part 3 PPC valve

Travel PPC valve

For operation, see the sections of the “Work equipment and swing PPC valve”.

P P1 P2 P3 P4 T

: From pilot pump through solenoid valve : R.H. travel FORWARD port : R.H. travel REVERSE port : L.H. travel FORWARD port : L.H. travel REVERSE port : To tank

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PC18MR-3

430 Hydraulic system, Part 3 PPC valve

1. 2. 3.

SEN04318-01

Valve Body Collar

4. 5. 6.

Plate Piston Bolt Unit: mm

No.

Check item

Criteria

Remedy

Standard clearance

Centering spring

Metering spring

PC18MR-3

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

52.06 x 15.5

31.9

135 N {13.8 kg}

â&#x20AC;&#x201D;

108 N {11.0 kg}

24.04 x 8.16

23.05

16.7 N {1.7 kg}

â&#x20AC;&#x201D;

13.3 N {1.36 kg}

Replace spring if damaged or deformed

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SEN04318-01

430 Hydraulic system, Part 3 PPC valve

Boom swing and attachment PPC valve

For operation, see the section of the “Work equipment and swing PPC valve”.

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PC18MR-3

430 Hydraulic system, Part 3 PPC valve

SEN04318-01

P P1 P2 T

: From pilot pump through solenoid valve : To boom swing and attachment valve : To boom swing and attachment valve : To tank

1. 2. 3. 4. 5. 6. 7.

Spool Piston Lever Plate Retainer Body Filter Unit: mm

No .

Check item

Criteria

Remedy

Standard clearance 8

Centering spring

Metering spring

PC18MR-3

Repair limit

Free length × Outside diameter

Installed length

Installed load

Free length

Installed load

33.88 × 15.3

28.4

125 N {12.7 kg}

—

100 N {10.2 kg}

22.73 × 8.1

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

Replace spring if damaged or deformed

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SEN04318-01

PC18MR-3 Hydraulic excavator Form No. SEN04318-01

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SEN04319-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

500 Work equipment Work equipment .............................................................................................................................................. 3 Dimensions of each part of work equipment ................................................................................................... 6

PC18MR-3

10-500

SEN04319-00

10-500

500 Work equipment

PC18MR-3

500 Work equipment Work equipment

Work equipment

PC18MR-3

SEN04319-00

10-500

SEN04319-00

10-500

500 Work equipment Work equipment

PC18MR-3

500 Work equipment Work equipment

SEN04319-00

Unit: mm No.

Check item

Clearance between mounting pin of revolving frame and swing bracket and bushing

Criteria Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

–0.036 –0.090

+0.153 +0.079

0.115 – 0.243

1.0

Clearance between mounting pin of swing bracket and boom and bushing

–0.025 –0.064

+0.115 +0.053

0.078 – 0.179

1.0

Clearance between mounting pin of boom and arm and bushing

–0.025 –0.064

+0.086 +0.036

0.061 – 0.15

1.0

Clearance between mounting pin of arm and bucket and bushing

–0.090 –0.130

+0.087 +0.034

0.124 – 0.217

1.0

Clearance between mounting pin of link and bucket and bushing

–0.090 –0.130

+0.087 +0.034

0.124 – 0.217

1.0

Clearance between mounting pin of links and bushing

–0.090 –0.130

+0.087 +0.034

0.124 – 0.217

1.0

Clearance between mounting pin of arm and link and bushing

–0.090 –0.130

+0.087 +0.034

0.124 – 0.217

1.0

Clearance between mounting pin of track frame and blade and bushing

–0.010 –0.050

+0.070 +0.040

0.05 – 0.12

1.0

PC18MR-3

Replace pin and bushing

10-500

SEN04319-00

Dimensions of each part of work equipment

500 Work equipment Dimensions of each part of work equipment

Arm section

10-500

PC18MR-3

500 Work equipment Dimensions of each part of work equipment

SEN04319-00 Unit: mm

No.

Measuring point

Standard size

—

Tolerance Shaft

Hole

–0.01 –0.05

+0.039 +0.000

Arm side

–0 –1

Cylinder head side

–0.5 –0.5

— Boom side

–0.09 –0.13

±0.25

96.5

+0.0 –0.5

4 Arm side

+0.086 +0.036

—

235.2

±0.5

—

84.2

±0.5

—

242.2

±0.5

—

1,114.7

±3

—

56.8

±0.5

—

149.7

—

±1

—

210

±0.5

—

193

±0.1

—

124

±1

—

527

—

–0.090 –0.130

+0.087 +0.034

Link side

118

0. –0.5

Bucket side

119

+1.0 –0.5

—

–0.090 –0.130

+0.087 +0.034

Arm side

118

0. –0.5

Bucket side

119

+1.0 –0.5

Min.

706

±1

Max.

1,153

—

965

±3

PC18MR-3

—

10-500

500 Work equipment Dimensions of each part of work equipment

SEN04319-00

Bucket section

Unit: mm No.

Measuring point

Standard size

Tolerance

—

124

±1

—

±1

—

440.6

±1

—

25°

—

45°

—

119

+1.0 –0.5

—

176

±1

—

+0.033 +0.009

10-500

PC18MR-3

500 Work equipment Dimensions of each part of work equipment

PC18MR-3

SEN04319-00

10-500

SEN04319-00

PC18MR-3 Hydraulic excavator Form No. SEN04319-00

10-500

SEN04320-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

600 Cab and its attachments Floor................................................................................................................................................................ 2

PC18MR-3

10-600

600 Cab and its attachments Floor

SEN04320-00

Floor

Tilt floor

1. 2. 3. 4. 5. 6. 7.

Hinge pin Lock pin Gas spring Reset lever Wire Tilt lock bracket Floor assembly

10-600

Outline q The tilt floor can be tilted open for the ease of adjusting of the fan belt, inspection and maintenance such as replacement of the hydraulic hoses, etc. Tilt open angle (a): Approx. 35Â°

PC18MR-3

600 Cab and its attachments Floor

PC18MR-3

SEN04320-00

10-600

SEN04320-00

PC18MR-3 Hydraulic excavator Form No. SEN04320-00

10-600

SEN04321-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

10 Structure, function and maintenance standard

700 Electrical system Engine control system..................................................................................................................................... 2 Electric control system .................................................................................................................................... 4 Component parts of system ............................................................................................................................ 9 KOMTRAX system........................................................................................................................................ 10 Monitor system.............................................................................................................................................. 13 Sensors......................................................................................................................................................... 16

PC18MR-3

10-700

700 Electrical system Engine control system

SEN04321-00

Engine control system

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Battery Starting switch Fuse box Engine stop solenoid Lock lever PPC lock switch Neutral engine start relay Safety relay Starting motor Fuel control lever KOMTRAX terminal KOMTRAX engine cut relay

10-700

PC18MR-3

700 Electrical system Engine control system

SEN04321-00

Starting engine q If starting switch (2) is set to the "ON" position, engine stop solenoid (4) sets the governor stop lever to the "RUN" position. Accordingly, if the electric system has a failure, the engine stops, that is, a fail-safe mechanism is formed. q If starting switch (2) is set to the "START" position while lock lever (5) is in the "LOCK" position, the start signal flows in starting motor (9) and the engine starts. If lock lever (5) is in the "FREE" position, neutral engine start relay (7) operates to shut off the start signal to starting motor (9), thus the engine does not start. q If the machine is equipped with the KOMTRAX terminal system and receives an engine cutout command generated by an external operation, KOMTRAX terminal (11) turns KOMTRAX engine cut-out relay (12) ON to shut off the current to starting motor (9), thus the engine cannot start. Engine speed control If fuel control lever (10) is operated, the cable is extended or retracted to control the engine speed.

Stopping engine q If starting switch (2) is set to the "OFF" position, engine stop solenoid (4) sets the governor stop lever to the "STOP" position to stop the engine.

PC18MR-3

10-700

700 Electrical system Electric control system

SEN04321-00

Electric control system

General system drawing

10-700

PC18MR-3

700 Electrical system Electric control system

SEN04321-00

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Battery Starting switch Fuse box Monitor panel 2nd travel speed selector switch 2nd travel speed selector solenoid relay Lock lever PPC lock switch PPC lock solenoid relay 2nd travel speed selector solenoid valve PPC lock solenoid valve Right work equipment PPC valve Travel PPC valve Left work equipment PPC valve Boom swing PPC valve Travel motor Engine Hydraulic pump 18a. Servo valve 18b. LS valve 18c. PC valve 19. Control valve 19a. Self pressure reducing valve

PC18MR-3

10-700

SEN04321-00

700 Electrical system Electric control system

Travel control function

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Battery Starting switch Fuse box 2nd travel speed selector switch 2nd travel speed selector solenoid relay 2nd travel speed selector solenoid valve Left travel motor Right travel motor Control valve Engine Hydraulic pump

10-700

Input and output signals a. Solenoid power supply b. 2nd travel speed selector signal c. Solenoid valve drive signal

PC18MR-3

700 Electrical system Electric control system

SEN04321-00

Function Changing travel speed q If the travel speed selector switch of the monitor panel is operated, the motor capacity changes, thus the travel speed changes.

2nd travel speed selector switch

Low speed

High speed

2nd travel speed selector monitor

OFF

2nd travel speed selector solenoid valve

OFF

Motor capacity (cm3/rev)

12.4

6.2

Travel speed (km/h)

2.3

4.3

Max.

Min.

Even while the machine is traveling at the high speed (High), if the load changes largely on a soft ground or on a slope, the travel speed is set to the low speed (Low) automatically. At this time, the 2nd travel speed selector monitor keeps lighting up.

17.8 ± 1 MPa {181 ± 10 kg/cm2}

19.2 ± 1 MPa {196 ± 10 kg/cm2}

PC18MR-3

Travel motor swash plate angle

10-700

SEN04321-00

700 Electrical system Electric control system

PPC lock function

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Battery Starting switch Fuse box Lock lever PPC lock lever PPC lock solenoid relay PPC lock solenoid valve Left PPC valve Right PPC valve Travel PPC valve Boom swing PPC valve Engine Hydraulic pump Control valve

Function q The PPC lock switch is interlocked with the lock lever. If the lock lever is set in the LOCK position, the PPC lock switch is turned OFF. q If the PPC lock switch is turned OFF, the current flowing to the PPC lock solenoid valve is shut off. Then, the work equipment and machine unit do not move even if any control lever or pedal is operated.

Input and output signals a. PPC lock signal b. Solenoid power supply c. Solenoid valve drive signal

10-700

PC18MR-3

700 Electrical system Component parts of system

Component parts of system

SEN04321-00

PPC lock solenoid valve 2nd travel speed selector solenoid valve a

See Solenoid valve.

Monitor panel a

See Monitor system.

PC18MR-3

10-700

700 Electrical system KOMTRAX system

SEN04321-00

KOMTRAX system

The KOMTRAX terminal transmits various kinds of machine information wirelessly. The KOMTRAX operator can refer to the information at the office to provide various kinds of services for customers. a

To provide the services, a separate arrangement for setting up the KOMTRAX terminal is required.

Information transmittable from the KOMTRAX terminal includes the following. 1. Operation information 2. Service meter 3. Position information 4. Fuel level

10-700

PC18MR-3

700 Electrical system KOMTRAX system

SEN04321-00

KOMTRAX terminal

1. 2. 3. 4. 5.

GPS antenna connection Connector (A) Connector (B) Connector (C) Communication antenna connection

Outline q The KOMTRAX terminal can obtain various kinds of information from network signals or input signals in the machine and transmit them through the wireless communication antenna. It has a CPU (Central Processing Unit) in it and also has wireless communication function and GPS (Global Positioning System) function. q This terminal has LED lamps and 7-segment indicator lamps used for inspection and troubleshooting on its unit.

PC18MR-3

10-700

700 Electrical system KOMTRAX system

SEN04321-00

Connector Input and output signals 174480-1 AMP (18 + 12 + 12 pins) Pin No.

Signal name

Input/ Output signal

Pin No.

Signal name

Input/ Output signal

Pin No.

Input/ Output signal

Signal name

GND

ACC input

Input

R terminal input

Input

Fuel sensor input 1

Input

Constant power supply

Input

Constant power supply

Input

Relay output

Output Input

Network selection 2

Input

Network selection 1

Input

CAN shield

Inspection mode selection signal

CAN (H)

C terminal input

Input

Fuel sensor input 2

Input

CAN (L)

Input/ Output Input/ Output

Fuel sensor selection 2

Input

Fuel sensor selection 1

Input

10-700

PC18MR-3

700 Electrical system Monitor system

Monitor system

1. 2. 3. 4.

Monitor panel Battery Each sensor Alarm buzzer

Input and output signals a. Power supply b. Sensor signal c. Alarm buzzer signal

PC18MR-3

SEN04321-00

Outline q The machine monitor system uses the net work circuit between the controllers and sensor installed to all parts of the machine to observe the condition of the machine. It processes this information, and display it on a panel to inform the operator of condition of the machine.

10-700

700 Electrical system Monitor system

SEN04321-00

Monitor panel

Outline q The monitor panel has the monitor display function, gauge display function and service meter function. q The monitor panel has a CPU (Central Processing Unit) in it to process, display and output information. q If there is a trouble in the monitor panel unit, the monitor does not display normally. Input and output signals AMP070-20P [CN-F15] Pin No.

Signal name

Input/Output signal

Pin No.

Signal name

GND

Input

Buzzer output

Input

Working lamp switch

Input/Output signal Output Input

Input

Fuel level sensor

Wake up switch

Input

CAN+

CANâ&#x20AC;&#x201C;

Input/Output

Speed increase solenoid relay output

Output

Speed increase

Input

Engine coolant temperature sensor

Input

Engine oil pressure switch

Input

Battery charge level

Input

Preheating switch

Input

Key input

Input

ACC

Input

Sensor GND

Input

Unswitched power supply

Input

10-700

Input Input/Output

PC18MR-3

700 Electrical system Monitor system

SEN04321-00

Operation

Gauge and monitor display unit No.

Type of display

Pilot

Gauge

Display item

Fuel level

Display range

When below red When normal: OFF range When below red range: Flashing Empty - Full

Service meter

Display method

0 – 99999.9 h

Operation during run of engine

Gauge

Pilot

Coolant temperature

Caution

Preheating

Caution

Engine oil pressure

Below specified When abnormal: Flashing pressure

Caution

Battery charge level

When charge is When abnormal: Flashing defective

Pilot

Travel speed increase

PC18MR-3

55 – 135°C

Indication with pointer

When coolant When normal: OFF temperature is When above 110°C: Flashing abnormal During preheating

During operation: Flashing (18 sec)

Display color

Light source element

Red

LCD

White

LED

Display of clock time White Red Green LED

Electrical When system is When abnormal: Lighting or flashing system warning abnormal

When travel speed is increased

When speed is increased: Lighting

Red

Orange

10-700

700 Electrical system Sensors

SEN04321-00

Sensors q q q

The signal from each sensor is input to the panel directly. The sensors are classified into contact type and resistance type. Either side of a sensor of contact type is always connected to the chassis ground. Category of display Caution Gauge

Name of sensor

Type of sensor

When normal

When abnormal

Engine oil pressure

Contact

OFF (Open)

ON (Closed)

Coolant temperature

Contact

OFF (Open)

ON (Closed)

Resistance

â&#x20AC;&#x201D;

Fuel level

Engine oil pressure sensor

1. 2. 3.

Plug Contact ring Contact

4. 5. 6.

Diaphragm Spring Terminal

Function q The engine oil pressure sensor is installed to the engine cylinder block and its diaphragm senses oil pressure. If the oil pressure lowers below the set level, the switch is turned ON.

Coolant temperature sensor

1. 2. 3.

Reed switch Magnet Thermo-ferrite

4. 5. 6.

Magnet Plug Connector

Function q The coolant temperature sensor is installed to the engine cylinder block and its thermo-ferrite senses temperature changes. If the temperature rises above the set level, the switch is turned ON. 10-700

PC18MR-3

700 Electrical system Sensors

SEN04321-00

Fuel level sensor

1. 2. 3. 4.

Float Arm Variable resistor Connector

Function q The fuel level sensor is installed to the top of the fuel tank and its float moves up and down according to the fuel level in the tank. The movement of the float operates the variable resistor through the arm, and then signals are generated according to the change of the resistance.

PC18MR-3

10-700

SEN04321-00

PC18MR-3 Hydraulic excavator Form No. SEN04321-00

10-700

SEN04495-02

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

20 Standard value table

100 Standard service value table Standard value table for engine related parts ................................................................................................. 2 Standard value table for chassis related parts ................................................................................................ 3

PC18MR-3

20-100

100 Standard service value table Standard value table for engine related parts

SEN04495-02

Standard value table for engine related parts

Applicable model

PC18MR-3

Engine

3D67E-2

Item

Measurement condition

Standard value for new machine

Service limit value

2,780 ± 50

—

1,375 ± 50

—

2,600

—

Max. 5.0

5.5

Max. 1.0

2.5

0.145 – 0.185

—

0.145 – 0.185

—

MPa {kg/cm2}

3.0 – 3.4 {31 – 35}

2.5 {25}

kPa {mmH2O}

— {—}

0.196 – 0.441 {2.0 – 4.5}

—

Min. 0.098 {1.0}

— {—}

ºC

Max. 120

°(degree)

19 ± 1

—

Approx. 10

—

Unit

High idle

Engine speed

Low idle

rpm

Rated speed

At sudden acceleration Bosch index

Exhaust gas color At high idle

Intake valve Valve clearance

Normal temperature

mm Exhaust valve

Compression pressure

Oil temperature: 40 – 60°C Engine speed: 200 – 300 rpm

Compression pressure

Coolant temperature: Blow-by pressure

Within operating range At high idle

Oil pressure

Coolant temperature: Within operating range Oil: SAE30W

At high idle At low idle

Oil temperature

Whole speed range (inside oil pan)

Fuel injection timing

B. T. D. C.

Fan belt tension

Deflection when pressed with finger force of approx. 98 N{10 kg}

20-100

MPa {kg/cm2}

PC18MR-3

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Standard value table for chassis related parts

Machine model

Engine speed

Category

Item

Speed when pump is relieved

PC18MR-3

Measurement conditions

Unit

Standard value for new machine

Service limit value

• Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C • Relief of pump: Relieve bucket circuit.

rpm

Min. 2,320

aFor details, see Fig. Control valve at the end of this section.

l = 30 a=6 b=6

Boom control valve

Stroke of control valve spool

Arm control valve Bucket control valve Swing control valve Breaker control valve Boom swing control valve Blade control valve Left travel control valve

Stroke of control lever and pedal

Right travel control valve Boom control lever

N o RAISE, LOWER

80 ± 10

Arm control lever

N o IN, OUT

80 ± 10

Bucket control lever

N o CURL, DUMP

80 ± 10

Swing control lever

N o Swing to LEFT, RIGHT

80 ± 10

25 ± 5

50 ± 5

Boom swing control pedal Blade control lever

• Stop engine. • Measure at center of lever grip. • Measure at pedal tip. • Read max. value to stroke end (excluding neutral play).

N o Swing boom to LEFT, RIGHT N o RAISE, LOWER

Travel control lever

N o FORWARD, REVERSE

100 ± 10

Fuel control lever

SLOW i o FULL THROTTLE

160 ± 20

Work equipment, swing

Max. 5

Travel

Max. 5

Play of control lever

PC18MR-3

20-100

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Machine model

Operating effort of control levers and pedals

Category

PC18MR-3 Standard value for new machine

Service limit value

Boom control lever

15.68 ± 4.9 {1.6 ± 0.5}

15.68 ± 9.8 {1.6 ± 1}

Arm control lever

15.68 ± 4.9 {1.6 ± 0.5}

15.68 ± 9.8 {1.6 ± 1}

Bucket control lever

15.68 ± 4.9 {1.6 ± 0.5}

15.68 ± 9.8 {1.6 ± 1}

15.68 ± 4.9 {1.6 ± 0.5}

15.68 ± 9.8 {1.6 ± 1}

78.4 ± 19.6 {8.0 ± 2.0}

78.4 ± 29.4 {8.0 ± 3.0}

Blade control lever

29.4 ± 9.8 {3.0 ± 1.0}

29.4 ± 19.6 {3.0 ± 2}

Travel control lever

19.6 ± 4.9 {2.0 ± 0.5}

19.6 ± 9.8 {2.0 ± 1}

Fuel control lever

29.4 ± 14.7 {3.0 ± 1.5}

29.4 ± 29.4 {3.0 ± 3}

Item

Swing control lever Boom swing control pedal

Unload pressure

Measurement conditions

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Install push-pull scale to center of lever grip or pedal tip to measure. • Read max. value to stroke end.

• • • •

Unit

N {kg}

Hydraulic oil temperature: 45 – 55°C Set all levers in neutral. Run engine at full throttle. Measure pump outlet pressure.

+ 0.98

2.5 0

+ 10

{25 0 } + 0.98

23.0 – 0.49

Boom relief pressure

+ 10

{235 – 5 } + 0.98

23.0 – 0.49

Arm relief pressure

+ 10

{235 – 5 } + 0.98

23.0 – 0.49

Bucket relief pressure

Oil pressure

Swing relief pressure

+ 10

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle and measure relief pressure (Relieve only circuit to be measured). • Measure pump outlet pressure. MPa {kg/cm2}

Boom swing relief pressure

Blade relief pressure

20-100

Control circuit oil pressure

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Measure circuit oil pressure when all control levers are in neutral. • Measure pump outlet pressure.

LS differential pressure

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Pump outlet pressure LS pressure

+ 10

{25 0 } + 0.98

23.0 – 0.49 + 10

{235 – 5 } + 0.98

23.0 – 0.49 + 10

{235 – 5 } + 0.98

23.0 – 0.49 + 10

{235 – 5 }

19.1 ± 0.98 {195 ± 10}

+ 0.98

23.0 – 0.49

+ 10 {253 – 5 }

{253 – 5 }

23.0 ± 0.98 {253 ± 10}

+ 0.98

Travel relief pressure

+ 0.98

2.5 0

+ 10

+ 0.98

23.0 – 0.49

+ 10 {253 – 5 }

{253 – 5 }

+ 0.39

3.72 – 0.1 +4

{38 – 1 } + 0.98

+ 10

+ 0.39

3.72 – 0.1 +4

{38 – 1 } + 0.98

When all levers are in neutral

2.5 0

+ 10 {25 0 }

{25 0 }

When arm lever is moved IN (half stroke)

1.57 ± 0.1 {16 ± 1}

+ 10

PC18MR-3

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Machine model Category

Time required to start swinging

Swing

Measurement conditions

Unit

Standard value for new machine

Service limit value

No load, max. reach Hydraulic oil temperature: 45 – 55°C Run engine at full throttle. Stop after swinging 1 turn and measure shifting distance of swing circle. • Value in ( ) is shifting distance of outside of swing circle. • For measuring posture, see Fig. Swing 1 at end of this section.

deg. (mm)

Max. 40 (–)

50 (–)

Max. 2.0

Max. 2.2

—

Item

Overrun of swing

Time required for swinging

• • • •

No load, max. reach Run engine at full throttle. Hydraulic oil temperature: 45 – 55°C Measure time required to pass 90° and 180° points after starting swinging. • For measuring posture, see Fig. Swing 1 at end of this section.

180° sec.

No load, max. reach Hydraulic oil temperature: 45 – 55°C Run engine at full throttle. Measure time required to swing 5 turns after swinging 1 turn. • For measuring posture, see Fig. Swing 1 at end of this section.

• • • •

Travel

90°

• • • •

• • • • Hydraulic drift of swing

PC18MR-3

Max. reach Hydraulic oil temperature: 45 – 55°C Stop engine. Fill bucket with rated load or dirt and sand. (Rated load: 706 N {72 kg}) Stop machine on slope of 15° and set its upper structure at 45° upward. Make match marks on swing circle outer race and track frame. Measure shifting distance of match marks in 15 minutes. For measuring posture, see Fig. Swing 2 at end of this section.

34 ± 3

Max. 41

33 ± 3

Max. 40

deg. (mm)

0 (0)

cc/min.

—

31.3 ± 3

31.3 ± 6

Leakage from swing motor

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Relieve swing circuit and measure leakage in 1 minute. Low speed

Travel speed

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • After approach run of at least 10 m on flat ground, measure time required to travel 20 m. • ( ): Machine with steel shoe specification • For measuring posture, see Fig. Travel 1 at end of this section.

High speed

16.7 ± 2

16.7 ± 4

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • After approach run of at least 10 m on hard and flat ground, measure travel deviation (X) in the travel of 20 m after approach run. • For measuring posture, see Fig. Travel 2 at end of this section.

Low speed

Max. 500

550

Max. 500

550

l/min.

—

Travel deviation

sec.

mm High speed

Hydraulic drift of travel

• Hydraulic oil temperature: 45 – 55°C • Stop engine. • Stop machine on slope of 30° with sprocket on upper side. • Measure hydraulic drift of travel in 5 minutes. • For measuring posture, see Fig. Travel 3 at end of this section.

Leakage from travel motor

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Lock shoe to relieve travel circuit.

*1: Applicable Serial No.: 20001 - 20993 *2: Applicable Serial No.: 20994 and up

PC18MR-3

20-100

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Machine model Category

PC18MR-3 Standard value for new machine

Service limit value

Max. 300

450

Max. 35

Max. 25

Max. 10

Boom swing cylinder (Retraction and extension of cylinder)

• Hydraulic oil temperature: 45 – 55°C • Stop engine • Bucket: Rated load (Rated load: 706 N {72 kg}) • Set machine in above position on slope of 15° with upper structure at right angle to its body and measure retraction and extension of cylinder for 15 minutes.

Max. 20

Blade (Hydraulic drift of blade tip)

• Hydraulic oil temperature: 45 – 55°C • Stop engine • Measure hydraulic drift of blade tip from maximum raising height for 15 minutes.

Max. 50

Max. 75

RAISE

2.0 ± 0.2 (To just before cushion)

2.6 (To just before cushion)

Boom speed

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Measure time required to move cylinder between extension stroke end and position at which bucket tooth is in contact with ground. • For measuring posture, see Fig. Work equipment 2 at end of this section.

LOWER

2.0 ± 0.2

2.6

2.5 ± 0.3

3.1

OUT

2.2 ± 0.2

2.6

CURL

2.2 ± 0.2

2.6

DUMP

1.7 ± 0.2

2.3

Swing boom to LEFT

5.0 ± 1.5

8.0

Swing boom to RIGHT

5.0 ± 1.5

8.0

RAISE

1.0 ± 0.3

1.6

LOWER

1.0 ± 0.3

1.6

Item

Measurement conditions

Unit

Work equipment

Hydraulic drift

Whole work equipment (Hydraulic drift of bucket tooth tip)

• Measure extension and retraction of each cylinder and lowering of bucket tooth tip from above position. • Stop machine on level and flat ground. • Bucket: Rated load Boom cylinder (Rated load: 706 N {72 kg}) (Retraction of cyl• Hydraulic oil temperature: 45 – 55°C inder) • Stop engine Arm cylinder • Set lever in neutral. (Extension of cyl- • Start measurement just after setting. inder) • Measure hydraulic drift every 5 minutes for 15 minutes. Bucket cylinder • For measuring posture, see Fig. Work equip(Retraction of cylment 1 at end of this section. inder)

Work equipment speed

Arm speed

Bucket speed

Boom swing speed

Blade speed

20-100

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Measure time required to move cylinder between extension and retraction stroke ends. • For measuring posture, see Fig. Work equipment 3 at end of this section. • Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Measure time required to move cylinder between extension and retraction stroke ends. • For measuring posture, see Fig. Work equipment 4 at end of this section. • Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Measure time required to move cylinder between extension and retraction stroke ends. • For measuring posture, see Fig. Work equipment 5 at end of this section. • Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Measure time required to move cylinder between position at which blade is in contact with ground and maximum blade raising position. • For measuring posture, see Fig. Work equipment 6 at end of this section.

sec.

PC18MR-3

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Machine model

—

Standard value for new machine

Service limit value

Boom time lag

• Hydraulic oil temperature: 45 – 55°C • Run engine slow. • Set arm to OUT stroke end, bucket to DUMP stroke end, and boom at RAISE stroke end. Then, lower bucket and measure time required to raise machine after bucket touches ground. • For measuring posture, see Fig. Work equipment 7 at end of this section.

Max. 2

Max. 3.9

Arm time lag

• Hydraulic oil temperature: 45 – 55°C • Run engine slow. • Set upper side of boom horizontally, bucket to DUMP stroke end, and arm to IN stroke end. Then, move arm IN and measure time required to start it again after it stops temporarily. • For measuring posture, see Fig. Work equipment 8 at end of this section.

Max. 1

Max. 2

Bucket time lag

• Hydraulic oil temperature: 45 – 55°C • Run engine slow. • Set upper side of boom horizontally, arm to IN stroke end, and bucket to DUMP stroke end. Then, CURL bucket and measure time required to start it again after it stops temporarily. • For measuring posture, see Fig. Work equipment 9 at end of this section.

Max. 1

Max. 2

Blade time lag

• Hydraulic oil temperature: 45 – 55°C • Run engine slow. • Lower blade from RAISE stroke end and measure time required to raise machine after blade touches ground. • For measuring posture, see Fig. Work equipment 10 at end of this section.

Max. 2

Max. 3.9

Max. 2

—

Time lag

Item

Internal leakage

Work equipment

Category

PC18MR-3

Leakage from each cylinder Leakage from center swivel joint

Performance of hydraulic pump

PC18MR-3

Measurement conditions

• Hydraulic oil temperature: 45 – 55°C • Run engine at full throttle. • Relieve circuit to be measured.

Unit

sec.

cc/min.

See section of Performance of hydraulic pump.

20-100

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Performance of hydraulic pump Gear pump Item

Measurement conditions

Discharge of gear pump

• Hydraulic oil temperature: 45 – 55°C • Engine speed: 2,600 rpm • Measure at set pressure of relief valve.

Unit

Standard value for new machine

Service limit value

l/min.

12.1

10.2

Piston pump Item

Discharge of piston pump

20-100

Measurement conditions

Checkpoint

Discharge pressure of piston pump (MPa{kg/cm2})

Standard discharge (l/min.)

Criterion (l/min.)

• Hydraulic oil temperature: 45 – 55°C • Engine speed: 2,600 rpm a Avoid measuring near broken part of graph since error become large at that part.

Any point

Q (See graph)

PC18MR-3

100 Standard service value table Standard value table for chassis related parts

SEN04495-02

Posture of machine for measuring performance and measurement procedure Control valve: Set spool to stroke end

Travel 1: Travel speed and travel deviation (Travel posture)

Swing 1: Overrun of the swing, time taken to start swing, and time taken to swing

Travel 2: Travel deviation (Distance of deviation)

Swing 2: Hydraulic drift of swing

Travel 3: Hydraulic drift of travel

PC18MR-3

20-100

SEN04495-02

100 Standard service value table Standard value table for chassis related parts

Work equipment 1: Hydraulic drift of work equipment

Work equipment 4: Bucket speed

Work equipment 2: Boom speed

Work equipment 5: Boom swing speed

Work equipment 3: Arm speed

Work equipment 6: Blade speed

20-100

PC18MR-3

100 Standard service value table Standard value table for chassis related parts

Work equipment 7: Boom time lag

SEN04495-02 Work equipment 10: Blade time lag

Work equipment 8: Arm time lag

Work equipment 9: Bucket time lag

PC18MR-3

20-100

SEN04495-02

PC18MR-3 Hydraulic excavator Form No. SEN04495-02

20-100

SEN04496-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

30 Testing and adjusting

100 Testing and adjusting List of testing, adjusting, and troubleshooting tools ........................................................................................ 3 Measuring engine speed................................................................................................................................. 5 Measurement of exhaust gas color................................................................................................................. 6 Adjusting valve clearance ............................................................................................................................... 7 Testing compression pressure ........................................................................................................................ 9 Testing engine oil pressure ........................................................................................................................... 10 Testing and adjusting fuel injection timing......................................................................................................11 Adjusting engine stop solenoid ..................................................................................................................... 13 Bleeding air from fuel circuit.......................................................................................................................... 14 Testing and adjusting fan belt tension........................................................................................................... 15 Adjusting fuel control lever linkage ............................................................................................................... 16 Measurement of clearance in swing circle bearings ..................................................................................... 17 Testing and adjusting track shoe tension ...................................................................................................... 18 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits............................. 20 Testing and adjusting control circuit basic pressure...................................................................................... 23 Testing and adjusting pump LS differential pressure .................................................................................... 25 Measuring solenoid valve output pressure ................................................................................................... 27 Measuring PPC valve output pressure ......................................................................................................... 29 Adjusting play of work equipment and swing PPC valves ............................................................................ 31 Measuring swing holding brake release pressure......................................................................................... 31 Testing oil leakage from cylinder................................................................................................................... 33 Releasing residual pressure from hydraulic circuit ....................................................................................... 35

PC18MR-3

30-100

SEN04496-00

100 Testing and adjusting

Bleeding air from cylinder.............................................................................................................................. 35 Pressurizing hydraulic tank ........................................................................................................................... 36 How to open and close (tilt) floor................................................................................................................... 37 Inspection procedures for diode.................................................................................................................... 39 How to start operation of KOMTRAX terminal .............................................................................................. 40 Lamp display of KOMTRAX terminal ............................................................................................................ 44 Removal and installation of KOMTRAX terminal .......................................................................................... 47 Preparation work for troubleshooting of electrical system............................................................................. 48

30-100

PC18MR-3

100 Testing and adjusting List of testing, adjusting, and troubleshooting tools

SEN04496-00

Part No.

Measuring engine speed

799-205-1100 1 799-201-9001

Measuring exhaust gas color

Handy smoke checker

Remarks Degital display: 6 – 99,999.9 rpm

Smoke meter

Clearance gauge

Intake : 0.145 – 0.185 mm Exhaust : 0.145 – 0.185 mm

Compression gauge

0 – 7 MPa {0 – 70 kg/cm2}

Adapter

For 3D67E-1 and 2 (YC-2)

Joint

For 3D67E-1 and 2

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

2 799-401-2320

Hydraulic tester

Pressure gauge: 1 MPa {10 kg/cm2}

Commercially available

Dial gauge

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

799-101-5220

Nipple

07002-11023

O-ring

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

799-101-5220

Nipple

07002-11023

O-ring

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

Differential pressure gauge

50 MPa {50 kg/cm2}

799-101-5220

Nipple

07002-11023

O-ring

Commercially available

D 2 795-111-1120 3 795-101-1571

1 E

Measuring swing circle bearing clearance

Measuring and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits

Bosch index: 0 – 9 2 Commercially available

1 795-502-1590

Measuring engine oil pressure

Tachometer kit

Adjusting valve clearance

Measuring compression pressure

Part Name

Q’ty

Testing/Adjusting item

Symbol

List of testing, adjusting, and troubleshooting tools

—

1 G 2

Size: 10 x 1.25 mm

1 Measuring control circuit oil pressure

H 2

Size: 10 x 1.25 mm

1 Measuring pump LS differential pressure

2 799-401-2701

PC18MR-3

Size: 10 x 1.25 mm

30-100

100 Testing and adjusting List of testing, adjusting, and troubleshooting tools

Measuring solenoid valve output pressure

Part Name

Q’ty

Testing/Adjusting item

Symbol

SEN04496-00

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

Adapter

Size : 02

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

Adapter

Size : 02

799-101-5002

Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

Adapter

Size : 02

Part No.

1 K

2 799-401-3100

Measuring PPC valve output pressure

1 L

2 799-401-3100

Measuring swing holding brake release pressure

Remarks

1 M

2 799-401-3100 Measuring leakage from work equipment cylinder

Commercially available

Measuring cylinder

Measuring coolant temperature and oil temperature

–

799-101-1502

Digital thermometer

- 99.9 – 1,299°C

Measuring operating effort and pressing force

0 – 294 N {0 – 30 kg}

–

0 – 490 N {0 – 50 kg}

Measuring stroke and hydraulic drift

–

Commercially available

Scale

—

Measuring work equipment speed

–

Commercially available

Stopwatch

—

Measuring voltage and resistance

–

Commercially available

Tester

—

79A-264-0021

—

Push-pull scale 79A-264-0091

For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the monitor panel, controllers, sensors, actuators, and wiring harnesses, see Troubleshooting, “T-branch box and T-branch adapter table”.

30-100

PC18MR-3

100 Testing and adjusting Measuring engine speed

SEN04496-00

Measuring engine speed a

a q q

Connect probe [3] to tachometer [4].

Measuring instruments for engine speed Symbol

Part No.

799-205-1100

Part Name Tachometer kit

Measure the engine speed under the following condition. Coolant temperature: Within operating range Hydraulic oil temperature : 45 â&#x20AC;&#x201C; 55Â°C Preparation work 1) Open the engine rear cover and stick reflector tape [1] of tachometer kit A to the end face of fan pulley (1).

Measuring low idle speed 1) Start the engine and set the fuel control lever in the low idle position. 2) Set all the control levers and pedals in neutral and measure the engine speed.

Measuring high idle speed 1) Start the engine and set the fuel control lever in the high idle position. 2) Set all the control levers and pedals in neutral and measure the engine speed.

Measuring engine speed when 1 pump is relieved 1) Start the engine and set the fuel control lever in the high idle position. 2) Set the lock lever in the FREE position and move the bucket cylinder to the CURL stroke end. 3) Relieve the bucket circuit in the CURL position under this condition and measure the engine speed.

Work after finishing measurement After finishing measurement, remove the measuring instruments and return the removed parts.

Using stand [2], set probe [3] straight at reflector tape [1].

PC18MR-3

30-100

100 Testing and adjusting Measurement of exhaust gas color

SEN04496-00

Measurement of exhaust gas color a

Exhaust gas color measurement tool Symbol B

a k

Part No.

Part Name

799-201-9001

Handy smoke checker

Commercially available

Smoke meter

Measurement of exhaust gas color under the following condition. Coolant temperature: Within operating range Be careful not to touch the highly heated parts, while fitting and detaching a measurement tool. If no compressed air or power is not available in the field, use handy smoke checker B1. For recording official data, use smoke meter B2. Measurement with handy smoke checker B1 1) Fit a filtering paper to handy smoke checker B1. 2) Insert the exhaust gas intake pipe into the exhaust pipe (1). 3) Start the engine. 4) Accelerate the engine suddenly or run it at high idle and operate the handle of smoke checker B1 so that the filter paper will absorb the exhaust gas.

6) 5) 6)

Remove the filter paper and compare it with the attached scale. After finishing measurement, remove the measuring instruments and return the removed parts.

Measurement with smoke meter B2 1) Insert probe [1] of the smoke meter B2 into the exhaust gas pipe (1) outlet, and fasten it to the outlet with a clip.

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Connect the probe hose, accelerator switch outlet and air hose to the smoke meter B2. a Keep the pressure of the supplied compressed air below 1.5 MPa {15 kg/cm2}. Connect the power cable to AC socket. a Confirm that the smoke meter power switch is in the OFF position, before connecting the power cable to an outlet. Fit a filtering paper by loosening the suction pump cap nut. a Fit the filtering paper securely so that air may not leak. Move the smoke meter B2 power switch to the ON position.

Accelerate the engine suddenly or run it at high idle and press the accelerator pedal of smoke meter B2 and collect the exhaust gas into the filter paper. Put the polluted filtering paper on non-polluted filtering paper (more than 10 sheets) in the filtering paper holder, and read the indicated value. After finishing measurement, remove the measuring instruments and return the removed parts.

PC18MR-3

100 Testing and adjusting Adjusting valve clearance

SEN04496-00

Adjusting valve clearance a

While checking through the inspection hole of the flywheel housing, rotate the crankshaft forward to bring the stamped "1.TC" line (a) of the flywheel to stamped line (b) in the housing and set the No. 1 cylinder to the compression top dead center. a Rotate the crankshaft with the crankshaft pulley mounting bolt. a If you cannot see stamped line (b) easily, match stamped line (a) to the projection in the inspection hole. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.

While the No. 1 cylinder is at the compression top dead center, adjust the valve clearances marked with q in the valve arrangement drawing according to the following procedure. a Valve arrangement drawing

Adjusting instrument for valve clearance Symbol

Part No.

Commercially available

Part Name Clearance gauge

Tilt the floor open. For details, see â&#x20AC;&#x153;How to open and close (tilt) floorâ&#x20AC;?.

Remove cylinder head cover (1).

PC18MR-3

30-100

SEN04496-00 1)

Insert clearance gauge C in clearance (c) between rocker arm (2) and valve cap (3) and adjust the clearance with adjustment screw (4). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the clearance gauge lightly.

While fixing adjustment screw (4), tighten locknut (5). a After adjusting all of the valves marked with q, go to the next procedure.

Rotate the crankshaft forward to bring the stamped "1.TC" line (a) of the flywheel to stamped line (b) in the housing or the projection in the inspection hole.

While the stamped lines are matched, adjust the valve clearances marked with Q in the valve arrangement drawing. a Adjust the valve clearance according to step 4 above.

After finishing adjusting, return the removed parts. 3 Cylinder head cover mounting bolt: 4.9 Nm {0.5 kgm}

30-100

100 Testing and adjusting Adjusting valve clearance

PC18MR-3

100 Testing and adjusting Testing compression pressure

SEN04496-00

Testing compression pressure a

Testing instruments for compression pressure Symbol D

Part No.

Part Name

795-502-1590

Compression gauge

795-111-1120

Adapter (YC-2)

795-101-1571

Joint

When testing the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Test the compression pressure under the following condition. q Engine oil temperature: 40 – 60°C

Adjust the valve clearance. For details, see “Adjusting valve clearance”.

Prepare for testing the engine speed. For details, see Testing engine speed.

Open the cooling cover and close the valve of water separator (1).

Disconnect M4 connectors (2) and (3) of the engine stop solenoid.

Remove nozzle holder (4) of the cylinder to measure the compression pressure. a If you remove the air cleaner assembly temporarily, you can work easily.

PC18MR-3

Install adapter D2 and joint D3 to the nozzle holder mounting part and connect compression gauge D1. a Install the packing to the end of the adapter. 3 Adapter: 58.8 Nm {6.0 kgm} a Since the compression gauge cannot be pulled out of the revolving frame, keep the floor tilted open. a If you have removed the air cleaner assembly, install it before starting the test.

Crank the engine with the starting motor and test the compression pressure. a Read the compression gauge when its pointer is stabilized. a When testing the compression pressure, test the engine speed, too, and check that it is in the measurement condition range.

After finishing testing, remove the testing instruments and return the removed parts. 3 Nozzle holder: 58.8 Nm {6.0 kgm}

30-100

100 Testing and adjusting Testing engine oil pressure

SEN04496-00

Testing engine oil pressure a

Tilt down the floor and connect the oil pressure test hose to oil pressure gauge [2] of hydraulic tester E2.

Start the engine and measure the engine oil pressure at low idle and high idle.

After finishing testing, remove the testing instruments and return the removed parts. 3 Engine oil pressure switch Switch: 9.8 – 11.8 Nm {1.0 – 1.2 kgm} Screw: 1.4 – 2.0 Nm {0.14 – 0.2 kgm}

Testing instruments for engine oil pressure Symbol E

1 2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

Test the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range

Tilt the floor open. For details, see “How to open and close (tilt) floor”.

Remove engine oil pressure switch (1).

Install adapter [1] of hydraulic tester E1 and pull the oil pressure test hose out of the revolving frame.

30-100

PC18MR-3

100 Testing and adjusting Testing and adjusting fuel injection timing

Testing and adjusting fuel injection timing a a

SEN04496-00 5.

Rotate the crankshaft forward slowly from this position about 1.5 turns.

Rotate the crankshaft forward slowly again. When the fuel rises at the end of No. 1 delivery holder hole (a) of fuel injection pump (2), stop the crankshaft.

Watch through the inspection hole of the flywheel housing and check that injection timing stamped line (b) on the flywheel is matched to stamped line (c) in the housing. a If you cannot see stamped line (c) easily, check the position of stamped line (b) by the projection in the inspection hole.

After finishing testing, return the removed parts. 3 Fuel injection pipe sleeve nut: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} a If the fuel injection timing is abnormal, adjust it before connecting the fuel injection pipe.

After the fuel injection pump is replaced or repaired, test and adjust the fuel injection timing according to the following procedure. Before testing and adjusting the fuel injection timing, bleed air from the fuel circuit.

Testing 1. Tilt the floor open. For details, see “How to open and close (tilt) floor”. 2.

Remove 3 fuel injection pipes (1). a If you remove the air cleaner assembly temporarily, you can work easily.

Set the fuel control lever in the high idle position. a Keep the fuel control lever in this position during the test.

Rotate the crankshaft forward slowly. When the fuel flows out of the end of No. 1 delivery holder hole (a) of fuel injection pump (2), stop the crankshaft. a Rotate the crankshaft with the crankshaft pulley mounting bolt. a After the fuel rises, wipe it off to check again.

PC18MR-3

30-100

100 Testing and adjusting Testing and adjusting fuel injection timing

SEN04496-00 Adjusting a If the fuel injection timing stamped line on the flywheel is not matched to the stamped line in the flywheel housing or the projection in the inspection hole, the fuel injection timing is abnormal. In this case, adjust according to the following procedure. 1.

Remove fuel injection pump (2) and check the thickness of shims (3).

Adjust the fuel injection timing by increasing or decreasing the thickness of shims (3). a If the fuel injection timing is q early, increase the shim thickness. q late, decrease the shim thickness a If the shim thickness is changed by 0.20 mm, the fuel injection timing changes about 2°. a The thickness of each shim is indicated by the number of the identification hole. q 0.20 mm shim: 2 identification holes q 0.25 mm shim: 1 identification hole q 0.30 mm shim: No identification hole

30-100

Set selected shim (3) and install fuel injection pump (2). a Thinly apply gasket sealant (ThreeBond 1215 or 1104) to both sides of the shim. 3 Fuel injection pump mounting bolt/nut: 9.8 – 11.3 Nm {1.0 – 1.15 kgm}

After finishing adjusting, check that the fuel injection timing is normal according to the above testing procedure.

PC18MR-3

100 Testing and adjusting Adjusting engine stop solenoid

Adjusting engine stop solenoid 1 a

SEN04496-00 4.

After tightening the bolts, push the rear end of bellows (6) and check that rod (4) and stop lever (2) move smoothly.

After finishing adjusting, start and stop the engine to check that the solenoid operates normally.

After the engine stop solenoid is removed and installed, adjust it according to the following procedure.

Function q The engine stop solenoid is a push-type solenoid which is normally energized (during operation) and which has a suction coil and a holding coil. q When the starting switch is turned ON, both of the suction coil and holding coil are energized. After set time (about 1 second), the suction coil is de-energized. q The following figure shows the operating condition of the solenoid. RUN: While the engine is operated (the power is applied), the rod is extracted. STOP: While the engine is stopped (the power is not applied), the rod is retracted.

<Precautions for checking operation> q When the solenoid is energized, if hook (1) presses (interferes with) stop lever (2) strongly, the solenoid may be installed wrongly. In this case, check the installation again (See the following figure). q If the operation stroke of the solenoid is insufficient, the holding power of the holding coil lowers and rod (1) may return to the stop position after the suction coil is de-energized.

Adjusting a Adjust the engine stop solenoid with the starting switch OFF. 1.

Insert hook (1) of the solenoid in the U-groove of stop lever (2) and tighten mounting bolts (3) temporarily.

Move stop lever (2) toward the RUN position with the hand to extract rod (4) of the solenoid.

Keep stop lever (2) in contact with stopper (5), tighten 2 mounting bolts (3) permanently. a The following figure shows the stop lever pulled fully toward the RUN position and in contact with the stopper. 3 Mounting bolt: 9.8 â&#x20AC;&#x201C; 11.3 Nm {1.0 â&#x20AC;&#x201C; 1.15 kgm}

PC18MR-3

30-100

100 Testing and adjusting Bleeding air from fuel circuit

SEN04496-00

Bleeding air from fuel circuit

After any fuel circuit part is removed and installed or the fuel piping is disconnected and reconnected or the fuel runs out, bleed air from the fuel circuit according to the following procedure.

Fill the fuel tank with the fuel.

Check that the fuel filter valve is at the OPEN position.

Turn the starting switch to the ON position and keep it there for 10 â&#x20AC;&#x201C; 15 seconds, and then return it to the OFF position.

The air in the fuel circuit is bled automatically by the above operation.

30-100

PC18MR-3

100 Testing and adjusting Testing and adjusting fan belt tension

Testing and adjusting fan belt tension

SEN04496-00

Testing 1. Tilt the floor open. For details, see “How to open and close (tilt) floor”. 2.

Press the center of the belt between the crankshaft pulley and fan pulley with your finger and measure the deflection of the belt. q Force to press belt: Approx. 98 N {10 kg} q Deflection: 9 – 13 mm a If the deflection is about 10 mm, the belt tension is roughly in the normal range.

PC18MR-3

Adjusting a If the belt deflection is abnormal, adjust it according to the following procedure. 1.

Tilt the floor open. For details, see “How to open and close (tilt) floor”.

Put a bar between alternator (1) and cylinder block and fix alternator (1). a Put a piece of wood between the bar and alternator to protect the alternator.

Loosen adjustment bolt (2) and mounting bolt (3) of the alternator.

Move alternator (1) to adjust the belt tension. q Force to press belt for adjustment: Approx. 98 N {10 kg} q Deflection for adjustment: Approx. 7 – 10 mm

Tighten adjustment bolt (2) and mounting bolt (3) to fix alternator (1). a Check each pulley for breakage, wear of the V-groove, and contact of the V-belt and V-groove. a If the V-belt is so lengthened that the adjustment allowance is eliminated or it has a cut or a crack, replace it.

After finishing adjusting, return the removed parts.

30-100

100 Testing and adjusting Adjusting fuel control lever linkage

SEN04496-00

Adjusting fuel control lever linkage

Adjusting low idle 1) Tilt fuel control lever (1) forward until it reaches stopper (2) on the low idle side. 2) Under this condition, adjust low idle adjustment screw (3) on the fuel injection pump side to set the low idle speed to the specified level.

Adjusting high idle 1) Tilt fuel control lever (1) backward until governor lever (4) of the fuel injection pump reaches screw (5) on the high idle side. 2) Under this condition, tighten stopper bolt (6) until it reaches fuel control lever (1), and then return the stopper bolt by 1/2 turn and fix it with the locknut. a Screw (5) on the high idle side of the fuel injection pump is not adjustable. If the high idle speed or power is still low even when the governor lever reaches the screw on the high idle side, check the nozzle holder, etc.

30-100

PC18MR-3

100 Testing and adjusting Measurement of clearance in swing circle bearings

Measurement of clearance in swing circle bearings a

a k

SEN04496-00 3.

Under this condition, set dial gauge F to the zero point.

Hold the arm nearly perpendicular to the ground, and lower the boom until the track shoes will be lifted at the work equipment. a The upper structure is raised at the front and lowered at the rear at that time.

Read off the value in dial gauge F in this condition. a The value indicated in dial gauge F expresses clearance in the bearings.

Return the machine to the posture in Item 2 above, and confirm reading of dial gauge F is zero. a If zero value is not indicated, repeat the steps in Items 3 through 5.

After finishing measurement, remove the measuring instruments and return the removed parts.

Swing circle bearing clearance measurement tools Mark

Part No.

Commercial product

Part Name Dial gauge

Follow the steps explained below, when measuring clearance in the swing circle bearing in the actual machine. Be careful not to put a hand or foot under the undercarriage, while taking measurement. Fix dial gauge F to the track frame and apply the probe to the underside of outer race (1) perpendicularly. a Set dial gauge F at the track frame rear.

Keep the work equipment in the max. reach posture and keep the height of the bucket teeth tip level with the lower height of the revolving frame. a At this time, the front side of the upper structure rises and the rear side lowers.

PC18MR-3

30-100

100 Testing and adjusting Testing and adjusting track shoe tension

SEN04496-00

Testing and adjusting track shoe tension 1 Testing 1. Run the engine at low idle and move the machine by the length of track on ground, then stop slowly. 2.

Place bar [1] on the track shoe between the idler and the shoe plate. a As bar [1], use an L-shape steel, etc. which will be deflected less.

Measure maximum clearance (a) between bar [1] and track shoe. q Standard maximum clearance (a) Steel shoe specification: 5 â&#x20AC;&#x201C; 15 mm Rubber shoe specification: 1 â&#x20AC;&#x201C; 3 mm

Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1.

To heighten tension 1) Supply grease throungh grease fitting (1). 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After finishing adjustment, check again that the tension is normal according to the above procedure.

30-100

When steel shoe is installed You may supply grease until distance (b) between the idler guide and track frame end is 0 mm. If the tension is still low, the pin and bushing are worn excessively. In this case, turn over or replace the pin and bushing.

PC18MR-3

100 Testing and adjusting Testing and adjusting track shoe tension

SEN04496-00

To lower tension 1) Loosen valve (2) to discharge the grease. k

2) 3)

Since the valve may jump out because of the internal high-pressure grease, do not loosen it more than 1 turn. Tighten valve (2). To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. After adjusting, check the tension again according to the procedure described above.

PC18MR-3

30-100

100 Testing and adjusting Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits

SEN04496-00

Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits 1 a

Install nipple G2 and pull the oil pressure test hose out of the revolving frame.

Tilt down the floor and connect the hose to oil pressure gauge [1] of hydraulic tester G1. a Use oil pressure gauges of 40 MPa {400 kg/cm2} for both hoses.

Pressurize the hydraulic tank. For details, see “Pressurizing hydraulic tank”.

Measuring instruments for oil pressures in work equipment, travel, swing, and blade circuits Symbol 1 G 2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Testing a Test the oil pressures in the work equipment, travel, swing, and blade circuits under the following condition. q Hydraulic oil temperature: 45 – 55°C k Release the residual pressure from the hydraulic tank. For details, see “Releasing residual pressure from hydraulic circuit”. 1.

Preparation work 1) Open the battery cover and tilt the floor open. For details, see “How to open and close (tilt) floor”. a You can connect the measuring instruments without tilting the floor open. If the floor is tilted open, however, you can work easily. 2) Remove pump discharge pressure pickup plug (1).

30-100

Measuring unload pressure 1) Start the engine. 2) Run the engine at high idle and set all the control levers and pedals in neutral and measure the oil pressure. a The unload pressure of the unload valve of the control valve is indicated.

Measuring work equipment (boom/arm/ bucket/boom swing/blade) circuit relief pressure a The variable gauge circuit is operated by applying the blade circuit pressure through the variable gauge selector valve. 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Run the engine at high idle and relieve the cylinder and measure the oil pressure. a The relief pressure of the main relief valve of the control valve is indicated. PC18MR-3

100 Testing and adjusting Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits

Measuring travel circuit relief pressure 1) Start the engine and lock the travel mechanism on the side to be measured. k Set pin [1] between the sprocket and track frame to lock the travel mechanism securely.

Adjusting 1. Adjusting unload pressure a The unload pressure cannot be adjusted. 2.

Adjusting relief pressure of work equipment circuit and travel circuit a If the relief pressure of the work equipment circuit and travel circuit is abnormal, adjust main relief valve (2) of the control valve according to the following procedure. a When adjusting the main relief valve of the control valve, tilt the floor open. For details, see “How to tilt (open and close) floor”.

Run the engine at high idle and relieve the travel circuit and measure the oil pressure. a The relief pressure of the main relief valve of the control valve is indicated.

Measuring swing circuit relief pressure 1) Start the engine and lock the swing mechanism with the work equipment securely. k Stick the bucket into the ground or press it against the blade. 2) Run the engine at high idle and relieve the swing circuit and measure the oil pressure. a The relief pressure of the swing motor safety valve is indicated. a The swing motor safety valves are installed to the right and left sides. Accordingly, measure the relief pressures on both sides respectively. a The swing motor relief pressure is lower than the main relief pressure.

1) 2)

3) 6.

SEN04496-00

Work after finishing measurement After finishing measurement, remove the measuring instruments and return the removed parts.

PC18MR-3

While fixing adjustment screw (3), loosen locknut (4). Turn adjustment screw (3) to adjust the pressure. a If the adjustment screw is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. a Quantity of adjustment per turn of adjustment screw: 12.6 MPa {128 kg/ cm2} While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 59 – 79 Nm {6 – 8 kgm}

30-100

SEN04496-00 4)

100 Testing and adjusting Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits

After finishing adjustment, check again that the oil pressure is normal according to the above described measurement procedure.

Adjusting relief pressure of swing circuit a If the relief pressure of the swing circuit is abnormal, adjust safety valves (5) and (6) according to the following procedure. q Safety valve (5): For right swing relief valve (A) q Safety valve (6): For left swing relief valve (B) a When adjusting the safety valves of the swing motor, tilt the floor open. For details, see â&#x20AC;&#x153;How to tilt (open and close) floorâ&#x20AC;?.

1) 2)

30-100

While fixing adjustment screw (7), loosen locknut (8). Turn adjustment screw (7) to adjust the pressure. a If the adjustment screw is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. a Quantity of adjustment per turn of adjustment screw: Approx. 4.5 MPa {46 kg/cm2} While fixing adjustment screw (7), tighten locknut (8). 3 Locknut: 3.92 Nm {0.4 kgm}

After finishing adjustment, check again that the oil pressure is normal according to the above described measurement procedure.

PC18MR-3

100 Testing and adjusting Testing and adjusting control circuit basic pressure

Testing and adjusting control circuit basic pressure a

SEN04496-00 3.

Install nipple H2 and pull the oil pressure test hose out of the revolving frame.

Tilt down the floor and connect the hose to oil pressure gauge [1] of hydraulic tester H1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.

Pressurize the hydraulic tank. For details, see “Pressurizing hydraulic tank”.

Run the engine at high idle and set all the control levers and pedals in neutral and measure the oil pressure.

After finishing measurement, remove the measuring instruments and return the removed parts.

Testing and measuring instruments for control circuit basic pressure Symbol 1 H 2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Testing a Measure the control circuit basic pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C k Release the residual pressure from the hydraulic tank. For details, see “Releasing residual pressure from hydraulic circuit”. 1.

Open the battery cover and tilt the floor open. For details, see “How to open and close (tilt) floor”. a You can connect the measuring instruments without tilting the floor open. If the floor is tilted open, however, you can work easily.

Remove control circuit basic pressure pickup plug (1).

PC18MR-3

30-100

SEN04496-00

100 Testing and adjusting Testing and adjusting control circuit basic pressure

Adjusting a If the control circuit basic pressure is abnormal, adjust relief valve (2) of the 2-spool solenoid valve according to the following procedure. a When adjusting the main relief valve of the control valve, tilt the floor open. For details, see â&#x20AC;&#x153;How to tilt (open and close) floorâ&#x20AC;?.

While fixing adjustment screw (3), loosen locknut (4).

Turn adjustment screw (3) to adjust the pressure. a If the adjustment screw is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. a Quantity of adjustment per turn of adjustment screw: 17.54 MPa {179 kg/cm2}

While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 9.8 Nm {1.0 kgm}

After finishing adjustment, check again that the oil pressure is normal according to the above described measurement procedure.

30-100

PC18MR-3

100 Testing and adjusting Testing and adjusting pump LS differential pressure

Testing and adjusting pump LS differential pressure 1 a

SEN04496-00 3.

Install nipples J3 and pull the oil pressure measurement hose out of the revolving frame.

Tilt down the floor and connect the hose to oil pressure gauge [1] of hydraulic tester J1 or to differential pressure gauge J2. a When using differential pressure gauge: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12-V power source, connect it to a battery. a When using oil pressure gauge: Use the oil pressure gauge of 40 MPa {400 kg/cm²}. Since the differential pressure is about 2.5 MPa {25 kg/cm²} at maximum, measure it by installing the same gauge to the pickup plugs alternately.

Pressurize the hydraulic tank. For details, see “Pressurizing hydraulic tank”.

Run the engine and operate the work equipment to set the boom top horizontally.

Testing and adjusting instruments for pump LS differential pressure Symbol 1 J

2 3

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2701

Differential pressure gauge

799-101-5220

Nipple (10 × 1.25 mm)

07002-11023

O-ring

Measuring a Measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them. a Measure the LS differential pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C k Release the pressure from the hydraulic tank. For details, see “Releasing pressure from hydraulic circuit”. 1.

Open the battery cover, then tilt the floor open. For details, see “How to open and close (tilt) floor”. a You can connect the measuring instruments without tilting the floor open. If the floor is tilted open, however, you can work easily.

Remove pump discharge pressure pickup plugs (1) and (2). q Plug (1): Pump discharge pressure pickup plug q Plug (2): LS pressure pickup plug

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30-100

100 Testing and adjusting Testing and adjusting pump LS differential pressure

SEN04496-00 7.

While running the engine at high idle, measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously under the following condition. q Work equipment, travel, swing, and blade circuits: Set all the levers in neutral and move the arm IN. a Move the arm lever halfway to move the arm IN and measure the oil pressure during this operation. a Calculation of LS differential pressure (when oil pressure gauge is used): LS differential pressure = Pump discharge pressure – LS pressure a If the LS differential pressure is as follows, it is normal.

Adjusting a If the LS differential pressure is abnormal, adjust LS valve (3) according to the following procedure. a When adjusting the LS valve, remove the battery cover.

Work equipment, travel, LS differential pressure swing, and blade levers

Set all levers in neutral

Unload pressure (See “Standard value table”)

Set arm lever in IN position (halfway)

Specified LS differential pressure (See “Standard value table”)

Loosen hose sleeve nut (4).

Fixing plug (5), loosen locknut (6).

Turn plug (5) to adjust the differential pressure. a If the plug is q turned to the right, the differential pressure rises. q turned to the left, the differential pressure lowers. a Quantity of adjustment (LS differential pressure) per turn of plug: 127 kPa {13 kg/cm²} a Tighten hose sleeve nut (4) temporarily and turn the plug, while checking the LS differential pressure.

Fixing plug (5), tighten locknut (6). 3 Locknut: 27.4 – 34.3 Nm {2.8 – 3.5 kgm}

Tighten hose sleeve nut (4).

After finishing measurement, remove the measuring instruments and return the removed parts.

30-100

PC18MR-3

100 Testing and adjusting Measuring solenoid valve output pressure

Measuring solenoid valve output pressure a

1 2

a k

Measuring instruments for solenoid valve output pressure Symbol

SEN04496-00

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3100

Adapter (02)

Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal. Measure the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C Release the residual pressure from the hydraulic tank. For details, see “Releasing residual pressure from hydraulic circuit”.

Tilt the floor open. For details, see “How to tilt (open and close) floor”.

Disconnect outlet hoses (1) and (2) of the solenoid valves to be measured. q Hose (1): PC lock solenoid valve q Hose (2): 2nd travel speed selection solenoid valve

3. 4.

Install adapter K2 and connect the disconnected hose again. Install nipple [1] of hydraulic tester K1 and pull the oil pressure measurement hose out of the revolving frame. a The figure shows the measuring instruments connected to the outlet hose of the PPC lock selection solenoid valve.

PC18MR-3

Tilt down the floor and connect the hose to oil pressure gauge [2] of hydraulic tester K1. a Use oil pressure gauge of 6 MPa {60 kg/ cm²}.

Pressurize the hydraulic tank. For details, see “Pressurizing hydraulic tank”.

Run the engine at high idle, turn the solenoid valve ON or OFF, and measure the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see “Operation table of solenoid valves”. a If the output pressure of each solenoid valve is as shown in “Operation table of solenoid valves”, it is normal.

After finishing measurement, remove the measuring instruments and return the removed parts.

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100 Testing and adjusting Measuring solenoid valve output pressure

SEN04496-00 Operation table of solenoid valves No.

30-100

Solenoid valve

State of solenoid

Output pressure of solenoid valve

Lock lever: LOCK

OFF

0 MPa {0 kg/cm²}

Lock lever: FREE

Travel speed shifting switch: Low speed mode (2nd travel speed monitor: OFF)

OFF

Travel speed shifting switch: High speed mode (2nd travel speed monitor: ON)

Operating condition

PPC lock

2nd travel speed selection

3.14

+ 0.2 0

+2 {32 0

MPa

kg/cm²}

0 MPa {0 kg/cm²} 3.14

+ 0.2 0

+2 {32 0

MPa

kg/cm²}

PC18MR-3

100 Testing and adjusting Measuring PPC valve output pressure

SEN04496-00

Measuring PPC valve output pressure a

Measuring instruments for PPC valve output pressure Symbol L

1 2

a a k

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3100

Adapter (02)

Before measuring the PPC valve output pressure, check that the basic pressure in the control circuit is normal. Measure the PPC valve output pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C Release the residual pressure from the hydraulic tank. For details, see “Releasing residual pressure from hydraulic circuit”.

Tilt the floor open. For details, see “How to tilt (open and close) floor”.

Disconnect PPC hose (1) of the solenoid valve to be measured. a The figure shows the hose of the ARM IN circuit.

Tilt down the floor and connect the hose to oil pressure gauge [2] of hydraulic tester L1. a Use oil pressure gauge of 6 MPa {60 kg/ cm²}.

Pressurize the hydraulic tank. For details, see “Pressurizing hydraulic tank”.

Run the engine at high idle, set the control lever or pedal of the circuit to be measured in the neutral position and stroke end, and measure the oil pressure. a If the output pressure of PPC valve is as follows, it is normal. Control lever/pedal

PPC valve output pressure 0 MPa {0 kg/cm²}

Install adapter L2 and connect the disconnected hose again.

Neutral

Install nipple [1] of hydraulic tester L1 and pull the oil pressure measurement hose out of the revolving frame. a The figure shows the measuring instruments connected to the hose of the ARM IN circuit.

Stroke end

PC18MR-3

3.14 {32

+ 0.2 0

+2 0

MPa

kg/cm²}

After finishing measurement, remove the measuring instruments and return the removed parts.

30-100

SEN04496-00

100 Testing and adjusting Measuring PPC valve output pressure

Connection diagram of PPC valve and control valve (ISO pattern) a The port position of each PPC valve is the position seen from the operator's seat side. Colors of hose bands are shown in ( ).

30-100

PC18MR-3

100 Testing and adjusting Adjusting play of work equipment and swing PPC valves

SEN04496-00

Adjusting play of work equipment and swing PPC valves 1

Measuring swing holding brake release pressure 1

If the play of the left or right work equipment control lever is excessive, adjust it according to the following procedure.

Measuring instruments for swing holding brake release pressure Symbol

Remove the PPC valve assembly. M

Remove boot (1).

Loosen locknut (2) and screw in disc (3) until it touches the heads of 4 pistons (4). a At this time, do not move the pistons.

Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 98 – 127 Nm {10 – 13 kgm}

Install boot (1).

Install the PPC valve assembly.

PC18MR-3

1 2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3100

Adapter (02)

Before measuring the swing holding brake release pressure, check that PPC valve output pressure (swing LEFT, swing RIGHT, and arm IN) is normal. Measure the swing holding brake release pressure under the following condition. q Hydraulic oil temperature : 45 – 55°C Release the residual pressure from the hydraulic tank. For details, see “Releasing residual pressure from hydraulic circuit”.

Testing release pressure a Since the output pressure of the PPC lock solenoid valve is used as the release basic pressure, test it in “Testing output pressure of solenoid valve”.

Testing release signal pressure 1) Tilt the floor open. For details, see “How to open and close (tilt) floor”. 2) Disconnect R-port hose (1) of the swing motor.

30-100

100 Testing and adjusting Measuring swing holding brake release pressure

SEN04496-00 3)

Install adapter M2 and connect the disconnected hose again.

Install nipple [1] of hydraulic tester M1 and pull the oil pressure measurement hose out of the revolving frame.

6) 7)

Pressurize the hydraulic tank. For details, see “Pressurizing hydraulic tank”. Run the engine at high idle, set all the control levers in the neutral position and operating position, and measure the oil pressure. a If the swing holding brake release pressure is as follows, it is normal.

Control lever/pedal

Swing holding brake release pressure

Neutral or other than following positions

0 MPa {0 kg/cm²}

Swing LEFT, Swing RIGHT, Arm IN

30-100

Tilt down the floor and connect the hose to oil pressure gauge [2] of hydraulic tester M1. a Use oil pressure gauge of 6 MPa {60 kg/cm²}.

3.14 {32

+ 0.2 0

+2 0

MPa

kg/cm²}

After finishing measurement, remove the measuring instruments and return the removed parts.

<Reference: Release pressure and release signal pressure> q The swing holding brake release pressure is the output pressure of the PPC solenoid valve, which is led to the swing motor. q If the swing holding brake does not operate, check the release pressure (output pressure of the PPC solenoid valve) first. q The swing holding brake release signal pressure is the PPC circuit pressure for swing LEFT, swing RIGHT, and arm IN, which is led to the swing motor through the shuttle valve in the control valve. q If the release pressure is normal but the swing holding brake is not released, check the release signal pressure, and then check the output pressure of the PPC valves for swing LEFT, swing RIGHT, and arm IN. q If the output pressure of each PPC valve is normal but the release signal pressure is not normal, the shuttle valve in the control valve may be malfunctioning. q If both of the output pressure of each PPC valve and the release signal pressure are normal, the swing holding brake in the swing motor may be malfunctioning.

PC18MR-3

100 Testing and adjusting Testing oil leakage from cylinder

SEN04496-00 k

Testing oil leakage from cylinder 1 a

Symbol N 1.

Testing instruments for oil leakage from cylinder. Part No. Part Name Commercially Measuring cylinder available

Testing leakage from boom cylinder 1) Run the engine and move the boom cylinder to the RAISE stroke end. k Release the residual pressure in the boom cylinder circuit. For details, see “Releasing residual pressure from hydraulic circuit”. 2) Disconnect hose (1) on the cylinder head side and block the hose side with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70210 (Plug #02)

4) 5)

3) 4) 5)

Take care not to disconnect the hose on the cylinder bottom side. Use the following part to block the hose side. 07376-70315 (Plug #03)

Run the engine at high idle and relieve the boom circuit by raising the boom. k Take care not to "lower the boom". Measure the oil leakage for 1 minute after 30 seconds since relieving is started. After finishing measurement, remove the measuring instruments and return the removed parts.

Run the engine at high idle and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". Measure the oil leakage for 1 minute after 30 seconds since relieving is started. After finishing measurement, remove the measuring instruments and return the removed parts.

Measuring oil leakage from bucket cylinder 1) Run the engine and move the bucket cylinder to the CURL stroke end. k Release the residual pressure in the bucket cylinder circuit. For details, see “Releasing residual pressure from hydraulic circuit”. 2) Disconnect hose (3) on the cylinder head side and block the hose side with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70210 (Plug #02)

Measuring oil leakage from arm cylinder 1) Run the engine and move the arm cylinder to the IN stroke end. k

Release the residual pressure in the arm cylinder circuit. For details, see “Releasing residual pressure from hydraulic circuit”. Disconnect hose (2) on the cylinder head side and block the hose side with a plug.

PC18MR-3

30-100

100 Testing and adjusting Testing oil leakage from cylinder

SEN04496-00 3)

4) 5)

Run the engine at high idle and relieve the bucket circuit by curling the bucket. k Take care not to "dump the bucket". Measure the oil leakage for 1 minute after 30 seconds since relieving is started. After finishing measurement, remove the measuring instruments and return the removed parts.

Measuring oil leakage from boom swing cylinder 1) Run the engine and move the boom swing cylinder to the left stroke end. k Release the residual pressure in the boom swing cylinder circuit. For details, see “Releasing residual pressure from hydraulic circuit”. 2) Disconnect hose (4) on the cylinder head side and block the hose side with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07367-70210 (Plug #02)

Measuring oil leakage from blade cylinder 1) Run the engine and push up the track shoe on the blade side with the work equipment and set a block under the track shoe. a Raise the track shoe to a degree that the blade will not touch the ground when it is lowered to the stroke end. 2) Lower the blade cylinder to the stroke end. k Release the residual pressure in the blade cylinder circuit. For details, see “Releasing residual pressure from hydraulic circuit”. 3) Disconnect hose (5) on the cylinder head side and block the hose side with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07367-70210 (Plug #02)

4) 5) 6) 3)

4) 5)

30-100

Run the engine at high idle and relieve the boom swing circuit by swinging the boom to the left. k Take care not to "swing the boom to the right". Measure the oil leakage for 1 minute after 30 seconds since relieving is started. After finishing measurement, remove the measuring instruments and return the removed parts.

Run the engine at high idle and relieve the blade circuit by lowering the blade. k Take care not to "raise the blade". Measure the oil leakage for 1 minute after 30 seconds since relieving is started. After finishing measurement, remove the measuring instruments and return the removed parts.

PC18MR-3

100 Testing and adjusting Releasing residual pressure from hydraulic circuit

Releasing residual pressure from hydraulic circuit 1

SEN04496-00

Bleeding air from cylinder a

Releasing residual pressure from hydraulic tank k The hydraulic tank is enclosed and pressurized. When removing a hose or a plug connected to the hydraulic tank, release the residual pressure from the hydraulic tank according to the following procedure. 1) Lower the work equipment to the ground in a stable posture and stop the engine. 2) Remove bolt (1) and plate (2). 3) Slowly loosen oil filler cap (3) of the hydraulic tank to release the air from the tank.

If a cylinder was removed and installed or its piping was disconnected and reconnected, bleed air according to the following procedure. If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment.

Run the engine at low idle for about 5 minutes.

Running the engine at low idle, raise and lower the boom 4 – 5 times. a Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil.

Running the engine at high idle, perform step 2.

Running the engine at low idle, move the piston rod to the stroke end and relieve the oil.

Bleed air from the arm cylinder, bucket cylinder, boom swing cylinder, and blade cylinder according to steps 2 – 4.

Releasing residual pressure from hydraulic cylinder circuit k When disconnecting the piping between a hydraulic cylinder and the control valve, release the residual pressure from the piping according to the following procedure. 1) Run the engine at low idle and lower the work equipment to the ground, taking care not to relieve the cylinder at the stroke end, and then stop the engine. k If the engine is stopped while the hydraulic cylinder is relieved at the stroke end, do not perform the following work for 5 – 10 minutes. 2) Release the air from the hydraulic tank. For details, see “1. Releasing residual pressure from hydraulic tank”. 3) Loosen the sleeve nut of the cylinder piping gradually to release the residual pressure from the piping until oil does not come out any more, then disconnect the piping. a When performing the above work, apply cloths to the sleeve nut to prevent the residual pressure from blowing out the oil.

PC18MR-3

30-100

100 Testing and adjusting Pressurizing hydraulic tank

SEN04496-00

Pressurizing hydraulic tank

If the oil filler cap is removed from the hydraulic tank, pressurize the hydraulic tank according to the following procedure.

Run the engine at low idle, set the work equipment in the pressurizing position, and stop the engine. a Extract the boom, arm, and bucket cylinders fully.

Remove bolt (1) and plate (2).

Remove oil filler cap (3) of the hydraulic tank, and then tighten it again.

Start the engine and lower the work equipment to the ground. a The hydraulic tank is pressurized by the above procedure.

30-100

PC18MR-3

100 Testing and adjusting How to open and close (tilt) floor

SEN04496-00

How to open and close (tilt) floor1 a

When checking or maintaining the underside of the floor or inside of the revolving frame, open and close (tilt) the floor according to the following procedure.

When opening (tilting open) 1. Lower the work equipment and blade to the ground, stop the engine, and set the lock lever in the LOCK position. 2.

Put blocks in the front and rear of the track shoes to stop the machine.

Open and fix engine rear cover (1).

Remove 2 floor fixing bolts (2).

Roll up floor mat (3).

While pulling floor lock release lever (4) toward the rear of the machine with the left hand, hold handrail (5) with the right hand and push up the floor toward the front of the machine (about 35Â°). k Do not put any part of your body under the floor while opening or closing the floor. a If the floor does not rise, the release lever may not be in the release position. a Since the gas spring assists you in opening the floor, the operating effort is increased when the ambient temperature is low.

PC18MR-3

After the floor rises, push up handrail (5) until lock pin (6) is fitted to lock groove (a) of lock plate (7). a When the lock pin moves to the lock groove, the 1st locking is completed.

Insert 2nd lock pin (8) in lock hole (b) securely and rotate it until lock hook (c) is hitched on fixing pin (9) securely. a Check that the lock pin is hitched on the fixing pin and it does not come off. a The 2nd locking is completed and the floor opening (tilting open) work is finished.

30-100

100 Testing and adjusting How to open and close (tilt) floor

SEN04496-00 When closing (tilting close) a Before closing the floor, check that the wiring, piping, and seats in the floor and revolving frame are free from damage and abnormality. 1.

Remove lock pin (8) and insert it in storage hole (d). a If you cannot remove the lock pin, pull it out while holding the handrail and pushing up the floor.

While pulling floor lock release lever (4) toward the rear of the machine with the left hand, hold handrail (5) with the right hand and pull down the floor toward the rear of the machine (about 45°). k Do not put any part of your body under the floor while opening or closing the floor. a While checking that the wiring and piping are not caught or damaged, pull down the floor slowly.

30-100

Install 2 floor fixing bolts (2). a If the fixing bolts are damaged, replace them with new ones. 3 Fixing bolt: 156.8 – 196 Nm {16 – 20 kgm}

Close engine rear cover (1). a The floor closing (tiling close) work is finished.

PC18MR-3

100 Testing and adjusting Inspection procedures for diode

SEN04496-00

Inspection procedures for diode 1 a a

Check an assembled-type diode (8 pins) and single diode (2 pins) in the following manner. The continuity direction of the assembled-type diode is as follows.

The conductive direction of each diode is marked on its surface as shown below.

When using digital type circuit tester 1) Switch the testing mode to diode range and confirm the indicated value. a Voltage of the battery inside is displayed with conventional circuit testers. 2) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode, and confirm the displayed value. 3) Determine if a specific diode is good or no good with the indicated value. q No change in the indicated value: No continuity (defective). q Change in the indicated value: Continuity established (normal) (Note) Note: A silicon diode shows a value between 460 and 600.

PC18MR-3

When using analog type circuit tester 1) Switch the testing mode to resistance range. 2) Check the needle swing in case of the following connections. i) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode. ii) Put the red probe (+) of the test lead to the cathode (N) and the black probe (–) to the anode (P) of diode. 3) Determine if a specific diode is good or no good by the way the needle swings. q If the needle does not swing in Case i), but swings in Case ii): Normal (but the breadth of swing (i.e. resistance value) will differ depending on a circuit tester type or a selected measurement range) q If the needle swings in either case of i) and ii): Defective (short-circuited internally) q If the needle does not swing in any case of i) and ii): Defective (short-circuited internally)

30-100

100 Testing and adjusting How to start operation of KOMTRAX terminal

SEN04496-00

How to start operation of KOMTRAX terminal

In the case where the KOMTRAX terminal has already been installed at the plant before shipment: a Implement the following procedure in the case where the KOMTRAX terminal has already been installed at the plant before shipment (as standard equipment). 1.

Notification of model, model number and serial number Notify the model, model number and serial number of the machine to the KOMTRAX operations administrator.

Turn the starting switch ON and keep that condition for 5 seconds. q Check that the 7-segment indicator lamp indicates a bar.

Disconnect test connectors F33 and F34 and keep that condition for 5 seconds. Reconnect test connectors F33 and F34 and keep that condition for 5 seconds. a If the KOMTRAX terminal detects disconnection or reconnection of the connectors, the dot of the 7-segment indicator lamp blinks 2 – 3 times. a If procedures 4) – 6) are not completed in 60 seconds, repeat from 2).

Registration of machine The KOMTRAX operations administrator registers the machine using a KOMTRAX client personal computer. a For the procedure, see “Manual for KOMTRAX operations administrator”. a Now the terminal is ready for use.

In the case where the KOMTRAX terminal is retrofitted on the machine after shipment: a Implement the following procedure in the case where the KOMTRAX terminal is retrofitted after shipment of the machine (retrofitted machine). 1.

Sign-up test on machine side a Complete procedures 4) – 6) in 60 seconds. 1) Park the machine in a place sufficiently apart from buildings etc. where its top is seen from every direction so that it can receive the radio waves from the satellite. a The inspection cannot be completed normally indoors. Be sure to perform the inspection outdoors. 2) Turn the starting switch OFF and wait for at least 5 seconds and then go to the next step. 3) Check visually that the test connectors under KOMTRAX terminal (1) are connected. a Test connectors: F33, F34 (male, female)

30-100

PC18MR-3

100 Testing and adjusting How to start operation of KOMTRAX terminal

Check that the 7-segment indicator lamp of the KOMTRAX terminal is displaying normally. a If the indication is normal, the 7-segment indicator lamp (a) is displayed for 30 seconds after 6) is completed. (“d”, “0” and “–” are displayed repeatedly.) q Display of the 2nd letter “0” may be different from the first. q Display of the 3rd letter “–” changes 30 seconds after the operation of 6).

PC18MR-3

SEN04496-00 a

Go to the next step if you can check that the display is “normal”. a If the display is “abnormal”, repeat from procedure 2) again. (“–” is displayed continuously.) 8) Turn the starting switch to the START position, keep it more than 5 seconds, and check that the engine does not start. a If the engine starts, repeat from procedure 2). a If the engine starts again, the engine start lock function does not work normally. Stop the inspection and check of the relays and wiring harnesses for trouble. 9) Return the starting switch to the ON position and keep it there for 5 seconds. a Do not return the starting switch to the OFF position. 10) Turn the starting switch to the START position again and ensure that the engine starts. 11) Check that the 7-segment indicator lamp of the KOMTRAX terminal is indicating normally without stopping the engine. a Go to the next step if you ensured that the display is [normal]. (It takes from 90 seconds to 15 minutes before the display turns normal.) a If [GPS position data detection trouble] is indicated, check if there is any external abnormality on the GPS antenna or cable. If there is any abnormality, repair it and repeat from procedure 1) again. a If [Reception trouble] is indicated, check if there is any external abnormality on the appearance of the communication antenna or cable. If there is any abnormality, repair it then repeat from procedure 1) again. a If [GPS position data detection trouble and reception trouble] is indicated, check if there is any external abnormality on the GPS antenna or cable and communication antenna or cable. If there is any abnormality, repair it and repeat from procedure 1) again. a If [Network trouble] is indicated, check the display of [LED-4] referring to “Lamp display of KOMTRAX terminal”. (If CAN is not recognized, check the CAN harness of the KOMTRAX terminal, and then if there is any abnormality, repair it and repeat from procedure 1) again.)

30-100

SEN04496-00 [A]: Normal finish (It takes at least 90 seconds for the system to display this) [B]: GPS position data detection trouble “Check the GPS antenna and cable for external abnormality.” (It takes 90 seconds – 5 minutes) [C]: Incomplete receiving “Check the communication antenna and cable for external abnormality.” (It takes 30 seconds – 1 minute) [D]: Network trouble or wiring harness trouble “The network type selection input does not agree with the obtained network data.” “Check the machine wiring for an error.”

a a

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100 Testing and adjusting How to start operation of KOMTRAX terminal

12) Turn the starting switch OFF. 13) Check that the 7-segment indicator lamp is indicating normally in 10 seconds. a If you checked that the display is [Normal], that is the end of the signup test. a If the display shows [Abnormal], re peat from procedure 1) again because the sign-up test has not been completed successfully.

If the display is not any of the above, call Customer Support Division. It takes 90 seconds – 5 minutes for the system to display “Normal finish” after the operation of 6).

PC18MR-3

100 Testing and adjusting How to start operation of KOMTRAX terminal

SEN04496-00

Application for the start of use a Application for the start of use must be made only after the sign-up test is finished. 1) Notify to the KOMTRAX operations administrator of the following information concerning the machine whose sign-up test on the machine side is completed. 1] Information on the machine whose sign-up test on the machine side is completed (Model, model number and serial number) 2] Part number and serial number of the KOMTRAX terminal 3] Reading of the service meter when the KOMTRAX terminal was installed (0.1h unit)

The KOMTRAX operations administrator registers the machine using KOMTRAX client personal computer. a For the procedure, see â&#x20AC;&#x153;Manual for KOMTRAX operations administratorâ&#x20AC;?. a Now the terminal is ready for use.

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SEN04496-00

Lamp display of KOMTRAX terminal

CPU LED 1. LED-1 (R signal and ACC signal) 2. LED-2 (Starting output status) 3. LED-3 (S-NET status and C signal status) 4. LED-4 (Fuel sensor and CAN connection status) 5. LED-5 (Downloading and writing status)

30-100

100 Testing and adjusting Lamp display of KOMTRAX terminal

7-segment and dot for CPU 6. 7-segment (Sign-up test status and operation status) 7. Dot (GPS positioning status and test connector disconnection/connection status))

PC18MR-3

100 Testing and adjusting Lamp display of KOMTRAX terminal

SEN04496-00

In the KOMTRAX system, various information and processing details are displayed on the LED of the upper surface of the KOMTRAX terminal. Therefore, if a defect is suspected in the system, perform the following checks. q Check of antennas q Check of terminal LED displays Application for the start of use and sign-up test on the machine side must be completed in advance in order to use KOMTRAX system. Check of antennas a Before checking the LED displays, check that there is no abnormality around the communication antenna and GPS antenna. q The communication antenna must not be off or damaged. q The communication antenna cable must not be broken and must be connected to the KOMTRAX terminal normally. q The GPS antenna must not be off or damaged. q The GPS antenna cable must not be broken and must be connected to the KOMTRAX terminal normally.

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30-100

100 Testing and adjusting Lamp display of KOMTRAX terminal

SEN04496-00 1. a

Contents of CPU LED, 7-segment and dot displays The LED displays must be checked with the starting switch in the ON or START position or with the engine started.

No. LED (Color)

LED-1 (Green)

LED-2 (Red)

LED-3 (Yellow)

LED-4 (Green)

LED-5

Name/Function

Display (*1)

ON Starting switch ACC Fast blinking signal and alternator Slow blinking R signal OFF Starting output status S-NET connection status and starting switch C signal status Fuel sensor and CAN connection status Downloading and writing status

Contents of display Starting switch ACC signal: ON, alternator R signal: ON Starting switch ACC signal: OFF, alternator R signal: ON Starting switch ACC signal: ON, alternator R signal: OFF Starting switch ACC signal: OFF, alternator R signal: OFF

Engine control signal: ON

OFF

Engine control signal: OFF

Fast blinking Starting switch C signal: ON ON

Starting switch C signal: OFF, S-NET connection: Made

OFF

Starting switch C signal: OFF, S-NET connection: Not made

CAN: Connected, (Fuel sensor: Disconnected)

Fast blinking CAN: Connected, (Fuel sensor: Connected) Slow blinking CAN: Disconnected, (Fuel sensor: Connected) OFF

CAN: Disconnected, (Fuel sensor: Disconnected)

Downloading and writing mode: ON

OFF

Downloading and writing mode: OFF (Normal mode)

Before execution of sign-up test Sign-up status

[–]

When sign-up test is not completed, “–” (bar) is always displayed.

During sign-up test Sign-up progress status

* For display during sign-up test, see “How to start operation of KOMTRAX terminal”.

After completion of sign-up test 6

7-segment

Initialization communication incompletion status

If server initialization communication is not completed, [C] is displayed. “ON” indicates that machine is within communication range. ON Fast blinking “Fast blinking” indicates that machine is out of communication range. [C]

Operation status [0 – 9] Number of unsent mails or within/out of communication range status

Dot (Red)

GPS connector positioning/ Test connector disconnection and connection status

Figure indicates number of mails waiting for to be sent (9 is displayed when number is 9 or larger). “ON” indicates that terminal is capturing satellite.

[0 – 9]

Figure indicates number of mails waiting for to be sent (9 is displayed when number is 9 or larger). Fast blinking Fast blinking indicates that terminal has not captured satellite. ON

GPS positioning has been executed. See *2.

OFF

GPS positioning has not been executed. See *2.

Fast blinking

If sign-up test connector is disconnected or connected, dot blinks 2 – 3 times.

Types and periods of blinking Fast blinking: Blinking at cycles of about 1 second (ON for 0.5 seconds o OFF for 0.5 seconds) Slow blinking: Blinking at cycles of about 4 seconds (ON for 2 seconds o OFF for 2 seconds)

It may take more than 1 minute from turning on the starting switch to the completion of positioning even in an outdoor place where radio wave can reach. Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio waves.

30-100

PC18MR-3

100 Testing and adjusting Removal and installation of KOMTRAX terminal

Removal and installation of KOMTRAX terminal

SEN04496-00

Installation q Carry out installation in the reverse order to removal.

Removal 1. Turn the starting switch to the OFF position. 2.

Remove the cover, garnish, etc. to expose KOMTRAX terminal (1).

Remove the cab wiring harness from KOMTRAX terminal (1). a Be sure to remove the cab wiring harness before the antenna cable (described in step 4).

Remove the communication antenna cable and GPS antenna cable from KOMTRAX terminal (1).

Remove all mounting bolts (2) and washers (3) of the KOMTRAX terminal. Reference: The mounting bolt size is M8.

Remove KOMTRAX terminal (1) from bracket (4). a When handling the KOMTRAX terminal, take care not to give an impact on it. (Never hit it against another part or drop it.)

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100 Testing and adjusting Preparation work for troubleshooting of electrical system

SEN04496-00

Preparation work for troubleshooting of electrical system a

When carrying out troubleshooting of an electric circuit related to the KOMTRAX terminal, expose the related connectors according to the following procedure. The KOMTRAX terminal is installed at the right front of the operator seat.

Remove the top cover of the KOMTRAX terminal.

Remove KOMTRAX terminal (1).

Insert or connect a troubleshooting T-adapter to connector F32 of KOMTRAX terminal (1). a Cable (2) is for the communication antenna (system 1). a Cable (3) is for the GPS antenna.

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100 Testing and adjusting Preparation work for troubleshooting of electrical system

PC18MR-3

SEN04496-00

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PC18MR-3 Hydraulic excavator Form No. SEN04496-00

30-100

SEN04497-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

40 Troubleshooting

100 General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 Sequence of events in troubleshooting ........................................................................................................... 3 Checks before troubleshooting ....................................................................................................................... 4 Classification and procedures of troubleshooting ........................................................................................... 5 Connection table for connector pin numbers .................................................................................................. 8 T- branch box and T- branch adapter table ................................................................................................... 44

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Points to remember when troubleshooting k k k k k k

100 General information on troubleshooting Points to remember when troubleshooting

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (â&#x20AC;&#x201C;) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Are abnormal symptoms detected in the machine? 2) Make checks before starting day's work. 3) Make checks of other items. 4) Check other maintenance items which can be visually checked and are considered necessary. Confirming failure Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a problem of handling, operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in items 2 â&#x20AC;&#x201C; 4 to narrow down the causes of failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. Measures to remove root cause of failure Even if the immediate failure is repaired, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.

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100 General information on troubleshooting Sequence of events in troubleshooting

SEN04497-00

Sequence of events in troubleshooting

PC18MR-3

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100 General information on troubleshooting Checks before troubleshooting

SEN04497-00

Checks before troubleshooting 1

Hydraulic, Electrical mechanical equipment equipment

Lubricating oil, coolant

Item

Electrics, electrical equipment

Action

1. Check fuel level, type of fuel

—

Add fuel

2. Check for impurities in fuel

—

Clean, drain

3. Check for clogging of fuel filter cartridge

—

Replace

4. Check engine oil level in oil pan, type of oil

—

Add oil

5. Check for clogging of engine oil filter

—

Replace

6. Check coolant level

—

Add coolant

7. Check for clogging of air cleaner

—

Clean or replace

8. Check hydraulic oil level, type of oil

—

Add oil

9. Check for clogging of hydraulic oil strainer

—

Clean, drain

10. Check for clogging of hydraulic oil filter

—

Replace

11. Check final drive oil level, type of oil

—

Add oil

—

Tighten or replace

1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring

—

Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

1. Check for abnormal noise, smell

—

Repair

2. Check for oil leakage

—

Repair

3. Carry out air bleeding 1. Check battery voltage (engine stopped)

40-100

Judgement value

— 10 – 15V

Bleed air Charge or replace

2. Check battery electrolyte level

—

Add or replace

3. Check for discolored, burnt, exposed wiring

—

Replace

4. Check for missing wiring clamps, hanging wiring

—

Repair

5. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)

—

Disconnect connector and dry

6. Check for blown, corroded fuses

—

Replace

7. Check alternator voltage (engine running at 1/2 throttle or above)

After running for several minutes : 13.5 – 14.5V

Replace

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100 General information on troubleshooting Classification and procedures of troubleshooting

SEN04497-00

Classification and procedures of troubleshooting

Classification of troubleshooting Mode

Contents

E-mode

Troubleshooting of electric system

H-mode

Troubleshooting of hydraulic and mechanical system

S-mode

Troubleshooting of engine

Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a corresponding phenomenon from "Phenomena looking like troubles and troubleshooting Nos.", and then go to explanation of the troubleshooting.

Phenomena looking like troubles and troubleshooting Nos. No.

Phenomena looking like troubles

Troubleshooting E-mode

H-mode

S-mode

Phenomena related to engine 1

Engine does not start

E-1

Engine does not stop

E-2

Engine hunts

Exhaust gas color is white or blue

Exhaust gas color is black or dark gray and output is insufficient

Oil is consumed much

Fuel is mixed in oil

Oil pressure is low

Oil pressure is high

10 Engine overheats

11 Battery is discharged quickly (Battery is dead)

12 Charge lamp (Charge level monitor) does not light up

13 Charge lamp (Charge level monitor) does not go off

Phenomena related to work equipment, travel, swing, and blade 14 Speed or power of whole work equipment, travel, swing, and blade is low

H-1

15 Engine speed lowers extremely or engine stalls

H-2

16 Work equipment, travel, swing, and blade systems do not work

E-14

H-3

17 Abnormal sound comes out from around hydraulic pump

H-4

18 Fine control performance or response is low

H-5

Phenomena related to work equipment 19 Speed or power of boom is low

H-6

20 Speed or power of arm is low

H-7

21 Speed or power of bucket is low

H-8

22 Speed or power of boom swing is low

H-9

23 Work equipment does not move singly

H-10

24 Hydraulic drift of work equipment is large

H-11

25 Time lag of work equipment is large

H-12

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100 General information on troubleshooting Classification and procedures of troubleshooting

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No.

Phenomena looking like troubles

Troubleshooting E-mode

H-mode

S-mode

Phenomenon related to compound operation 26 During compound operation of work equipment, speed of part loaded more is low

H-13

Phenomena related to travel 27 Machine deviates during travel

H-14

28 Speed or power of travel is low

H-15

29 Machine is not steered well or steering power is low

H-16

30 Travel speed does not change

H-17

31 Travel motor does not work (only 1 side)

H-18

Phenomena related to swing 32 Speed or power of swing is low

H-19

33 Machine does not swing

H-20

34 Swing acceleration is low

H-21

35 Machine overruns largely when it stops swinging

H-22

36 Large shock is made when machine stops swinging

H-23

37 Large sound is made when machine stops swinging

H-24

38 Hydraulic drift of swing is large

H-25

Phenomena related to blade and variable gauge 39 Speed or power of blade is low

H-26

40 Blade does not move

E-15

41 Hydraulic drift of blade is large

H-27 H-28

42 Variable gauge does not move

E-15

H-29

Phenomena related to hydraulic breaker 43 Troubleshooting for hydraulic breaker

H-30

Phenomena related to monitor panel 44 When starting switch is turned ON, any item does not operate

E-3

45 When starting switch is turned ON, some item does not operate

E-4

46 Alarm buzzer is abnormal

E-5

47 Engine oil pressure caution is turned ON

E-6

48 Charge level caution is turned ON

E-7

49 Travel speed shifting system does not operate normally

H-17

50 Preheating does not operate or preheater does not become hot

E-8

51 Coolant temperture gauge is abnormal

E-9

52 Fuel level gauge is abnormal

E-10

53 Service meter does not operate while engine is running

E-11

54 2nd travel speed is not selected

E-12 Other phenomena

55 Lock lever does not operate normally

E-14

H-3

56 Blade/Variable gauge selector system does not operate normally

E-15

H-27 H-29

57 Night lamp of machine monitor and working lamp do not light up

E-16

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100 General information on troubleshooting Classification and procedures of troubleshooting

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Connection table for connector pin numbers a

100 General information on troubleshooting Connection table for connector pin numbers

(Rev. 2007.12)

The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

40-100

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting Connection table for connector pin numbers

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100 General information on troubleshooting T- branch box and T- branch adapter table

SEN04497-00

T- branch box and T- branch adapter table

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q q

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

(Rev. 2008.02) 1

799-601-2600 T-box (for ECONO)

799-601-3100 T-box (for MS)

799-601-3200 T-box (for MS)

q q

799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)

MS-24P

799-601-3420 Adapter for BENDIX (MS)

MS-24P

799-601-3430 Adapter for BENDIX (MS)

MS-17P

799-601-3440 Adapter for BENDIX (MS)

MS-17P

799-601-3450 Adapter for BENDIX (MS)

MS-5P

799-601-3460 Adapter for BENDIX (MS)

MS-10P

799-601-3510 Adapter for BENDIX (MS)

MS-5P

799-601-3520 Adapter for BENDIX (MS)

MS-17P

799-601-3530 Adapter for BENDIX (MS)

MS-19P

799-601-2910 Adapter for BENDIX (MS)

MS-14P

q q

799-601-3470 Case 799-601-2710 Adapter for MIC

MIC-5P

q q

799-601-2720 Adapter for MIC

MIC-13P

q q

799-601-2730 Adapter for MIC

MIC-17P

q q q

q q

799-601-2740 Adapter for MIC

MIC-21P

q q q

q q

q q q

799-601-2950 Adapter for MIC

MIC-9P

799-601-2750 Adapter for ECONO

ECONO2P

q q

799-601-2760 Adapter for ECONO

ECONO3P

q q

799-601-2770 Adapter for ECONO

ECONO4P

q q

799-601-2780 Adapter for ECONO

ECONO8P

q q

799-601-2790 Adapter for ECONO

12 ECONO12P q q

799-601-2810 Adapter for DLI

DLI-8P

q q

799-601-2820 Adapter for DLI

DLI-12P

q q

799-601-2830 Adapter for DLI

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

799-601-4350 T-box (for DRC 60, ECONO)

799-601-2850 Case

799-601-4360 Case 799-601-7010 Adapter for X (T-adapter)

799-601-7020 Adapter for X

X2P

q q q

799-601-7030 Adapter for X

X3P

q q q

q q

799-601-7040 Adapter for X

X4P

q q q

799-601-7050 Adapter for SWP

SW6P

q q q q q q

799-601-7060 Adapter for SWP

SW8P

799-601-7310 Adapter for SWP

SW12P

799-601-7070 Adapter for SWP

SW14P

799-601-7320 Adapter for SWP

SW16P

799-601-7080 Adapter for M (T-adapter)

799-601-7090 Adapter for M

M2P

q q q

799-601-7110 Adapter for M

M3P

q q q

40-100

q q

PC18MR-3

100 General information on troubleshooting T- branch box and T- branch adapter table

799-601-7120 Adapter for M

M4P

q q q

799-601-7130 Adapter for M

M6P

q q q

799-601-7340 Adapter for M

M8P

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

T-adapter kit 799-601-2500

Part name

Number of pins

Part No.

SEN04497-00

799-601-7140 Adapter for S

S8P

q q q

799-601-7150 Adapter for S (White)

S10P

q q q

799-601-7160 Adapter for S (Blue)

S12P

q q q

799-601-7170 Adapter for S (Blue)

S16P

q q q

799-601-7330 Adapter for S (White)

S16PW

799-601-7350 Adapter for S (White)

S12PW

799-601-7180 Adapter for AMP040

A8P

799-601-7190 Adapter for AMP040

A12P

q q q q

799-601-7210 Adapter for AMP040

A16P

q q q

799-601-7220 Adapter for AMP040

A20P

q q q

799-601-7230 Short connector for X

—

q q q

q q

799-601-7240 Case

799-601-7270 Case 799-601-7510 Adapter for 070

07-10

799-601-7520 Adapter for 070

07-12

799-601-7530 Adapter for 070

07-14

799-601-7540 Adapter for 070

07-18

799-601-7550 Adapter for 070

07-20

799-601-7360 Adapter for relay

REL-5P

799-601-7370 Adapter for relay

REL-6P

799-601-7380 Adapter for JFC

—

799-601-9010 Adapter for DTM

DTM2

799-601-9020 Adapter for DT

DT2

799-601-9030 Adapter for DT

DT3

799-601-9040 Adapter for DT

DT4

799-601-9050 Adapter for DT

DT6

799-601-9060 Adapter for DT (Gray)

DT8GR

799-601-9070 Adapter for DT (Black)

DT8B

799-601-9080 Adapter for DT (Green)

DT8G

799-601-9090 Adapter for DT (Brown)

DT8BR

799-601-9110 Adapter for DT (Gray)

DT12GR

799-601-9120 Adapter for DT (Black)

DT12B

799-601-9130 Adapter for DT (Green)

DT12G

799-601-9140 Adapter for DT (Brown)

DT12BR

799-601-9210 Adapter for HD30-18

D18-8

799-601-9220 Adapter for HD30-18

D18-14

q q

D18-20

q q

799-601-9240 Adapter for HD30-18

D18-21

q q

799-601-9250 Adapter for HD30-24

D24-9

q q

799-601-9260 Adapter for HD30-24

D24-16

q q

799-601-9270 Adapter for HD30-24

D24-21

q q

799-601-9280 Adapter for HD30-24

D24-23

q q

799-601-9290 Adapter for HD30-24

D24-31

q q

799-601-9320 T-box (for ECONO)

PC18MR-3

q q

799-601-9230 Adapter for HD30-18

799-601-9310 Plate for HD30 (24-pin)

q q

40-100

100 General information on troubleshooting T- branch box and T- branch adapter table

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

SEN04497-00

799-601-9330 Case

799-601-9340 Case 799-601-9350 Adapter for DRC

DRC-40

q q

799-601-9360 Adapter for DRC

DRC-24

799-601-9410* Socket for engine (CRI-T2)

Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor

q q

799-601-9440* Socket for engine (CRI-T2)

1,2,3

795-799-5520* Socket for engine (HPI-T2)

Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor

q q

795-799-5460 Cable for engine (HPI-T2)

—

795-799-5470 Cable for engine (HPI-T2)

—

795-799-5480 Cable for engine (HPI-T2)

—

799-601-9430*

795-799-5540*

Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM

799-601-4110 Adapter for engine (140-T3) PIM

ITT3N

q q

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

FCIN

q q

Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure

FCIG

q q

799-601-4150 Adapter for engine (CRI-T3) POIL

FCIB

q q

Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch

4160

q q

799-601-4180 Adapter for engine (CRI-T3) PEVA

4180

q q

Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure

1,2,3L

q q

1,2,3,4C

q q

799-601-4230*

Socket for engine (CRI-T3) Air intake pressure/temperature

799-601-4240* Socket for engine (CRI-T3) PAMB

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

1,2,3,G

q q q q

799-601-4340*

Socket for engine (CRI-T3) Pump actuator

2,PA

799-601-4380*

Socket for engine (CRI-T3)(95) Air intake pressure/temperature

1,2,3,4T

q q q

799-601-4260 Adapter for controller (ENG)

DTP4

799-601-4211 Adapter for controller (ENG)

DRC50

q q

799-601-4220 Adapter for controller (ENG)

DRC60

799-601-4390* Socket for controller (95 ENG)

—

799-601-4280 Box for controller (PUMP)

121

—

799-601-9720 Adapter for controller (HST)

HST16A

799-601-9710 Adapter for controller (HST)

HST16B

799-601-9730 Adapter for controller (HST)

HST26A

2, 3, 4,

—

799-601-9890

Multi-adapter for DT2 – 4 and DTM2

“*” Shows not T-adapter but socket. 40-100

PC18MR-3

100 General information on troubleshooting T- branch box and T- branch adapter table

PC18MR-3

SEN04497-00

40-100

SEN04497-00

PC18MR-3 Hydraulic excavator Form No. SEN04497-00

40-100

SEN04498-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

40 Troubleshooting

200 Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting for electrical system (E-mode) ............................................................... 2 Information contained in troubleshooting table ............................................................................................... 4 E-1 Engine does not start ............................................................................................................................... 5 E-2 Engine does not stop.............................................................................................................................. 12 E-3 When starting switch is turned ON, any item does not operate ............................................................. 14 E-4 When starting switch is turned ON, some items do not operate ............................................................ 16 E-5 Alarm buzzer is abnormal....................................................................................................................... 17 E-6 Engine oil pressure caution is turned ON............................................................................................... 19 E-7 Charge level caution is turned ON ......................................................................................................... 20 E-8 Preheating system does not operate or preheater does not become hot .............................................. 22 E-9 Coolant temperature gauge is abnormal ................................................................................................ 24 E-10 Fuel level gauge is abnormal ............................................................................................................... 28 E-11 Service meter does not operate while engine is running ...................................................................... 32 E-12 2nd travel speed is not selected........................................................................................................... 35 E-13 Working lamp does not light up ............................................................................................................ 38 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves.................................................................................................................. 40 E-15 Blade/Variable gauge selector system does not operate normally....................................................... 43

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting for electrical system (E-mode)

SEN04498-00

Before carrying out troubleshooting for electrical system (E-mode)

Connection table of fusible link and fuse box a This connection table shows the devices (circuits) to which each power supply of the fusible link and fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the ON position and OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fusible link and fuse box to see if the power is supplied normally. Fusible link (M2) Type of power supply

Fuse No.

Fuse capacity

Constant power supply (Battery)

45 A

Type of power supply

Fuse No.

Fuse capacity

Battery power source

1 (Between terminals 1 and 7)

10 A

Battery relay

2 (Between terminals 2 and 8)

30 A

Drive

3 (Between terminals 3 and 9)

30 A

Destination of power Starting switch (Terminal B)

Fuse box 1 (FB1) Destination of power Radio circuit Work lamp circuit Fuel pump circuit Engine stop solenoid circuit Safety relay circuit PPC lock solenoid valve circuit Control

4 (Between terminals 4 and 10)

20 A

Acceleration solenoid circuit Variable solenoid circuit Monitor panel circuit

Other accessory

5 (Between terminals 5 and 11)

Horn circuit 20 A

Rotary lamp circuit (if equipped) Travel alarm (if equipped) Room lamp circuit

Cab accessory

6 (Between terminals 6 and 12)

30 A

Wiper circuit Washer circuit Heater circuit

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting for electrical system (E-mode)

SEN04498-00

Location of fuse and fuse numbers

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table

SEN04498-00

Information contained in troubleshooting table a

The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work. Failure information Relative information

Phenomena occurring on machine Information on the failure occurred as well as the troubleshooting Cause

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting <Content Included> • Standard value in normalcy by which to pass "good" or "no good" 1 judgement over the presumed cause • Reference for passing the above "good" or "no good" judgement <Phenomenon of Wiring Harness Failure> • Disconnection There is a faulty contact at the connector or disconnection of wiring harness occurred. • Defective grounding A wiring harness that is not connected with a grounding circuit has a 2 contact with the grounding circuit. • Short circuit with power source Wiring harness which is not connected to power source (12 V) circuit is in contact with power source (12 V) circuit. Cause that presumably • Short circuit triggered failure in quesIndependent wiring harnesses are in contact with each other abnortion mally. (The assigned No. is for <Precaution for Troubleshooting> filing purpose only. It does 1)Connector No. display method and handling of T-adapter not stand for any priority) Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. • If there is no indication of "male" or "female" in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides. • If there is an indication of "male" or "female" in a specific connector 3 No., disconnect the connector and connect the T-adapter with only one side of either "male" or "female". 2)Entry sequence of pin No. and handling of circuit tester lead Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following manner unless otherwise instructed. • Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness. • Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.

Relative circuit diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow ( ): Indicates the rough location on the machine

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

SEN04498-00

E-1 Engine does not start

Failure information

(1) When the starting switch is set in START, the starting motor does not revolve.

Relative information

• Since the engine starting circuit has the lock function, the engine does not start unless the PPC lock lever is in the LOCK position. • The lock lever is installed to the right and left. Cause Low charge level of battery 1 or low electrolyte specific gravity

Standard value in normalcy and references for troubleshooting Battery voltage Electrolyte specific gravity Min. 12 V

Min. 1.26

If the fusible link is broken, the circuit probably has a grounding fault. (See Cause 12.) If the fuse is broken, the circuit probably has a grounding fault. (See 3 Defective fuse No. 4 Cause 12.) aPrepare with starting switch OFF, then hold starting switch in OFF/ON/ START and carry out troubleshooting. Starting switch Position Resistance Defective starting switch OFF Min. 1 Mz 4 Between T-F1 (B) and (Internal disconnection) T-F3 (ACC) ON Max. 1 z OFF Min. 1 Mz Between T-F1 (B) and T-F4 (C) START Max. 1 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective left PPC lock F2 (male) Position of lock lever Resistance 5 switch (Internal disconnection) LOCK Min. 1 Mz Between (1) and (2) FREE Max. 1 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective right PPC lock F5 (male) Position of lock lever Resistance 6 switch (Internal disconnection) LOCK Min. 1 Mz Between (1) and (2) FREE Max. 1 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. R1 (male) Resistance Defective relay for engine Between (1) and (2) 82 – 88 z 7 start circuit (Internal disBetween (3) and (5) Min. 1 Mz connection) Between (3) and (6) Max. 1 z When relay (R1) for the engine start circuit is replaced with another one, if the condition becomes normal, relay (R1) is defective. aPrepare with starting switch OFF, then hold starting switch in START and carry out troubleshooting. R4 Voltage Between (4) and Start input 10 – 15 V chassis ground Defective safety relay 8 (Internal defect) Between (1) and (3) Charge input Max. 1 V Between (2) and 10 – 15 V Start output chassis ground If the start input, charge input, and power input are normal, the safety relay is defective. 2 Defective fusible link M2

Presumed cause and standard value in normalcy

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

SEN04498-00

Cause

Standard value in normalcy and references for troubleshooting aPrepare with starting switch OFF, then hold starting switch in START and carry out troubleshooting. Starting motor Starting switch Voltage Between T-M2 (B) Defective starting motor Power input 10 – 15 V 9 and (E) (Internal defect) Between M3 (ST) Start input 10 – 15 V and (E) If the power input and start input are normal but the starting motor does not revolve, the starting motor is defective. aPrepare with starting switch OFF, then hold starting switch ON and carry out troubleshooting. Defective alternator (Inter10 nal short circuit) M7 Voltage Between (2) and chassis ground Max. 1 V aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between battery (–) and chassis Resistance Max. 1 z ground Wiring harness between T-M1 (+) and M2 Presumed Resistance Max. 1 z (female) (2) cause and Wiring harness between M2 (female) (1) and Tstandard value Resistance Max. 1 z F1 (B) in normalcy Wiring harness between T-F3 (ACC) and FB1 Resistance Max. 1 z (3), (4) Wiring harness between FB1 (10) and F2 Resistance Max. 1 z (female) (2) Disconnection in wiring Wiring harness between F2 (female) (1) and F6 Resistance Max. 1 z harness (Disconnection or (female) (2) 11 defective contact of conWiring harness between F6 (female) (1) and R1 nector) Resistance Max. 1 z (female) (1) Wiring harness between R1 (female) (2) and Resistance Max. 1 z chassis ground (T-M6) Wiring harness between T-F4 (C) and R1 Resistance Max. 1 z (female) (6) Wiring harness between R1 (female) (3) and R4 Resistance Max. 1 z (female) (4) Wiring harness between R4 (female) (2) and M3 Resistance Max. 1 z (female) (ST) Wiring harness between T-M1 (+) and T-M2 (B) Resistance Max. 1 z Wiring harness between starting motor (E) and Resistance Max. 1 z chassis ground

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

Cause

Presumed cause and Grounding fault in wiring standard value 12 harness (Contact with in normalcy ground circuit)

PC18MR-3

SEN04498-00

Standard value in normalcy and references for troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between T-M1(+) – M2 (female) (2) wiring harResistance Min. 1 z ness and chassis ground Between M2 (female) (1) – T-F1 (B) wiring harResistance Min. 1 z ness and chassis ground Between T-F3 (ACC) – FB1 (3), (4) wiring harResistance Min. 1 z ness and chassis ground Between FB1 (10) – F2 (female) (2) or other related circuit wiring harness and chassis Resistance Min. 1 z ground Between F2 (female) (1) – F6 (female) (2) wiring Resistance Min. 1 z harness and chassis ground Between R4 (female) (2) – M3 (female) (ST) wirResistance Min. 1 z ing harness and chassis ground Between F6 (female) (1) – R1 (female) (1) or other related circuit wiring harness and chassis Resistance Min. 1 z ground Between T-F4 (C) – R1 (female) (6) or other related circuit wiring harness and chassis Resistance Min. 1 z ground Between R1 (female) (3) – R4 (female) (4) or other related circuit wiring harness and chassis Resistance Min. 1 z ground Between T-M1 (+) – T-M2 (B) wiring harness Resistance Min. 1 z and chassis ground Between R4 (female) (3) – M7 (female) (1) or TResistance Min. 1 z M2 (2) wiring harness and chassis ground

40-200

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

SEN04498-00

Failure information Relative information

(2) When the starting switch is set in START, the starting motor revolves. • If the engine stop solenoid does not operate, the fuel injection pump does not inject fuel. Cause

Presumed cause and standard value in normalcy 5

40-200

Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has a grounding fault (See Defective fuse No. 3 Cause 8). aPrepare with starting switch OFF, then carry out troubleshooting with starting switch OFF and ON. Defective starting switch Starting switch Starting switch Resistance (Internal disconnection) OFF Min. 1 Mz Between T-F1 (B) and T-F3 (ACC) ON Max. 1 z aPrepare with starting switch OFF, then keep starting switch OFF and turn it ON and carry out troubleshooting in each case. M4 (female) Voltage Defective engine stop Between (A) and (C) Holding voltage 10 – 15 V solenoid (Internal disconFor 1 sec: 10 – 15 V nection or short circuit) Between (B) and (C) Pulling voltage After 1 sec: Max. 1 V If the folding voltage and pulling voltage are normal but the solenoid rod does not operate, the solenoid is defective. aPrepare with starting switch OFF, then keep starting switch OFF and turn it ON and carry out troubleshooting in each case. F13 Voltage Defective engine stop Between (4) and (3) Input voltage 10 – 15 V solenoid timer (Internal For 1 sec: 10 – 15 V defect) Between (1) and (2) Output voltage After 1 sec: Max. 1 V If the input voltage is normal but the output voltage is not normal, the timer is defective. aPrepare with starting switch OFF, then keep starting switch OFF and turn it ON and carry out troubleshooting in each case. Defective engine stop R5 Voltage solenoid relay (Internal For 1 sec: 10 – 15 V disconnection or short cir- Between (e) and (g) Coil voltage After 1 sec: Max. 1 V cuit) For 1 sec: Max. 1 V Between (B) and (G) Contact voltage After 1 sec: 10 – 15 V aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective diode (Internal short circuit) D2 (male) Resistance/Continuity Between (1) and (2) Min. 1 Mz (No continuity) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between T-F3 (ACC) – FB1 (3) Resistance Max. 1 z Wiring harness between FB1 (9) – M4 (female) Resistance Max. 1 z (A) or R5 (female) (B) or F13 (female) (4) Wiring harness between F13 (female) (3) – Resistance Max. 1 z Disconnection in wiring chassis ground (T-M6) harness (Disconnection or defective contact of con- Wiring harness between F13 (female) (1) – R5 Resistance Max. 1 z (female) (e) nector) Wiring harness between F13 (female) (2) – R5 Resistance Max. 1 z (female) (g) Wiring harness between R5 (female) (G) – M4 Resistance Max. 1 z (female) (B) Wiring harness between M4 (female) (C) – Resistance Max. 1 z chassis ground (T-M6)

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

Cause

Presumed cause and standard value in normalcy

PC18MR-3

Grounding fault in wiring 8 harness (Contact with ground circuit)

SEN04498-00

Standard value in normalcy and references for troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between T-F3 (ACC) – FB1 (3) wiring harness Resistance Min. 1 Mz and chassis ground Between FB1 (9) – M4 (female) (A) or R5 (female) (B) or F13 (female) (4) or circuit branch Resistance Min. 1 Mz end and chassis ground Between F13 (female) (1) – R5 (female) (e) wirResistance Min. 1 Mz ing harness and chassis ground Between F13 (female) (2) – R5 (female) (g) wirResistance Min. 1 Mz ing harness and chassis ground Between R5 (female) (G) – M4 (female) (B) wirResistance Min. 1 Mz ing harness and chassis ground

40-200

SEN04498-00

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

Circuit diagram related to engine preheating, start, charge, and stop

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

PC18MR-3

SEN04498-00

40-200

200 Troubleshooting of electrical system (E-mode) E-2 Engine does not stop

SEN04498-00

E-2 Engine does not stop Failure information Relative information

Engine dose not stop. • If the engine stop solenoid does not stop, the fuel injection pump does not stop injecting fuel. Cause

Presumed cause and standard value in normalcy

Defective starting switch (Internal short circuit)

Defective engine stop solenoid (Internal defect)

Short circuit with power 3 source (Contact with 12V circuit) in wiring harness

40-200

Standard value in normalcy and references for troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting with starting switch OFF and ON. Starting switch Position of switch Resistance OFF Min. 1 Mz Between T-F1 (B) and T-F3 (ACC) ON Max. 1 z aCarry out troubleshooting with starting switch OFF. When the connector (Right No.) of the engine stop solenoid is disconnected, if the engine does not stop, the solenoid M4 may be seized or stuck. aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between T-F3 (ACC) – FB1 (3) wiring harness Voltage Max. 1 V and chassis ground Between FB1 (9) – M4 (female) (A) or D2 (female) (1) or R5 (female) (B) or F13 (female) Voltage Max. 1 V (4) or circuit branch end and chassis ground

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-2 Engine does not stop

SEN04498-00

Circuit diagram related to engine preheating, start, charge, and stop

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned ON, any item does not operate

SEN04498-00

E-3 When starting switch is turned ON, any item does not operate Failure information

Relative information

• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the monitor panel. 1) The warning lamps and indicators do not light up (for 3 seconds). 2) The buzzer does not sound (for 1 second). • The fuel level gauge and coolant temperature gauge do not operate even a while after the starting switch is turned ON. • Before starting troubleshooting, check that fuses No. (4) – (10) and No. (1) – (7) and fusible link are not broken. Causes

Presumed cause and standard value in normalcy

Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)

2 Defective monitor panel

40-200

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector F7. 3) Turn starting switch ON. Between F7 (female) (20) and ground Voltage 10 – 15 V Between F7 (female) (19) and ground Voltage 10 – 15 V 1) Turn starting switch OFF. 2) Remove fuses No. (4) – (10) and No. (1) – (7). 3) Turn starting switch ON. Between FB1 (1) and ground Voltage 10 – 15 V Between FB1 (4) and ground Voltage 10 – 15 V 1) Turn starting switch OFF. 2) Remove starting switch. 3) Turn starting switch ON. Between T-F1 and ground Voltage 10 – 15 V Between T-F3 and ground Voltage 10 – 15 V 1) Turn starting switch OFF. 2) Disconnect connector F7. 3) Connect T-adapter to female side of F7. Wiring harness between F7 (female) (1) and Resistance Max. 1 z ground If the floor wiring harness is normal, the monitor panel is defective.

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned ON, any item does not operate

SEN04498-00

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-4 When starting switch is turned ON, some items do not operate

SEN04498-00

E-4 When starting switch is turned ON, some items do not operate

Failure information

• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the monitor panel. 1) Some warning lamps and indicators do not light up (for 3 seconds). 2) The buzzer does not sound (for 1 second). • The fuel level gauge and coolant temperature gauge do not operate even a while after the starting switch is turned ON.

Relative information

• Distinguish this fault from “E-3 When starting switch is turned ON, any item does not operate”.

Presumed cause and standard value in normalcy

40-200

Causes 1 Defective monitor panel

Standard value in normalcy and references for troubleshooting See Structure, function and maintenance standard, “Monitor system”.

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-5 Alarm buzzer is abnormal

SEN04498-00

E-5 Alarm buzzer is abnormal 1)

Alarm buzzer does not sound Failure information Relative information

• When the starting switch is turned from OFF to ON, the self-check buzzer does not sound (for 1 second). • When the starting switch is turned ON and the 2nd travel speed selection switch and light switch are pressed, the selection sound (a short sound) is not heard. • Before starting troubleshooting, check that fuse No. (4) – (10) is not broken. • Refer to troubleshooting E-3, too. Causes

1 Defective monitor panel

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector F7. 3) Turn starting switch ON. Connect F7 (female) (11) to ground.

Presumed cause and standard value in normalcy

Buzzer

Sounds only when connected.

Buzzer

Sounds only when connected.

1) Turn starting switch OFF. 2) Insert T-adapter in connector F8. 3) Turn starting switch ON. 2 Defective alarm buzzer

Disconnection in wiring harness (Disconnection in 3 wiring harness or defective contact in connector)

Connect T-adapter box No. 1 to ground.

Between F8 (2) and ground Voltage 10 – 15 V 1) Turn starting switch OFF. 2) Disconnect connectors F7 and F8. 3) Connect T-adapter to F7 (female) and F8 (female). Wiring harness between F7 (female) (11) Resistance Max. 1 z and F8 (female) (1) Wiring harness between fuse (10) and F8 Resistance Max. 1 z (female) (2)

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-5 Alarm buzzer is abnormal

SEN04498-00 2)

Alarm buzzer does not stop sounding Failure information

• Alarm buzzer does not stop sounding.

Relative information

• Before starting troubleshooting, check that fuse No. (4) – (10) is not broken. • Refer to troubleshooting E-3, too. Causes

Presumed cause and standard value in normalcy

1 Defective monitor panel

Short circuit with chassis 2 ground in wiring harness (Contact with ground circuit)

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector F7. 3) Turn starting switch ON. Disconnect connector F7, and turn starting Stops Buzzer sounding. switch ON. 1) Turn starting switch OFF. 2) Disconnect connectors F7 and F8. 3) Connect T-adapter to F7 (female) and F8 (female). Between wiring harness between F7 Resistance Min. 1 Mz (female) (11) and F8 (female) (1) and ground

For the related circuit diagram, see 1).

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-6 Engine oil pressure caution is turned ON

SEN04498-00

E-6 Engine oil pressure caution is turned ON Failure information

Relative information

• The monitor panel performs the following operations to notify abnormal engine oil pressure while the engine is running. 1) The engine oil pressure caution lamp flashes. 2) The buzzer sounds. • Check that the engine oil pressure is normal. • When the starting switch is turned from OFF to ON, the monitor panel performs the following operations. This does not indicate a fault. 1) The engine oil pressure caution lamp and charge level caution lamp light up. 2) The buzzer does not sound. Causes

Presumed cause and standard value in normalcy

Short circuit with chassis 1 ground in wiring harness (Contact with ground circuit)

2 Defective monitor panel

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T-M3 and connector F7. 3) Connect T-adapter to F7 (female). Between wiring harness between F7 Resistance Min. 1 Mz (female) (7) and T-M3 and ground 1) Turn starting switch OFF. 2) Disconnect T-M3. 3) Start engine. While T-M3 is disconnected

Defective engine oil pressure switch

Oil pressure caution

Stopped

If the monitor panel and wiring harnesses are normal, the engine oil pressure switch is defective.

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-7 Charge level caution is turned ON

SEN04498-00

E-7 Charge level caution is turned ON Failure information

Relative information

• The monitor panel performs the following operations to notify abnormal charge level while the engine is running. 1) The charge level caution lamp flashes. 2) The buzzer sounds. • Check that the fan belt tension is normal. • When the starting switch is turned from OFF to ON, the monitor panel performs the following operations. This does not indicate a fault. 1) The engine oil pressure caution lamp and charge level caution lamp light up. 2) The buzzer does not sound. Causes 1

Presumed cause and standard value in normalcy

Defective alternator (Internal disconnection)

Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)

Short circuit with chassis 3 ground in wiring harness (Contact with ground circuit)

4 Defective monitor panel

40-200

Standard value in normalcy and references for troubleshooting 1) Prepare with starting switch OFF. 2) Start engine and carry out troubleshooting. Between M7 (1) and ground (just after Voltage 10 – 15 V starting engine) 1) Turn starting switch OFF. 2) Disconnect connectors M7 and F7. 3) Connect T-adapter to female side of F7. Wiring harness between battery (+) terminal Resistance Max. 1 z and alternator terminal B Wiring harness between M7 (female) (1) and Resistance Max. 1 z F7 (female) (17) 1) Turn starting switch OFF. 2) Disconnect connectors M7 and F7. 3) Connect T-adapter to female side of F7. Between wiring harness between F7 (female) (17) and M7 (female) (1) and Resistance Min. 1 Mz ground 1) Turn starting switch OFF. 2) Insert T-adapter in F7. 3) Start engine. Between F7 (17) and ground (just after Voltage 10 – 15 V starting engine)

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-7 Charge level caution is turned ON

SEN04498-00

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-8 Preheating system does not operate or preheater does not become hot

SEN04498-00

E-8 Preheating system does not operate or preheater does not become hot Failure information Relative information

• When the starting switch is set to HEAT, the following preheating system of the monitor panel does not operate. 1) The preheating indicator flashes (for about 18 seconds). 2) The buzzer sounds at start and end of preheating. • Check that the fusible link is not broken. • Refer to troubleshooting E-3, too. Causes 1 Defective fusible link

Presumed cause and standard value in normalcy

Defective air heater (Internal disconnection)

Defective starting switch (Internal defective contact)

Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)

Standard value in normalcy and references for troubleshooting If the fusible link is burned, the circuit probably has a grounding fault. 1) Prepare with starting switch OFF. 2) Turn starting switch ON and carry out troubleshooting. Between T-M5 (female) (1) and ground Voltage 10 – 15 V 1) Turn starting switch OFF. 2) Disconnect negative (–) terminal of battery. Between T-F1 and T-F5 or T-F6 Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect related connectors and terminals. 3) Connect T-adapter to female side of F7. Wiring harness between T-M5 (female) (1) Resistance Max. 1 z and T-F5, T-F6 or F7 (female) (8) Wiring harness between T-F1 and M2 (2) (1) Resistance Max. 1 z and positive (+) terminal of battery

Related circuit diagram

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-8 Preheating system does not operate or preheater does not become hot

PC18MR-3

SEN04498-00

40-200

200 Troubleshooting of electrical system (E-mode) E-9 Coolant temperature gauge is abnormal

SEN04498-00

E-9 Coolant temperature gauge is abnormal 1)

The pointer of the gauge does not move from C on the panel Failure information

• When the starting switch is turned ON, the pointer of the gauge does not move from C on the panel.

Relative information

• Check that the coolant temperature is normal. • While the starting switch is in OFF, the pointer does not move from C. This is not abnormal. • Refer to troubleshooting E-3, too. Causes

Presumed cause and standard value in normalcy

40-200

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors M6 and F7. Disconnection in wiring 3) Connect T-adapter to M6 (female) and F7 (female). harness (Disconnection in Wiring harness between F7 (female) (10) 1 wiring harness or defective Resistance Max. 1 z and M6 (female) (1) contact in connector) Wiring harness between F7 (female) (16) Resistance Max. 1 z and M6 (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector M6. 3) Connect T-adapter to M6 (male). M6 (male) Temperature Resistance 25°C 38.18 – 47.77 kz 30°C 31.59 – 39.07 kz Defective coolant temperature 2 80°C 6.199 – 6.935 kz sensor 85°C 5.386 – 5.975 kz Between (1) and (2) 90°C 4.695 – 5.166 kz 95°C 4.107 – 4.483 kz 100°C 3.604 – 3.903 kz 105°C 3.157 – 3.426 kz If the wiring harness and coolant temperature sensor are normal, 3 Defective monitor panel the monitor panel is defective.

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-9 Coolant temperature gauge is abnormal

SEN04498-00

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-9 Coolant temperature gauge is abnormal

SEN04498-00 2)

The pointer of the gauge does not move from H on the panel Failure information

• When the starting switch is turned ON, the pointer of the gauge does not move from H on the panel.

Relative information

• Check that the coolant temperature is normal. • Refer to troubleshooting E-3, too. Causes

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors M6 and F7. Disconnection in wiring 3) Connect T-adapter to M6 (female) and F7 (female). harness (Disconnection in Wiring harness between F7 (female) (10) or 1 wiring harness or defective Resistance Min. 1 Mz M6 (female) (1) and ground contact in connector) Wiring harness between F7 (female) (16) or Resistance Min. 1 Mz M6 (female) (2) and ground 1) Turn starting switch OFF. 2) Disconnect connector M6. 3) Connect T-adapter to M6 (male). M6 (male) Temperature Resistance 25°C 38.18 – 47.77 kz 30°C 31.59 – 39.07 kz Defective coolant temperature 2 80°C 6.199 – 6.935 kz sensor 85°C 5.386 – 5.975 kz Between (1) and (2) 90°C 4.695 – 5.166 kz 95°C 4.107 – 4.483 kz 100°C 3.604 – 3.903 kz 105°C 3.157 – 3.426 kz If the wiring harness and coolant temperature sensor are normal, 3 Defective monitor panel the monitor panel is defective.

For the related circuit diagram, see 1).

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PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-9 Coolant temperature gauge is abnormal

SEN04498-00

Temperature indicated by gauge is very different from actual temperature Failure information Relative information

• When the starting switch is turned ON, the temperature indicated by the gauge is very different from the actual temperature. • Check that the coolant temperature is normal. • Refer to troubleshooting E-3, too. Causes

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector M6. 3) Connect T-adapter to M6 (male). M6 (male) Temperature Resistance 25°C 38.18 – 47.77 kz 30°C 31.59 – 39.07 kz Defective coolant temperature 1 80°C 6.199 – 6.935 kz sensor 85°C 5.386 – 5.975 kz Between (1) and (2) 90°C 4.695 – 5.166 kz 95°C 4.107 – 4.483 kz 100°C 3.604 – 3.903 kz 105°C 3.157 – 3.426 kz If the wiring harness and coolant temperature sensor are normal, 2 Defective monitor panel the monitor panel is defective.

For the related circuit diagram, see 1).

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-10 Fuel level gauge is abnormal

SEN04498-00

E-10 Fuel level gauge is abnormal 1)

The pointer of the gauge does not move from E on the panel Failure information

• When the starting switch is turned ON, the pointer of the gauge does not move from E on the panel.

Relative information

• Check that the fuel level is normal. • While the starting switch is in OFF, the pointer does not move from E. This is not abnormal. • Refer to troubleshooting E-3, too. Causes

Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)

Presumed cause and standard value in normalcy

2 Defective fuel level sensor

3 Defective monitor panel

40-200

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors M8 and F7. 3) Connect T-adapter to M8 (female) and F7 (female). Wiring harness between F7 (female) (13) Resistance Max. 1 z and M8 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors M8. 3) Connect T-adapter to M8 (female). Wiring harness between M8 (female) (2) and Resistance Max. 1 z ground 1) Turn starting switch OFF. 2) Disconnect connector M8. 3) Connect T-adapter to M8 (male). Resistance M8 (male) Position of float ( ) is reference value. FULL 0 +2 –0 z 1/2 (50) z Between (2) and (3) EMPTY 150 ± 10 z If the wiring harness and fuel level sensor are normal, the monitor panel is defective.

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-10 Fuel level gauge is abnormal

SEN04498-00

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-10 Fuel level gauge is abnormal

SEN04498-00 2)

The pointer of the gauge does not move from F on the panel Failure information

• When the starting switch is turned ON, the pointer of the gauge does not move from F on the panel.

Relative information

• Check that the fuel level is normal. • Refer to troubleshooting E-3, too. Causes Short circuit with chassis 1 ground in wiring harness (Contact with ground circuit)

Presumed cause and standard value in normalcy

2 Defective fuel level sensor

3 Defective monitor panel

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors M8 and F7. 3) Connect T-adapter to M8 (female) and F7 (female). Wiring harness between F7 (female) (13) Resistance Min. 1 Mz and M8 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connector M8. 3) Connect T-adapter to M8 (male). Resistance M8 (male) Position of float ( ) is reference value. FULL 0 +2 –0 z 1/2 (50) z Between (2) and (3) EMPTY 150 ± 10 z If the wiring harness and fuel level sensor are normal, the monitor panel is defective.

For the related circuit diagram, see 1).

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-10 Fuel level gauge is abnormal

Fuel level indicated by gauge is very different from actual oil level Failure information Relative information

• When the starting switch is turned ON, the fuel level indicated by the gauge is very different from the actual temperature. • Check that the fuel level is normal. • Refer to troubleshooting E-3, too. Causes

Presumed cause and standard value in normalcy

1 Defective fuel level sensor

2 Defective monitor panel

SEN04498-00

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector M8. 3) Connect T-adapter to M8 (male). Resistance M8 (male) Position of float ( ) is reference value. FULL 0 +2 –0 z Between (2) and (3) 1/2 (50) z EMPTY 150 ± 10 z If the wiring harness and fuel level sensor are normal, the monitor panel is defective.

For the related circuit diagram, see 1).

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-11 Service meter does not operate while engine is running

SEN04498-00

E-11 Service meter does not operate while engine is running 1)

Engine oil pressure caution is turned ON Failure information Relative information

1) Service meter (Operating hour integrator) does not Engine oil pressure caution is turned ON. operate while engine is running. • While the engine is running, the service meter operates even if the machine does not move at all. • While the engine is stopped, the service meter does not operate. • Refer to troubleshooting E-3, too. a Carry out troubleshooting “E-6 Engine oil pressure caution is turned ON” first, then carry out the following troubleshooting. Causes

Presumed cause and standard value in normalcy

Disconnection in wiring harness (Disconnection in 1 wiring harness or defective contact in connector) 2 Defective monitor panel

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector F7. 3) Connect T-adapter to F7 (female). 4) Turn starting switch to START (Do not hold for long time, however). Between T-F4 and ground Voltage 10 – 15 V Between F7 (female) (9) and ground Voltage 10 – 15 V If the wiring harness is normal, the monitor panel is defective.

Related circuit diagram

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-11 Service meter does not operate while engine is running

Charge warning is displayed, too Failure information Relative information

2) Service meter (Operating hour integrator) does not Charge warning is displayed, too. operate while engine is running. • While the engine is running, the service meter operates even if the machine does not move at all. • While the engine is stopped, the service meter does not operate. • Refer to troubleshooting E-3, too. a Carry out the troubleshooting for “E-7 Charge level caution is turned ON” first, then carry out the following troubleshooting. Causes

Presumed cause and standard value in normalcy

Disconnection in wiring harness (Disconnection in 1 wiring harness or defective contact in connector) 2 Defective monitor panel

For the related circuit diagram, see 1).

Engine oil pressure and charge does not indicate warning Failure information Relative information

Presumed cause and standard value in normalcy

SEN04498-00

3) Service meter (Operating hour integrator) does not Engine oil pressure and charge does not operate while engine is running. indicate warning. • While the engine is running, the service meter operates even if the machine does not move at all. • While the engine is stopped, the service meter does not operate. • Refer to troubleshooting E-3, too. a If the service meter still does not work after the troubleshooting for E-6 and E-7, the possible cause is as follows. Causes 1 Defective monitor panel

Standard value in normalcy and references for troubleshooting If any abnormality is not detected by 1) and 2), the monitor panel is defective.

For the related circuit diagram, see 1).

PC18MR-3

40-200

SEN04498-00

40-200

200 Troubleshooting of electrical system (E-mode) E-11 Service meter does not operate while engine is running

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-12 2nd travel speed is not selected

SEN04498-00

E-12 2nd travel speed is not selected 1)

Monitor panel does not respond and 2nd travel speed is not selected Failure information

â&#x20AC;˘ When the 2nd travel speed selection switch is pressed while the engine is running, the monitor panel does not make the following responses. 1) Turning ON/OFF of 2nd travel speed indicator 2) Changing sound by buzzer (Short sound)

Relative information

â&#x20AC;&#x201D;

Carry out troubleshooting E-3.

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-12 2nd travel speed is not selected

SEN04498-00 2)

Monitor panel responds but 2nd travel speed is not selected Failure information Relative information

• Monitor panel responds but 2nd travel speed is not selected. • Refer to troubleshooting E-3, too. Causes 1 Defective fuse (4) – (10)

Presumed cause and standard value in normalcy

Defective starting switch (Internal defective contact)

Defective 2nd travel speed selection relay

Defective 2nd travel speed selection solenoid

Disconnection in wiring harness (Disconnection in 5 wiring harness or defective contact in connector)

Short circuit with chassis 6 ground in wiring harness (Contact with ground circuit)

40-200

Standard value in normalcy and references for troubleshooting If the fuse is burned, the circuit probably has a grounding fault. 1) Turn starting switch OFF. 2) Disconnect negative (–) terminal of battery. Starting switch Position Resistance OFF Min. 1 Mz Between terminals B and ACC ON Max. 1 z 1) Turn starting switch OFF. 2) Disconnect connector R3. 3) Connect T-adapter to R3 (male). R3 (male) Resistance Between (1) and (2) 86 – 106 z Between (3) and (6) Max. 1 z Between (3) and (5) Min. 1 Mz 1) Turn starting switch OFF. 2) Insert T-adapter in R3. 3) Turn starting switch ON. 2nd travel speed Voltage R3 selection switch Between (5) and ON 10 – 15 V ground 1) Turn starting switch OFF. 2) Disconnect connector M10. 3) Connect T-adapter to M10 (male). Between (1) and (2) Resistance 10.5 – 12 z M10 (male) Between (1) and body Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T-F3 and connectors F7, R3 and M10. 3) Connect T-adapter to F7, R3 and M10 (female). Wiring harness between T-F3 and fuse (4) or Resistance Max. 1 z between (10) and R3 (female) (3) Wiring harness between R3 (female) (5) and Resistance Max. 1 z M10 (female) (1) Wiring harness between F7 (female) (6), F10 Resistance Max. 1 z (2), (1) and R3 (female) (1) Wiring harness between R3 (female) (2) and Resistance Max. 1 z ground 1) Turn starting switch OFF. 2) Disconnect T-F3 and connectors F7, R3 and M10. 3) Connect T-adapter to F7, R3 and M10 (female). Between wiring harness between fuse (10) Resistance Min. 1 Mz and R3 (female) (3) and ground Between wiring harness between R3 (female) (5) and M10 (female) (1) and Resistance Min. 1 Mz ground Between wiring harness between F7 (female) (6), F10 (2), (1) and R3 (female) (1) Resistance Min. 1 Mz and ground

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-12 2nd travel speed is not selected

SEN04498-00

Related circuit diagram

PC18MR-3

40-200

200 Troubleshooting of electrical system (E-mode) E-13 Working lamp does not light up

SEN04498-00

E-13 Working lamp does not light up Failure information Relative information

• Working lamp does not light up. • Refer to troubleshooting E-3, too. Causes 1 Defective fuse (2) – (8)

Presumed cause and standard value in normalcy

40-200

Standard value in normalcy and references for troubleshooting If the fuse is burned, the circuit probably has a grounding fault. 1) Turn starting switch OFF. 2) Disconnect connector W2. 3) Connect T-adapter to W2 (female). Defective lamp 4) Turn starting switch ON. 5) Turn lamp switch ON. Between W2 (female) (A) and ground Voltage 10 – 15 V 1) Turn starting switch OFF. 2) Disconnect relay F9. F9 (female) Lamp switch operation Resistance Defective lamp switch (1) and (2) ON Max. 1 z Between (2) and (4) (3) and (4) OFF Min. 1 Mz 1) Turn starting switch OFF. Disconnection in wiring 2) Disconnect connectors F9 and W2. harness (Disconnection in 3) Connect T-adapter to W2 (female). wiring harness or defective Wiring harness between F9 (female) (2), W1 contact in connector) Resistance Max. 1 z (1) and W2 (female) (A). 1) Turn starting switch OFF. 2) Disconnect connectors F9 and W2. 3) Connect T-adapters to W2 (female). Short circuit with chassis ground in wiring harness Between wiring harness between fuse (8) and Resistance Min. 1 Mz (Contact with ground circuit) ground Between wiring harness between F9 (female) Resistance Min. 1 Mz (2), W1 (2) and W2 (female) (A) and ground

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-13 Working lamp does not light up

SEN04498-00

Related circuit diagram

PC18MR-3

40-200

SEN04498-00

200 Troubleshooting of electrical system (E-mode) E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still

E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves Failure information

• When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves. (Without blade)

Relative information

Presumed cause and standard value in normalcy

40-200

Causes Standard value in normalcy and references for troubleshooting Defective fuse (2) – (12), (3) – If fuse is broken, circuit probably has ground fault. 1 (13) 1) Turn starting switch OFF. 2) Disconnect cable from negative (–) terminal of battery. Defective starting switch Starting switch Position Resistance 2 (Internal defective contact) OFF Min. 1 Mz Between (T-F1) terminal B – (T-F3) termiON Max. 1 z nal ACC 1) Turn starting switch OFF. 2) Disconnect connector F2. 3) Connect T-adapter to F2 (male). Defective PPC lock switch 3 (left) (Internal defective F6 (male) Lock lever position Resistance contact) Free Max. 1 z Between (1) – (2) Lock Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connector F6. Defective PPC lock switch 3) Connect T-adapter to F6 (male). (right) (Internal defective 4 F6 (male) Lock lever position Resistance contact) a Canopy specification only Free Max. 1 z Between (1) – (2) Lock Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect relay R2. 3) Connect T-adapter to R2 (male). R2 (male) Resistance Between (1) – (2) 86 – 106 z Defective PPC lock relay Between (3) – (6) Max. 1 z 5 (Internal disconnection, Between (3) – (5) Min. 1 Mz defective contact or sticking) 1) Turn starting switch OFF. 2) Insert T-adapter in relay R2. 3) Turn starting switch ON. R2 Lock lever position Voltage Between (5) – ground Lock 10 – 15 V 1) Turn starting switch OFF. Defective PPC lock solenoid 2) Disconnect connector M9. 3) Connect T-adapter to M9 (male). 6 (Internal disconnection or Resistance 10.5 – 12 z short circuit) Between (1) – (2) M9 (male) Between (1) – body Resistance Min. 1 Mz

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still

SEN04498-00

Causes

Presumed cause and standard value in normalcy

PC18MR-3

Standard value in normalcy and references for troubleshooting 1) Turn starting switch OFF. 2) Disconnect related connector. 3) Set PPC lock switch in LOCK. Wiring harness between (T-F3) terminal B – Resistance Max. 1 z fuse (7) – R2 (female) (3) Wiring harness between R2 (female) (5) – Disconnection in wiring Resistance Max. 1 z M9 (female) (1) harness (Disconnection in 7 wiring or defective contact in Wiring harness between (T-F3) terminal connector) ACC – fuse (10) – F2 (2) or between (1) – F6 (2) or between (1) – R2 (female) (1) Resistance Max. 1 z a F14 is installed to only canopy specification. Wiring harness between R2 (female) (2) – Resistance Max. 1 z ground 1) Turn starting switch OFF. 2) Disconnect related connector. 3) Set PPC lock switch in LOCK. Between wiring harness fuse (7) – R2 Resistance Min. 1 Mz Ground fault in wiring harness (female) (3) and ground 8 (Contact with GND or GND Between wiring harness R2 (female) (5) – circuit) Resistance Min. 1 Mz M9 (female) (1) and ground Between wiring harness fuse (10) – F2 (2) or Resistance Min. 1 Mz (1) – F6 (2) or (1) – R2 (female) (1) and ground

40-200

SEN04498-00

200 Troubleshooting of electrical system (E-mode) E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still

Related circuit diagram

40-200

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-15 Blade/Variable gauge selector system does not operate normally

SEN04498-00

E-15 Blade/Variable gauge selector system does not operate normally 1 Failure information Relative information

(1) When blade/variable gauge selector switch is set in BLADE position, variable gauge moves. • The blade and variable gauge are selected by changing the blade control valve circuit with the variable gauge selector solenoid valve. Cause Defective blade/variable 1 gauge selector switch (Internal short circuit)

Presumed cause and standard value in normalcy

Defective variable gauge selector solenoid valve 2 (Internal disconnection or short circuit)

Short circuit with power 3 source (Contact with 12V circuit) in wiring harness

PC18MR-3

Standard value in normalcy and references for troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Blade/variable gauge F1 (male) Resistance selector switch Blade Min. 1 Mz Between (2) and (3) Variable gauge Max. 1 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. M11 (male) Resistance Between (1) and (2) 5.5 ± 0.4 z Between (1) and chassis ground Min. 1 Mz Disconnect the variable gauge solenoid valve (M11). If the condition does not become normal at this time, the valve may be seized or stuck. aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between F1 (female) (2) – M11 (male) (1) or D3 Voltage Max. 1 V (female) (1) wiring harness and chassis ground

40-200

200 Troubleshooting of electrical system (E-mode) E-15 Blade/Variable gauge selector system does not operate normally

SEN04498-00

Failure information Relative information

(2) When blade/variable gauge selector switch is set in VARIABLE GAUGE position, blade moves. • The blade and variable gauge are selected by changing the blade control valve circuit with the variable gauge selector solenoid valve. Cause

Presumed cause and standard value in normalcy

40-200

Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has a grounding fault (See Defective fuse No. 4 Cause 6). aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective blade/variable Blade/variable gauge F1 (male) Resistance gauge selector switch selector switch (Internal disconnection) Blade Min. 1 Mz Between (2) and (3) Variable gauge Max. 1 z aPrepare with starting switch OFF, then carry out troubleshooting withDefective variable gauge out turning starting switch. selector solenoid valve M11 (male) Resistance (Internal disconnection or Between (1) and (2) 5.5 ± 0.4 z short circuit) Between (1) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective diode (Internal short circuit) D3 (male) Resistance/Continuity Between (1) and (2) Min. 1 Mz (No continuity) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between T-F3 (ACC) – FB1 (4) Resistance Max. 1 z Disconnection in wiring Wiring harness between FB1 (10) – F1 (female) harness (Disconnection or Resistance Max. 1 z (3) defective contact of conWiring harness between F1 (female) (2) – M11 nector) Resistance Max. 1 z (female) (1) Wiring harness between M11 (female) (2) – Resistance Max. 1 z chassis ground (T-M6) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between T-F3 (ACC) – FB1 (4) wiring harness Resistance Min. 1 Mz Grounding fault in wiring and chassis ground harness (Contact with Between FB1 (10) – F1 (female) (3) or circuit Resistance Min. 1 Mz ground circuit) branch end wiring harness and chassis ground Between F1 (female) (2) – M11 (female) (1) or D3 (female) (1) wiring harness and chassis Resistance Min. 1 Mz ground

PC18MR-3

200 Troubleshooting of electrical system (E-mode) E-15 Blade/Variable gauge selector system does not operate normally

SEN04498-00

Circuit diagram related to blade/variable gauge selector switch

PC18MR-3

40-200

SEN04498-00

PC18MR-3 Hydraulic excavator Form No. SEN04498-00

40-200

SEN04499-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

40 Troubleshooting

300 Troubleshooting of hydraulic and mechanical system (H-mode) Information contained in troubleshooting table ............................................................................................... 3 H-1 Speed or power of whole work equipment, travel, swing, and blade is low ............................................. 4 H-2 Engine speed lowers extremely or engine stalls ...................................................................................... 5 H-3 Whole work equipment, travel system, swing system, and blade do not move ....................................... 6 H-4 Abnormal sound comes out from around hydraulic pump........................................................................ 7 H-5 Fine control performance or response is low ........................................................................................... 7 H-6 Speed or power of boom is low ................................................................................................................ 8 H-7 Speed or power of arm is low................................................................................................................... 9 H-8 Speed or power of bucket is low ............................................................................................................ 10 H-9 Speed or power of boom swing is low.....................................................................................................11 H-10 Work equipment does not move singly .................................................................................................11 H-11 Work equipment hydraulic drift is large ................................................................................................ 12 H-12 Time lag of work equipment is large..................................................................................................... 13 H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 13 H-14 Machine deviates during travel ............................................................................................................ 14 H-15 Travel speed or travel power is low...................................................................................................... 16 H-16 Machine is not steered well or steering power is low ........................................................................... 16 H-17 Travel speed does not change ............................................................................................................. 17 H-18 Travel motor does not work (one side only) ......................................................................................... 17 H-19 Speed or power of swing is low............................................................................................................ 18

PC18MR-3

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SEN04499-00

300 Troubleshooting of hydraulic and mechanical system (H-mode)

H-20 Machine does not swing....................................................................................................................... 20 H-21 Swing acceleration performance is low ................................................................................................ 22 H-22 Machine overruns when it stops swinging............................................................................................ 23 H-23 Large shock is made when machine stops swinging ........................................................................... 24 H-24 When upper structure stops swinging, it makes large sound ............................................................... 24 H-25 Hydraulic drift of swing is large............................................................................................................. 25 H-26 Speed or power of blade is low ............................................................................................................ 26 H-27 Blade does not move............................................................................................................................ 27 H-28 Hydraulic drift of blade is large ............................................................................................................. 27 H-29 Variable gauge does not move............................................................................................................. 28 H-30 Troubleshooting for hydraulic breaker .................................................................................................. 29

40-300

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) Information contained in troubleshooting table

SEN04499-00

Information contained in troubleshooting table a

Troubleshooting Table and relative circuit diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Failure information Relative information

Phenomena occurring on machine Information on occurred failures and troubleshooting

Cause

Standard value in normalcy and references for troubleshooting

2 Presumed cause and standard value in normalcy

Cause for presumed failure <Contents> (The attached No. for filing â&#x20AC;˘ The standard values in normalcy by which to judge "good" or "no 3 and reference purpose good" about presumed causes. only. It does not stand for â&#x20AC;˘ References for making judgement of "good" or "no good" any priority) 4

PC18MR-3

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300 Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Speed or power of whole work equipment, travel, swing, and blade is low

SEN04499-00

H-1 Speed or power of whole work equipment, travel, swing, and blade is low 1 Failure information Relative information

• Speed or power of whole work equipment, travel, swing, and blade is low. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause Standard value in normalcy and references for troubleshooting 1 Clogged suction strainer The suction filter of the hydraulic tank may be clogged. Check it directly. Low performance or inter- The gear pump performance may be lowered or the gear pump may 2 nal defect of gear pump have a defect in it. Check the gear pump directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever Control circuit basic pressure 3

Malfunction of relief valve in 2-spool solenoid valve

Malfunction of PPC lock solenoid valve

+0.39

All levers in neutral

3.72 –0.10 MPa {38 +4 –1 kg/cm²}

After adjustment, if the oil pressure does not become normal, the relief valve in the 2-spool solenoid valve may be malfunctioning or may have a defect in it. Check the relief valve directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. PPC lock solenoid valve output Lock lever pressure 0 MPa LOCK {0 kg/cm²} +0.2

FREE

Presumed cause and standard value in normalcy

3.14 –0 MPa {32 +20 kg/cm²}

Low performance or inter- The piston pump performance may be lowered or the piston pump may nal defect of piston pump have a defect in it. Check the piston pump directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever LS differential pressure +0.98

Malfunction or defective adjustment of LS valve

All levers IN neutral

2.5 0 MPa {25 +10 0 kg/cm²}

1.57 ± 0.1 MPa {16 ± 1 kg/cm²} After adjustment, if the oil pressure does not become normal, the LS valve may be malfunctioning or may have a defect in it. Check the LS valve directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever Main relief pressure Arm-in operation (Half stroke)

Malfunction or defective 7 adjustment of main relief valve

Malfunction of unload valve

+0.98

Arm-IN relief

After adjustment, if the oil pressure does not become normal, the main relief valve may be malfunctioning or may have a defect in it. Check the main relief valve directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever Unload pressure All levers in neutral

40-300

23.0 –0.49 MPa {235 +10 –5 kg/cm²}

2.5 {235

+0.98 MPa 0 +10 0 kg/cm²}

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-2 Engine speed lowers extremely or engine stalls

SEN04499-00

H-2 Engine speed lowers extremely or engine stalls Failure information Relative information

• Engine speed lowers extremely or engine stalls. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever LS differential pressure +0.98

Malfunction or defective adjustment of LS valve

All levers IN neutral

2.5 0 MPa {25 +10 0 kg/cm²}

1.57 ± 0.1 MPa {16 ± 1 kg/cm²} After adjustment, if the oil pressure does not become normal, the LS valve may be malfunctioning or may have a defect in it. Check the LS valve directly. The LS circuit orifices (on the pump side and control valve side) may be clogged. Check them directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever Main relief pressure Arm-IN operation (Half stroke)

Presumed cause and standard value in normalcy

2 Clogged LS circuit orifice

Malfunction or defective 3 adjustment of main relief valve

4 Low engine output

PC18MR-3

+0.98

Arm-IN relief

23.0 –0.49 MPa {235 +10 –5 kg/cm²}

After adjustment, if the oil pressure does not become normal, the main relief valve may be malfunctioning or may have a defect in it. Check the main relief valve directly. If none of causes 1 – 3 is the cause of the trouble, the engine output may be lowered. Carry out troubleshooting for the engine unit (S-mode).

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-3 Whole work equipment, travel system, swing system, and blade do not move

SEN04499-00

H-3 Whole work equipment, travel system, swing system, and blade do not move 1 Failure information Relative information

• Whole work equipment, travel system, swing system, and blade do not move. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause 1 Clogged suction strainer Defective coupling or gear 2 pump shaft Low performance or inter3 nal defect of gear pump

Presumed cause and standard value in normalcy

Malfunction of relief valve in 2-spool solenoid valve

Malfunction of PPC lock solenoid valve

Standard value in normalcy and references for troubleshooting The suction filter of the hydraulic tank may be clogged. Check it directly. The coupling (between the piston pump and gear pump) or the gear pump shaft may be defective. Check the gear pump directly. The gear pump performance may be lowered or the gear pump may have a defect in it. Check the gear pump directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever Control circuit basic pressure +0.39

All levers in neutral

FREE Defective damper or piston pump shaft Low performance or inter7 nal defect of piston pump 6

Malfunction or defective 8 adjustment of main relief valve

Malfunction of unload valve

3.14 0 MPa {32 +20 kg/cm²}

The damper (between the engine and piston pump) or the piston pump shaft may be defective. Check them directly. The piston pump performance may be lowered or the piston pump may have a defect in it. Check the piston pump directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control lever Main relief pressure +0.98

Arm-IN relief

23.0 –0.49 MPa {235 +10 –5 kg/cm²}

All levers in neutral

40-300

3.72 –0.10 MPa {38 +4 –1 kg/cm²}

2.5 0 MPa {25 +10 0 kg/cm²}

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-4 Abnormal sound comes out from around hydraulic pump

SEN04499-00

H-4 Abnormal sound comes out from around hydraulic pump Failure information Relative information

Presumed cause and standard value in normalcy

• Abnormal sound comes out from around hydraulic pump. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.

Cause 1 Low hydraulic oil level 2 Hydraulic oil of low quality Clogging of hydraulic tank 3 cap Clogging of hydraulic tank 4 strainer 5 Defective piston pump

Standard value in normalcy and references for troubleshooting The hydraulic oil level may be low. Check it directly. The hydraulic oil may contain air. Check it directly. The hydraulic tank cap may be clogged and negative pressure may be applied to the tank. Check the cap directly. The hydraulic tank strainer may be clogged and negative pressure may be supplied to the suction circuit. Check the strainer directly. The piston pump may have internal defect. Check it directly. If none of causes 1 – 5 is the cause of the trouble, operate the machine – Cause cannot be found out for a while and see if the condition changes.

H-5 Fine control performance or response is low Failure information Relative information

• Fine control performance or response is low. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control levers LS differential pressure +0.98

Malfunction or defective 1 adjustment of LS valve

All levers in neutral

1.57 ± 0.1 MPa {16 ± 1 kg/cm²} If normal oil pressure is not obtained by adjustment, the LS valve may be malfunctioning or may have internal defect. Check the LS valve directly. The LS circuit orifices (on pump side and control valve side) may be clogged. Check them directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Control levers Unload pressure Arm IN (Half stroke)

Presumed cause and standard value in normalcy 2

Clogging of LS circuit orifice

Malfunction of unload valve

+0.98

All levers in neutral

PC18MR-3

2.5 0 MPa {25 +10 0 kg/cm²}

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-6 Speed or power of boom is low

SEN04499-00

H-6 Speed or power of boom is low

Failure information

• Speed or power of boom is low.

Relative information

• Before carrying out troubleshooting, check that other work equipment, travel system, swing system, and blade system are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or power of whole work equipment, travel, swing, and blade speed is low".) • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure and leakage from the cylinder while the hydraulic oil temperature is 45 – 55°C. Cause

Malfunction of right PPC valve (boom circuit)

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Right work equipment control lever PPC valve output pressure 0 MPa Set in neutral {0 kg/cm²} Operate to raise boom Operate to lower boom

Malfunction of boom control valve (spool) Malfunction of boom con3 trol valve (pressure compensation valve) Malfunction or defective 4 seal of boom control valve (suction valve) Malfunction or defective 5 seal of centralized safetysuction valves 2

Presumed cause and standard value in normalcy

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The boom control valve spool may have a malfunction. Check it directly. The pressure compensation valve of the boom control valve may be malfunction. Check it directly. The suction valve of the boom control valve may have a malfunction or defective seal. Check it directly.

The centralized safety valve may be malfunctioning or its seal may be defective. Check the centralized safety valve directly. (A trouble in the centralized safety valve has effects on the arm and bucket.) aPrepare with engine stopped, then run engine at high idle and carry out Defective seal of boom cyl- troubleshooting. 6 inder Boom cylinder Leakage from cylinder Relieve by raising boom 10 cc/min

40-300

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-7 Speed or power of arm is low

SEN04499-00

H-7 Speed or power of arm is low

Failure information

• Speed or power of arm is low.

Relative information

Malfunction of left PPC valve (arm circuit)

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Left work equipment control lever PPC valve output pressure 0 MPa Set in neutral {0 kg/cm²} Operated to move arm IN Operated to move arm OUT

Malfunction of arm control valve (spool) Malfunction of arm control 3 valve (pressure compensation valve) Malfunction or defective 4 seal of arm control valve (suction valve) 2

Presumed cause and standard value in normalcy

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The arm control valve spool may have a malfunction. Check it directly. The pressure compensation valve of the arm control valve may be malfunction. Check it directly. Since the suction valves of the arm control valve may have a malfunction, check them directly.

The centralized safety valve may be malfunctioning or its seal may be Malfunction or defective defective. Check the centralized safety valve directly. (A trouble in the 5 seal of centralized safetycentralized safety valve has effects on the arm, bucket, boom swing, and suction valves blade, too.) aPrepare with engine stopped, then run engine at high idle and carry out Defective seal of arm cylin- troubleshooting. 6 Arm cylinder Leakage from cylinder der Relieved in arm-IN operation 10 cc/min

PC18MR-3

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Speed or power of bucket is low

SEN04499-00

H-8 Speed or power of bucket is low

Failure information

• Speed or power of bucket is low.

Relative information

Malfunction of right PPC valve (bucket circuit)

Malfunction of bucket control valve (spool) Malfunction of bucket con3 trol valve (pressure compensation valve) Malfunction or defective 4 seal of bucket control valve (suction valve) 2

Presumed cause and standard value in normalcy

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The bucket control valve spool may have a malfunction. Check it directly. The pressure compensation valve of the bucket control valve may be malfunction. Check it directly. Since the suction valves of the bucket control valve may have a malfunction, check them directly.

The centralized safety valve may be malfunctioning or its seal may be Malfunction or defective defective. Check the centralized safety valve directly. (A trouble in the 5 seal of centralized safetycentralized safety valve has effects on the arm, bucket, boom swing, and suction valves blade, too.) aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Defective seal of bucket 6 Bucket cylinder Leakage from cylinder cylinder 10 cc/min Relieved in bucket-CURL operation

40-300

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-9 Speed or power of boom swing is low

SEN04499-00

H-9 Speed or power of boom swing is low

Failure information

• Speed or power of boom swing is low.

Relative information

2 Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Boom swing control pedal PPC valve output pressure Malfunction of boom swing 0 MPa Set in neutral PPC valve {0 kg/cm²} Operated to move left boom swing +0.2 3.14 0 MPa Operated to move right boom {32 +20 kg/cm²} swing Malfunction of boom swing The boom swing control valve spool may have a malfunction. Check it control valve (spool) directly. Malfunction of boom swing The pressure compensation valve of the boom swing control valve may control valve (pressure have a malfunction. Check it directly. compensation valve) Malfunction or defective The suction valve of the boom swing control valve may have a malfuncseal of boom swing control tion. Check it directly. valve (suction valve) The centralized safety valve may be malfunctioning or its seal may be Malfunction or defective defective. Check the centralized safety valve directly. (A trouble in the seal of suction valves centralized safety valve has effects on the arm, bucket, boom swing, and blade, too.) aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Defective seal of boom Boom swing cylinder Leakage from cylinder swing cylinder Relieved at left swing 10 cc/min

H-10 Work equipment does not move singly Failure information Relative information

(1) Boom does not move singly. (2) Arm does not move singly. (3) Bucket does not move singly. (4) Boom swing system does not move singly. • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper. • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C. Cause

Presumed cause and standard value in normalcy

1 Malfunction of PPC valve

Operate lever 2

PC18MR-3

Malfunction of control valve (spool)

3.14 0 MPa {32 +20 kg/cm²}

The control valve spool may have a malfunction. Check it directly.

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-11 Work equipment hydraulic drift is large

SEN04499-00

H-11 Work equipment hydraulic drift is large Failure information Relative information

(1) Hydraulic drift of boom is large. (2) Hydraulic drift of arm is large. (3) Hydraulic drift of bucket is large. (4) Hydraulic drift of boom swing is large. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the leakage from the cylinder while the hydraulic oil temperature is 45 – 55°C. Cause

Presumed cause and standard value in normalcy

40-300

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Work equipment cylinder Leakage from cylinder Defective seal of hydraulic 1 Relieved by boom RAISE cylinder Relieved by arm IN 10 cc/min Relieved by bucket CURL Relieved by boom SWING LEFT Malfunction of control 2 The control valve spool may be malfunctioning. Check it directly. valve (spool) Malfunction of control The suction valve of the control valve may be malfunctioning. Check it 3 valve (suction valve) directly.

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-12 Time lag of work equipment is large

SEN04499-00

H-12 Time lag of work equipment is large Failure information

(1) Time lag of boom is large. (2) Time lag of arm is large. (3) Time lag of bucket is large.

Relative information

• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Malfunction of control valve (suction valve)

The suction valve of the control valve may have a malfunction. Check it directly.

H-13 In compound operation of work equipment, speed of part loaded more is low 1 Failure information Relative information

• In compound operation of work equipment, speed of part loaded more is low. • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.

Cause

Presumed cause and standard value in normalcy

PC18MR-3

Malfunction of pressure 1 compensation valve on less load side

Standard value in normalcy and references for troubleshooting The pressure compensation valve of the control valve on less load side may have a malfunction. Check it directly. More load Less load Combination of operations side side RAISE boom + Move arm IN Boom Arm RAISE boom + Move arm OUT Arm Boom RAISE boom + CURL bucket Boom Bucket Move arm OUT + CURL bucket Arm Bucket LOWER boom + Move arm OUT Arm Boom

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-14 Machine deviates during travel

SEN04499-00

H-14 Machine deviates during travel Failure information Relative information

(1) Machine deviates during ordinary travel. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Standard value in normalcy and references for troubleshooting The undercarriage may be defective. Check the following items. • Check that the track shoe tension is adjusted evenly on both sides. 1 Defective undercarriage • Check that the idlers, rollers, etc. are free from revolution trouble, deformation, and damage. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Travel lever PPC valve output pressure 0 MPa Neutral Malfunction of travel PPC {0 kg/cm²} 2 valve +0.2 Operated to right, left, forward, 3.14 0 MPa +2 or reverse {32 0 kg/cm²} Presumed cause and standard value in normalcy

Output difference of above between right and left Malfunction of travel control valve (spool) Malfunction of travel con4 trol valve (pressure compensation valve) 3

Max. 0.4 MPa {Max. 4 kg/cm²}

The travel control valve spool may be malfunctioning. Check it directly. The pressure compensation valve (with right and left junction mechanism) of the travel control valve may be malfunctioning. Check it directly.

The seal of the center swivel joint may be defective. Check it directly. • Replace right and left hoses between the center swivel joint and travel motor with each other. If the turning direction becomes opposite, the center swivel joint is defective. The travel motor unit may be malfunctioning or its performance is low. Malfunction or low perfor- Check it directly. • Replace right and left hoses between the center swivel joint and 6 mance of travel motor travel motor with each other. If the turning direction does not change, (motor unit) the motor is defective. The final drive of the travel motor may be malfunctioning. Check it Malfunction of travel motor 7 directly. (It can be judged by abnormal sound, abnormal heating, quan(final drive) tity of metal dust in drained oil, etc.)

Defective seal of center 5 swivel joint

40-300

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-14 Machine deviates during travel

Failure information Relative information

SEN04499-00

(2) Machine deviates when it starts (It does not deviate during ordinary travel). • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper. • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C. Cause

Presumed cause and standard value in normalcy

PC18MR-3

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Travel lever PPC valve output pressure 0 MPa Set in neutral Malfunction of travel PPC {0 kg/cm²} 1 valve +0.2 Operate to drive left-right, 3.14 0 MPa forward-reverse {32 +20 kg/cm²} Output difference between Max. 0.4 MPa above both sides {Max. 4 kg/cm²} Malfunction of travel motor The travel motor counterbalance valve may have a malfunction. Check 2 (counterbalance valve) it directly. Malfunction of travel motor The travel motor holding brake may have a malfunction. Check it 3 (holding brake) directly.

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-15 Travel speed or travel power is low

SEN04499-00

H-15 Travel speed or travel power is low

Failure information

• Travel speed or travel power is low.

Relative information

• Before carrying out troubleshooting, check that work equipment, swing system, and blade system are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or power of whole work equipment, travel, swing, and blade speed is low".) • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting The undercarriage may be defective. Check the following items. • Check that the track shoe tension is adjusted evenly on both sides. 1 Defective undercarriage • Check that the idlers, rollers, etc. are free from revolution trouble, deformation, and damage. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Travel lever PPC valve output pressure Malfunction of travel PPC 0 MPa 2 Neutral valve {0 kg/cm²} Operated to right, left, forward, or reverse Malfunction of travel control valve (spool) Malfunction of travel con4 trol valve (pressure compensation valve) 3

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The travel control valve spool may be malfunctioning. Check it directly. The pressure compensation valve of the travel control valve may be malfunctioning. Check it directly.

H-16 Machine is not steered well or steering power is low Failure information Relative information

• Machine is not steered well or steering power is low. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

40-300

Operated to right, left, forward, or reverse Malfunction of travel control valve (spool) Malfunction of travel con3 trol valve (pressure compensation valve) Defective seal of center 4 swivel joint 2

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The travel control valve spool may be malfunctioning. Check it directly. The pressure compensation valve of the travel control valve may be malfunctioning. Check it directly. The seal of the center swivel joint may be defective. Check it directly.

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-17 Travel speed does not change

SEN04499-00

H-17 Travel speed does not change

Failure information

• Travel speed does not change.

Relative information

• The travel motor has the automatic speed change mechanism. If the travel load increases while the machine is traveling in the high speed mode, the travel speed is set low automatically. (If the travel load decreases, the travel speed is set high again.) • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Presumed cause and standard value in normalcy

Malfunction of 2nd travel 1 speed selection solenoid valve

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. 2nd travel speed Travel speed shifting 2nd travel speed selection solenoid switch selection monitor valve output pressure 0 MPa Low speed mode OFF {0 kg/cm²} +0.2

High speed mode 2

3.14 0 MPa {32 +20 kg/cm²}

Malfunction of travel motor The speed change section (selector valve and servo valve) of the travel (speed change section) motor may be malfunctioning. Check it directly.

H-18 Travel motor does not work (one side only) Failure information Relative information

• Travel motor does not work (one side only). • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

PC18MR-3

Operated to right, left, forward, or reverse Malfunction of travel control valve (spool) Malfunction of travel motor 3 (with counterbalance valve) Malfunction of travel motor 4 (motor unit) 2

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The travel control valve spool may be malfunctioning. Check it directly. The counterbalance valve of the travel motor may be malfunctioning. Check it directly. The motor unit of the travel motor may be malfunctioning. Check it directly.

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-19 Speed or power of swing is low

SEN04499-00

H-19 Speed or power of swing is low

Failure information

(1) Speed or power of swing is low in both directions.

Relative information

• Before carrying out troubleshooting, check that work equipment, travel system, and blade system are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or power of whole work equipment, travel, swing, and blade speed is low".) • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Causet

Presumed cause and standard value in normalcy

40-300

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Swing holding brake Work equipment control levers release signal pressure Malfunction of shuttle 1 valve for swing holding 0 MPa All levers in neutral brake (inside control valve) {0 kg/cm²} Operated to swing LEFT +0.2 3.14 0 MPa Operated to swing RIGHT +2 {32 0 kg/cm²} Operated to arm IN Malfunction of swing con2 The swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) Malfunction of swing motor The parking brake section (timer valve and parking brake) of the swing 3 (parking brake section) motor may be malfunctioning. Check it directly.

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-19 Speed or power of swing is low

Failure information Relative information

SEN04499-00

(2) Speed or power of swing is low in only one direction. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Work equipment control levers PPC valve output pressure Malfunction of swing PPC 0 MPa 1 All levers in neutral valve {0 kg/cm²} Operated to swing LEFT Operated to swing RIGHT

Presumed cause and standard value in normalcy

Malfunction of shuttle 2 valve for swing holding brake

+0.2

3.14 0 MPa {32 +20 kg/cm²}

aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Swing holding brake Work equipment control levers release signal pressure 0 MPa All levers in neutral {0 kg/cm²} Operated to swing LEFT +0.2 3.14 0 MPa Operated to swing RIGHT +2 {32 0 kg/cm²} Operated to arm IN

Malfunction of swing conThe swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction of swing motor Work equipment control levers Swing relief pressure 4 (safety valve) 19.1 ± 0.98 MPa Relieved by swing (to right and left) {195 ± 10 kg/cm²} Malfunction of swing motor The suction valve of the swing motor may be malfunctioning. Check it 5 (suction valve) directly. 3

PC18MR-3

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-20 Machine does not swing

SEN04499-00

H-20 Machine does not swing

Failure information

(1) Machine does not swing in either direction.

Relative information

• Before carrying out troubleshooting, check that work equipment, travel system, and blade system are normal. (If any of them is abnormal, perform troubleshooting for "H-2 Whole work equipment, travel system, swing system, and blade system do not work".) • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

1 Presumed cause and standard value in normalcy 2 3 4

40-300

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Swing holding brake Work equipment control levers release signal pressure Malfunction of shuttle valve for swing holding 0 MPa All levers in neutral brake (inside control valve) {0 kg/cm²} Operated to swing LEFT +0.2 3.14 0 MPa Operated to swing RIGHT +2 {32 0 kg/cm²} Operated to arm IN Malfunction of swing conThe swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) Malfunction of swing motor The parking brake section (timer valve and parking brake) of the swing (parking brake section) motor may be malfunctioning. Check it directly. Malfunction of swing motor The motor unit of the travel motor may be malfunctioning. Check it (motor unit) directly.

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-20 Machine does not swing

Failure information Relative information

SEN04499-00

(2) Machine does not swing in only one direction. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Presumed cause and standard value in normalcy

3 4

PC18MR-3

+0.2

3.14 0 MPa {32 +20 kg/cm²}

aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Swing holding brake Work equipment control levers release signal pressure Malfunction of shuttle valve for swing holding 0 MPa All levers in neutral brake (inside control valve) {0 kg/cm²} Operated to swing LEFT +0.2 3.14 0 MPa Operated to swing RIGHT +2 {32 0 kg/cm²} Operated to arm IN Malfunction of swing conThe swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) Malfunction of swing conThe load check valve in the spool of the swing control valve may be maltrol valve (load check valve functioning. Check it directly. in spool) aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction of swing motor Work equipment control levers Swing relief pressure (safety valve) 19.1 ± 0.98 MPa Relieved by swing (to right and left) {195 ± 10 kg/cm²} Malfunction of swing motor The suction valve of the swing motor may be malfunctioning. Check it (suction valve) directly.

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-21 Swing acceleration performance is low

SEN04499-00

H-21 Swing acceleration performance is low Failure information Relative information

Presumed cause and standard value in normalcy

Failure information Relative information

(1) Swing acceleration performance is low in both directions. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.

Cause Malfunction of swing con1 trol valve (spool) Malfunction of swing motor 2 (parking brake section) Malfunction of swing motor 3 (motor unit)

Standard value in normalcy and references for troubleshooting The swing control valve spool may be malfunctioning. Check it directly. The parking brake section (timer valve and parking brake) of the swing motor may be malfunctioning. Check it directly. The motor unit of the travel motor may be malfunctioning. Check it directly.

(2) Swing acceleration performance is low in only one direction. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

40-300

+0.2

3.14 0 MPa {32 +20 kg/cm²}

Malfunction of swing conThe swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) Malfunction of swing conThe load check valve in the spool of the swing control valve may be mal3 trol valve (load check valve functioning. Check it directly. in spool) aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction of swing motor 4 Work equipment control levers Swing relief pressure (safety valve) 19.1 ± 0.9 MPa Relieved by swing (to right and left) {195 ± 10 kg/cm²} Malfunction of swing motor The suction valve of the swing motor may be malfunctioning. Check it 5 (suction valve) directly. 2

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-22 Machine overruns when it stops swinging

SEN04499-00

H-22 Machine overruns when it stops swinging Failure information Relative information

Presumed cause and standard value in normalcy

Failure information Relative information

(1) Machine overruns when it stops swinging in both directions. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.

Cause Standard value in normalcy and references for troubleshooting Malfunction of swing con1 The swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) Malfunction of swing motor The motor unit of the travel motor may be malfunctioning. Check it 2 (motor unit) directly.

(2) Machine overruns when it stops swinging in only one direction. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

PC18MR-3

Operated to swing LEFT Operated to swing RIGHT

+0.2

3.14 0 MPa {32 +20 kg/cm²}

Malfunction of swing conThe swing control valve spool may be malfunctioning. Check it directly. trol valve (spool) aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction of swing motor 3 Work equipment control levers Swing relief pressure (safety valve) 19.1 ± 0.9 MPa Relieved by swing (to right and left) {195 ± 10 kg/cm²} Malfunction of swing motor The suction valve of the swing motor may be malfunctioning. Check it 4 (suction valve) directly. 2

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-23 Large shock is made when machine stops swinging

SEN04499-00

H-23 Large shock is made when machine stops swinging Failure information Relative information

• Large shock is made when machine stops swinging. • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper. • When starting troubleshooting, set the hydraulic oil temperature to 45 – 55°C. Cause

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Work equipment control lever PPC valve output pressure Malfunction of swing PPC 0 MPa 1 Set all in neutral valve {0 kg/cm²} Operated to swing LEFT Operated to swing RIGHT Presumed cause and standard value in normalcy

Malfunction of shuttle 2 valve for swing holding brake (inside control valve) Malfunction of swing con3 trol valve (spool)

+0.2

3.14 0 MPa {32 +20 kg/cm²}

The shuttle valve for the swing holding brake may be malfunctioning. Check it directly.

Since the swing control valve spool may have a malfunction, check it directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction of swing motor 4 Work equipment control levers Swing relief pressure (safety valve) 19.1 ± 0.98 MPa Relieved by swing (to right and left) {195 ± 10 kg/cm²} Malfunction of swing motor The parking brake section (timer valve and parking brake) of the swing 5 (parking brake section) motor may be malfunctioning. Check it directly.

H-24 When upper structure stops swinging, it makes large sound Failure information Relative information

Presumed cause and standard value in normalcy

40-300

• When upper structure stops swinging, it makes large sound. • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.

Cause Malfunction of back pres1 sure check valve

Standard value in normalcy and references for troubleshooting The back pressure check valve may have a malfunction. Check it directly. The swing motor safety valves may have a malfunction. Check the Malfunction of swing motor 2 valves directly. (They may be checked by exchanging with each other (safety valve) and checking change of the phenomenon.) The swing motor suction valves may have a malfunction. Check the Malfunction of swing motor 3 valves directly. (They may be checked by exchanging with each other (suction valves) and checking change of the phenomenon.)

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-25 Hydraulic drift of swing is large

SEN04499-00

H-25 Hydraulic drift of swing is large Failure information Relative information

(1) While swing holding brake is applied, hydraulic drift of swing is large. • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal. • Check the oil pressure while the hydraulic oil temperature is 45 – 55°C. Cause

Standard value in normalcy and references for troubleshooting aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Swing holding brake Lock lever release pressure 0 MPa LOCK {0 kg/cm²} +0.2

Presumed cause and standard value in normalcy

FREE Malfunction or defective 1 seal of swing motor (parking brake section)

Work equipment control lever All levers in neutral

3.14 0 MPa {32 +20 kg/cm²} Swing holding brake release signal pressure 0 MPa {0 kg/cm²}

Operated to swing LEFT +0.2 3.14 0 MPa Operated to swing RIGHT {32 +20 kg/cm²} Operated to arm IN If the above oil pressure is normal, the parking brake section (selector valve, pressure reducing valve, and orifice) of the swing motor may be malfunctioning or its seal is defective. Check it directly.

Failure information Relative information

(2) While swing holding brake is released, hydraulic drift of swing is large. • Release the swing holding brake by swinging and moving the arm IN.

Cause Defective seal of swing 1 control valve (spool) Presumed cause and standard value in normalcy

PC18MR-3

Defective seal of swing motor (safety valve)

Defective seal of swing motor (suction valve)

Standard value in normalcy and references for troubleshooting The seal of the swing control valve spool may be defective. Check it directly. The seal of the safety valve of the swing motor may be defective. Check it directly. (The sealing condition can be judged by replacing the right and left safety valves and checking the change of the phenomenon.) The seal of the suction valve of the swing motor may be defective. Check it directly. (The sealing condition can be judged by replacing the right and left suction valves and checking the change of the phenomenon.)

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-26 Speed or power of blade is low

SEN04499-00

H-26 Speed or power of blade is low

Failure information

• Speed or power of blade is low.

Relative information

• Before carrying out troubleshooting, check that work equipment, travel system, and swing system are normal. (If any of them is abnormal, perform troubleshooting for "H-1 Speed or power of whole work equipment, travel, swing, and blade speed is low".) • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper. • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.

Presumed cause and standard value in normalcy

40-300

Cause Malfunction of blade con1 trol valve (spool) Malfunction of variable 2 gauge selector solenoid valve

Standard value in normalcy and references for troubleshooting The blade control valve spool may have a malfunction. Check it directly.

The variable gauge solenoid valve may be malfunctioning. Check it directly. (If the solenoid valve is not changed normally, the variable gauge probably moves when the blade is operated.) aPrepare with engine stopped, then run engine at high idle and carry out Defective seal of blade cyl- troubleshooting. 3 inder Blade cylinder Leakage from cylinder Relieved by lowering blade 10 cc/min

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-27 Blade does not move

SEN04499-00

H-27 Blade does not move

Failure information

• Blade does not move.

Relative information

• Before carrying out troubleshooting, check that work equipment, travel system, and swing system are normal. (If any of them is abnormal, perform troubleshooting for "H-2 Whole work equipment, travel system, swing system, and blade system do not work".) • The blade circuit pressure is also used for the variable gauge. Accordingly, the blade does not move while the blade/variable gauge selector switch is set in the variable gauge position. • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper. • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.

Presumed cause and standard value in normalcy

Cause Malfunction of blade con1 trol valve (spool) Malfunction of variable 2 gauge selector solenoid valve

Standard value in normalcy and references for troubleshooting The blade control valve spool may have a malfunction. Check it directly.

The variable gauge solenoid valve may be malfunctioning. Check it directly. (If the solenoid valve is not changed normally, the variable gauge probably moves when the blade is operated.) aPrepare with engine stopped, then run engine at high idle and carry out Defective seal of blade cyl- troubleshooting. 3 Blade cylinder Leakage from cylinder inder Relieved by lowering blade 10 cc/min Deformation of blade cylin4 The blade cylinder or blade is deformed. Check them directly. der or blade

H-28 Hydraulic drift of blade is large Failure information Relative information

Presumed cause and standard value in normalcy

PC18MR-3

• Hydraulic drift of blade is large. • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper. • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C. Cause Defective seal of blade 1 control valve (spool) Defective seal of blade cyl2 inder

Standard value in normalcy and references for troubleshooting The seal of blade control valve spool may be defective. Check it directly. aPrepare with engine stopped, then run engine at high idle and carry out troubleshooting. Blade cylinder Leakage from cylinder Relieved by lowering blade 10 cc/min

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-29 Variable gauge does not move

SEN04499-00

H-29 Variable gauge does not move

Failure information

â&#x20AC;˘ Variable gauge does not move.

Relative information

â&#x20AC;˘ Since the blade circuit pressure is also used for the variable gauge, check that the blade moves normally before carrying out troubleshooting. (If the blade does not move normally, carry out troubleshooting for "H-27 Blade does not move".)

Presumed cause and standard value in normalcy

40-300

Cause Malfunction of variable 1 gauge selector solenoid valve Defective variable gauge 2 cylinder Deformed track frame 3 (variable gauge section)

Standard value in normalcy and references for troubleshooting The variable gauge solenoid valve may be malfunctioning. Check it directly. (If the solenoid valve is not changed normally, the blade probably moves when the variable gauge is operated.) The variable gauge cylinder seal may be defective. Check it directly. The variable gauge section of the track frame may be deformed. Check it directly.

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-30 Troubleshooting for hydraulic breaker

SEN04499-00

H-30 Troubleshooting for hydraulic breaker Failure information Relative information

Presumed cause and standard value in normalcy

(1) Breaker does not strike. • Before carrying out troubleshooting, check that hydraulic tank oil level is normal.

1 2 3 4

Failure information Relative information

Presumed cause and standard value in normalcy

Failure information Relative information

Cause Malfunction of control valve Breakage of control valve Low hydraulic oil level Loosened mounting nuts of valve body assembly and front end assembly

Failure information Relative information Presumed cause and standard value in normalcy

PC18MR-3

Standard value in normalcy and references for troubleshooting Disassemble and check that valve body and control valve slide normally. Replace. Add. Retighten.

(2) Blow impact and blow frequency are low. • Before carrying out troubleshooting, check that hydraulic tank oil level is normal.

Cause 1 Low engine speed Malfunction of control 2 valve 3 Seized chisel 4 Improper setting of chisel

Standard value in normalcy and references for troubleshooting Increase engine speed. Disassemble and check that valve body and control valve slide normally. Remove chisel and repair seized part (apply grease). Press chisel straight.

(3) Blow frequency is normal but blow impact is low. • Before carrying out troubleshooting, check that hydraulic tank oil level is normal.

Cause Presumed cause and standard value in normalcy

Low accumulator gas pressure

Broken accumulator diaphragm

Standard value in normalcy and references for troubleshooting Add nitrogen gas. 5.4 MPa Gas pressure {55 kg/cm²} Replace.

(4) Much oil or little black oil leaks through chisel socket. —

Cause 1 Worn U-packing 2 Damaged U-packing 3 Grease leakage

Standard value in normalcy and references for troubleshooting Replace. Remove flaws of hammer piston and replace packing. This is not abnormal phenomenon.

40-300

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-30 Troubleshooting for hydraulic breaker

SEN04499-00

Failure information Relative information

(5) High-pressure hose swings abnormally. • Before carrying out troubleshooting, check that hydraulic tank oil level is normal.

Cause

Presumed cause and standard value in normalcy

Failure information Relative information Presumed cause and standard value in normalcy

40-300

High accumulator gas pressure

Low accumulator gas pressure

Broken accumulator diaphragm

Standard value in normalcy and references for troubleshooting Adjust nitrogen gas pressure. 5.4 MPa Gas pressure {55 kg/cm²} Add nitrogen gas. 5.4 MPa Gas pressure {55 kg/cm²} Replace.

(6) Oil leakage through mating faces of valve body, cylinder and accumulator. —

Cause 1 Worn or hardened O-ring

Standard value in normalcy and references for troubleshooting Replace.

2 Loosened bolt and nut

Retighten.

PC18MR-3

300 Troubleshooting of hydraulic and mechanical system (H-mode) H-30 Troubleshooting for hydraulic breaker

PC18MR-3

SEN04499-00

40-300

SEN04499-00

PC18MR-3 Hydraulic excavator Form No. SEN04499-00

40-300

SEN04500-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

40 Troubleshooting

400 Troubleshooting of engine (S-mode) Troubleshooting chart ..................................................................................................................................... 2

PC18MR-3

40-400

400 Troubleshooting of engine (S-mode) Troubleshooting chart

SEN04500-00

Troubleshooting chart a

This troubleshooting chart is transferred from the Shop Manual for 3D67E-2 Engine. Symptom

Engine Does Not Start

Starter Does Not Run

Engine Revolution Is Not Smooth

Probable Cause

Solution

No fuel

Replenish fuel

Air in the fuel system

Bleed

Water in the fuel system

Change fuel and repair or replace fuel system

Fuel hose clogged

Clean or replace

Fuel filter clogged

Replace

Excessively high viscosity of fuel or engine oil at low temperature

Use specified fuel or engine oil

Fuel with low cetane number

Use specified fuel

Fuel leak due to loose injection pipe retaining nut

Tighten retaining nut

Incorrect injection timing

Adjust

Fuel camshaft worn

Replace

Injection nozzle clogged

Clean or replace

Injection pump malfunctioning

Repair or replace

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Repair or replace

Compression leak from cylinder

Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

Improper valve timing

Correct or replace timing gear

Piston ring and cylinder worn

Replace

Excessive valve clearance

Adjust

Stop solenoid malfunctioning

Replace

Battery discharged

Charge

Starter malfunctioning

Repair or replace

Wiring disconnected

Connect

Fuel filter clogged or dirty

Replace

Air cleaner clogged

Clean or replace

Fuel leak due to loose injection pipe retaining nut

Tighten retaining nut

Injection pump malfunctioning

Repair or replace

Incorrect nozzle injection pressure

Adjust

Injection nozzle stuck or clogged

Repair or replace

Governor malfunctioning

Repair W1046115

40-400

PC18MR-3

400 Troubleshooting of engine (S-mode) Troubleshooting chart

Symptom

SEN04500-00

Probable Cause

Solution

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil

Reduce to specified level

Piston ring and cylinder worn or stuck

Repair or replace

Incorrect injection timing

Adjust

Either Black or Dark Gray Exhaust Gas Is Observed

Overload

Reduce the load

Low grade fuel used

Use specified fuel

Fuel filter clogged

Replace

Air cleaner clogged

Clean or replace

Deficient nozzle injection

Repair or replace nozzle

Incorrect injection timing

Adjust

Engine’s moving parts seem to be seizing

Repair or replace

Injection pump malfunctioning

Repair or replace

Deficient nozzle injection

Repair or replace nozzle

Compression leak

Check the compression pressure and repair

Piston ring’s gap facing the same direction

Shift ring gap direction

Oil ring worn or stuck

Replace

Piston ring groove worn

Replace piston

Valve stem and valve guide worn

Replace

Crankshaft bearing and crank pin bearing worn

Replace

Oil leaking due to defective seals or packing

Replace

Injection pump’s plunger worn

Repair or replace

Deficient nozzle injection

Repair or replace nozzle

Injection pump broken

Replace

Head gasket defective

Replace

Cylinder block or cylinder head flawed

Replace

Deficient Output

Excessive Lubricant Oil Consumption

Fuel Mixed into Lubricant Oil

Water Mixed into Lubricant Oil

W1047740

PC18MR-3

40-400

400 Troubleshooting of engine (S-mode) Troubleshooting chart

SEN04500-00

Symptom Low Oil Pressure

Probable Cause

Solution

Engine oil insufficient

Replenish

Oil strainer clogged

Clean

Relief valve stuck with dirt

Clean

Relief valve spring weaken or broken

Replace

Excessive oil clearance of crankshaft bearing

Replace

Excessive oil clearance of crankpin bearing

Replace

Excessive oil clearance of rocker arm

Replace

Oil passage clogged

Clean

Different type of oil

Use specified type of oil

Oil pump defective

Replace

High Oil Pressure

Different type of oil

Use specified type of oil

Relief valve defective

Replace

Engine Overheated

Engine oil insufficient

Replenish

Fan belt broken or elongated

Replace or adjust

Coolant insufficient

Replenish

Radiator net and radiator fin clogged with dust

Clean

Inside of radiator corroded

Clean or replace

Coolant flow route corroded

Clean or replace

Radiator cap defective

Replace

Overload running

Reduce the load

Head gasket defective

Replace

Incorrect injection timing

Adjust

Unsuitable fuel used

Use specified fuel

Battery electrolyte insufficient

Replenish distilled water and charge

Fan belt slips

Adjust belt tension or replace

Wiring disconnected

Connect

Rectifier defective

Replace

Alternator defective

Replace

Battery defective

Replace

Battery Quickly Discharged

W1049318

40-400

PC18MR-3

400 Troubleshooting of engine (S-mode) Troubleshooting chart

PC18MR-3

SEN04500-00

40-400

SEN04500-00

PC18MR-3 Hydraulic excavator Form No. SEN04500-00

40-400

SEN04620-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 100 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tool list ................................................................................................................................................ 7 Sketches of special tools ................................................................................................................................ 9

PC18MR-3

50-100

100 General information on disassembly and assembly How to read this manual

SEN04620-00

How to read this manual 1.

Removal and installation of assemblies Special tools q Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q This mark means part No. of special tools starting with 79 Tand that they can not be supplied from Komatsu in Japan (i.e. locally made parts).

* *** ****

Removal q The “Removal” section contains procedures and precautions for implementing the work, know how and the amount of oil or coolant to be drained. q General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. q Various symbols used in the “Removal” section are explained and listed below. k : This mark indicates safety-related precautions that must be followed when implementing the work. a: Know-how or precautions for work [*1] : This mark shows that there are instructions or precautions for installing parts. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component

Installation q Except where otherwise instructed, installation of parts is done in the reverse order to removal. q Instructions and precautions for installing parts are shown with [*1] mark in the “Installation” Section, identifying which step the instructions are intended for. q General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. q Marks shown in the “Installation” section stand for the following. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools Various special tools are illustrated for the convenience of local manufacture.

50-100

PC18MR-3

100 General information on disassembly and assembly How to read this manual

SEN04620-00

Disassembly and assembly of assemblies Special tools q Special tools which are deemed necessary for disassembly or assembly of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q This mark means part No. of special tools starting with 79 Tand that they can not be supplied from Komatsu in Japan (i.e. locally made parts).

* *** ****

Disassembly q In “Disassembly” section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. q General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work 6: Quantity of oil or coolant drained

Assembly q In “Assembly” section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k : Precautions related to safety in execution of work a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.

PC18MR-3

50-100

100 General information on disassembly and assembly Coating materials list

SEN04620-00

Coating materials list a a

The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.

Category

Komatsu code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

LT-3 Adhesive

(Rev. 2007.06) 1

790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)

LT-4

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

ThreeBond 1735

Gasket sealant

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

• Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.

790-129-9130

Loctite 648-50

79A-129-9110

50 cc

LG-1

790-129-9010

200 g

790-129-9080

• Used to stick and seal metal, glass, and plastics.

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.

Aron-alpha 201

LG-5

1 kg

• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures. Tube

• Used to stick or seal gaskets and packings of power train case, etc.

• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-6

790-129-9020

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9070

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

LG-8 ThreeBond 1207B

50-100

790-129-9140

Can

419-15-18131

100 g

PC18MR-3

100 General information on disassembly and assembly Coating materials list

Seizure prevention compound

Part number

Container

Main features and applications

790-129-9310

200 g

Tube

• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube

• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.

ThreeBond 1211

790-129-9090

100 g

Tube

• Gasket sealant used to repair engine.

Tube

• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.

—

Can

• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Various

• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.

LM-P

LC-G NEVER-SEEZ

09940-00040

—

SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)

Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM

Grease

Q'ty

LG-9 ThreeBond 1206D

Molybdenum disulfide lubricant

Gasket sealant

CateKomatsu code gory

SEN04620-00

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)

Hyper White Grease G2-T, G0-T (*)

SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855

G2-U-S ENS grease

PC18MR-3

—

427-12-11871

200 g

• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like 400 g x 20 container swing circle bearings, etc. and spline. 16 kg Can • The grease should be applied to work equipment pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg

400 g 16 kg

200 g

2 kg

• Bellows-type container Can •

Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.

Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.

Tube

• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.

Can

• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

50-100

100 General information on disassembly and assembly Coating materials list

SEN04620-00

Part number

SUNSTAR PAINT PRIMER 580 SUPER

SUNSTAR PAINT PRIMER 435-95

Container

Main features and applications

20 ml

Glass container

• Used as primer for cab side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

417-926-3910

22M-54-27230

• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)

SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”

417-926-3910

320 ml

Polyethylene container

• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Used to seal front window. (Using limit: 6 months after date of manufacture)

Cartridge

• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

50-100

22M-54-27220

333 ml

Adhesive for cab glass

Caulking material

Adhesive

Primer

SUNSTAR GLASS PRIMER 580 SUPER

Q'ty

Adhesive for cab glass

CateKomatsu code gory

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)

PC18MR-3

100 General information on disassembly and assembly Special tool list

Special tool list

SEN04620-00

Part Name Push tool KIT

790-201-5131

• Plate

790-101-5021

• Grip

01010-50816

• Bolt

790-201-2720

Spacer

790-101-5001

Push tool KIT

790-101-5081

• Plate

790-101-5021

• Grip

01010-50816

• Bolt

790-201-2710

Spacer

Installation of floating seal

792-371-1400

Sleeve

Disassembly, assembly of recoil spring assembly

790-101-2501

Push puller

790-101-2510

• Block

790-101-2520

• Screw

791-112-1180

• Nut

790-101-2540

• Washer

790-101-2630

• Leg

790-101-2570

• Plate

790-101-2560

• Nut

790-101-2660

• Adapter

Press fitting of bushing

PC18MR-3

Installation of floating seal

Press fitting of bushing

Disassembly, assembly of track roller assembly

Disassembly, assembly of center swivel joint assembly

Nature of work, remarks

790-101-5001 1

Disassembly, assembly of idler assembly

Disassembly, assembly of recoil spring assembly

Sketch

Part No.

Q’ty

Symbol

New/ Remodel

Component

Necessity

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity: t.........Cannot be substituted, must always be installed (used) q.........Extremely useful if available or, can be substituted with commercially available part. a New/Remodel: N.........Tools with new part numbers, newly developed for this model. : R.........Tools with upgraded part numbers, remodeled from items already available for other mode.ls : Blank:...Tools already available for other models, can be used without any modification a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See “Sketches of special tools”).

Separation of rotor and swivel joint

50-100

100 General information on disassembly and assembly Special tool list

Cylinder repair stand t

790-101-1102

Hydraulic pump

790-330-1100

Wrench assembly

Commercially available

Socket

Commercially available

Socket

Commercially available

Socket

790-201-1702

Push tool KIT

790-101-5021

• Grip

01010-50816

• Bolt

790-201-1721

• Push tool

790-201-1731

• Push tool

790-201-1500

Push tool KIT

790-101-5021

• Grip

01010-50816

• Bolt

790-201-1530

• Plate

790-201-1540

• Plate

For bucket, swing, variable gauge For boom, arm, blade

790-720-1000

Expander

Installation of piston ring

796-720-1740

Piston ring ø65

07281-00709

Clamp

796-720-1630

Piston ring ø65, 55

For boom, arm, swing

796-720-1620

Piston ring ø50

For bucket, variable gauge

07281-00609

Piston clamp ø50 – q 60

For boom. arm, swing, bucket, variable gauge

796T-170-2420

Stand

Q Installation of breaker

796T-170-2430

Shaft

Q Pulling out of bushing

796T-170-2440

Shaft

Q Press fitting of bushing

V 4

796T-170-2450

Shaft

Q Press fitting of bushing

796T-170-2460

Shaft

Q Press fitting of dust seal

796-170-2160

Handle

Removal and installation of cover

796-170-2170

Valve assembly

Charging with nitrogen gas

Part No.

1 2

Disassembly, assembly of hydraulic cylinder assembly

Disassembly, assembly of hydraulic breaker assembly

50-100

Part Name

Sketch

790-502-1003

Symbol

New/ Remodel

Q’ty

Component

Necessity

SEN04620-00

Nature of work, remarks Disassembly, assembly of hydraulic cylinder assembly Removal, installation of cylinder head Width across flats: 32 mm Removal, installation Width across of piston flats: 36 mm nut Width across flats: 41 mm

Press fitting of bushing

For arm, swing, variable gauge For arm, blade

Press fitting of dust seal

For blade

PC18MR-3

100 General information on disassembly and assembly Sketches of special tools

Sketches of special tools V1 Stand

SEN04620-00

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these drawings.

V2 Shaft

PC18MR-3

50-100

SEN04620-00

100 General information on disassembly and assembly Sketches of special tools

V3 Shaft

V4 Shaft

50-100

PC18MR-3

100 General information on disassembly and assembly Sketches of special tools

SEN04620-00

V5 Shaft

PC18MR-3

50-100

SEN04620-00

PC18MR-3 Hydraulic excavator Form No. SEN04620-00

50-100

SEN04621-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 200 Engine and cooling system Removal and installation of fuel injection pump assembly.............................................................................. 2 Removal and installation of radiator assembly ............................................................................................... 3 Removal and installation of hydraulic oil cooler assembly .............................................................................. 5 Removal and installation of engine and hydraulic pump assembly ................................................................ 6

PC18MR-3

50-200

SEN04621-00

Removal and installation of fuel injection pump assembly 1

200 Engine and cooling system Removal and installation of fuel injection pump assembly

Removal 1.

Tilt up the floor frame. For details, see “Removal and installation of radiator assembly”.

Disconnect air hoses (1) and (2) and remove air cleaner (3). [*1]

Remove 4 mounting bolts (10) and fuel injection pump (9). a While turning lever (R), remove the fuel injection pump.

Installation q

Close fuel valve (A).

Remove fuel injection tubes (4) together.

Disconnect fuel return hose (5) and fuel supply hose (6).

Remove pin (7) and disconnect fuel control cable (8). a Check the position of the pin hole.

50-200

[*1]

Carry out installation in the reverse order to removal. 3 3

Air hose (1) clamp: 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm} Air hose (2) clamp: 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

PC18MR-3

200 Engine and cooling system Removal and installation of radiator assembly

Removal and installation of radiator assembly

SEN04621-00 4)

While pulling back lever (5) with the left hand, raise the floor frame with the right hand and push it forward until it is locked. (The floor frame is locked when pin (C) is caught in lock plate (D).) a If the floor frame is floating, lever (5) does not move (it is not in the reset position) and you cannot tilt up the floor frame. (Let a person on the rear part of the floor frame to set the floor frame down, and then pull lever (5).) k When opening and closing the floor, do not put any part of body under the floor.

Take lock pin (6) (red) out of part (H) of bracket (E) (red) and insert it in the position shown below. k Check that lock pin (6) is fixing pin (P).

Removal k

Lower the boom to bring the work equipment in contact with the ground. Tilt up the floor frame. 1) Lower boom (1) so that bar (B) will not touch the boom when the floor frame is tilted up. 2) Remove mat (2) and open cover (3).

Angle between bar (B) and boom (1) when floor frame is tilted up

Remove bolts (4).

PC18MR-3

[1]

50-200

200 Engine and cooling system Removal and installation of radiator assembly

SEN04621-00 2.

Installation

Drain the coolant. 6

Coolant: 1.0 l

Disconnect reservoir tank hose (7).

Disconnect clip (8), brackets (9) and remove cover (10).

[*1] 3

[*2]

Disconnect radiator lower hose (11).

[*2]

Disconnect radiator upper hose (12).

[*2]

Remove radiator assembly (13). a When removing the radiator assembly, take care not to damage its core.

50-200

Carry out installation in the reverse order to removal.

Floor frame mounting bolt: 151.9 – 191.1 Nm {15.5 – 19.5 kgm} Radiator hose clamp: 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

PC18MR-3

200 Engine and cooling system Removal and installation of hydraulic oil cooler assembly

Removal and installation of hydraulic oil cooler assembly

SEN04621-00

Installation

Carry out installation in the reverse order to removal.

Removal k

Loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. Tilt up the floor frame. For details, see “Removal and installation of radiator assembly”.

[*1]

Drain the hydraulic oil. 6

Hydraulic oil: 15.2 l

Open cover (1).

Disconnect reservoir tank hose (2).

Disconnect clip (3).

Remove sponge (4) and cover (1).

Disconnect hoses (5) and (6) from the hydraulic oil cooler. [*1]

Remove the 4 mounting bolts and hydraulic oil cooler assembly (7). a When removing the hydraulic oil cooler assembly, take care not to damage its core.

PC18MR-3

When the floor frame tilted up is lowered, hose (5) touches it easily. To prevent this, be sure to connect hose (5) so that it will go under flange (F). (Part A)

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, Testing and adjusting, “Bleeding air from each part”.

50-200

SEN04621-00

Removal and installation of engine and hydraulic pump assembly

200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly

Fuel: 19 l (When full)

Loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. For details, see Tilt up the floor frame. â&#x20AC;&#x153;Removal and installation of radiator assemblyâ&#x20AC;?.

Drain the coolant. 6

Removal k

Drain the fuel.

Coolant: 3.1 l

Drain the hydraulic oil. 6

Hydraulic oil: 15.2 l

Disconnect air hoses (3) and (4) and remove air cleaner (5). [*2]

Disconnect fuel hoses (6).

Remove water drain valve bracket (7) and disconnect the fuel hose from back side.

Lift off roof (1). 4 Roof: 17 kg

Lift off canopy pole (2). 4 4

50-200

Canopy pole: 50 kg

[*1]

Canopy: 68 kg

PC18MR-3

200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly

10. Disconnect fuel return hose (8).

SEN04621-00

18. Sling counterweight and fuel tank assembly (17) temporarily.

11. Remove cover (9). 19. Remove mounting bolts (18), (19) and (20). 12. Remove battery (10).

13. Disconnect hydraulic hose (11).

20. Move counterweight and fuel tank assembly (17) backward.

14. Disconnect clips (12) and (13). 15. Disconnect ground (14). 16. Remove bracket (15). 17. Disconnect bracket (16).

PC18MR-3

50-200

SEN04621-00

200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly

21. Disconnect drain hose (21) attached to fuel tank.

22. Lift off counterweight and fuel tank assembly (17). [*3] 4

Counterweight and fuel tank assembly (17): 180 kg

26. Remove fan (26) and fan guard (27).

[*4]

27. Disconnect connectors (28) and (29) and heater terminal (30). 28. Disconnect clip (31).

29. Disconnect connector (32) and terminal (33) from the alternator. 23. Remove pin (22). 24. Remove bracket (23). a Fuel control cable (24) and fuel filter (F) come off, too.

30. Disconnect connector (34) and terminal (35) from the starting motor. 31. Disconnect terminal (36).

25. Remove radiator assembly (25). For details, see â&#x20AC;&#x153;Removal and installation of radiator assemblyâ&#x20AC;?.

50-200

PC18MR-3

200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly

32. Disconnect engine ground cable (37) from under the starting motor.

SEN04621-00

35. Sling engine and hydraulic pump assembly (41) temporarily. 36. Remove 4 mounting bolts (42).

[*5]

33. Disconnect gear pump hose (38) and piston pump hose (39). 37. Lift off engine and hydraulic pump assembly (43). a Check that all the wires and pipes are disconnected. a When lifting off the assembly, take care that it will not interfere with other parts. 4

Engine and hydraulic pump assembly: 130 kg

34. Disconnect hose (40).

PC18MR-3

50-200

SEN04621-00

200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly

Installation q

[*1]

[*2]

[*5]

Carry out installation in the reverse order to removal. 3

Canopy mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}

Air hose (2) clamp: 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm} Air hose (3) clamp: 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

Counterweight mounting bolt Right side: 152 – 191 Nm {15.5 – 19.5 kgm} Left side: 456 – 568 Nm {46.5 – 58 kgm} a Fuel hose (6) may be flattened between the counterweight (F) and frame. To prevent this, check that the route of hose (6) is on the upside of (F).

Coolant: 3.1 l

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

Engine mounting bolt: Adhesive (LT-2) Engine mounting bolt: 59 – 74 Nm {6 – 7.6 kgm}

Refilling with coolant a Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5

[*3]

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, Testing and adjusting, “Bleeding air from each part”. k Run the engine and check that air comes (is pushed) out from the radiat o r. I f a i r d o e s n o t c o m e ( i s n o t pushed) out, check to see if the cooling fan is installed in reverse.

[*4] a Take care of the installed direction of the fan. Install fan (26) so that it will be as shown in the figure at left when seen from above. a If fan (26) is installed in the correct direction, its pulley (44) is seen clearly.

50-200

PC18MR-3

200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly

PC18MR-3

SEN04621-00

50-200

SEN04621-00

PC18MR-3 Hydraulic excavator Form No. SEN04621-00

50-200

SEN04622-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 300 Power train Removal and installation of swing circle assembly ......................................................................................... 2

PC18MR-3

50-300

300 Power train Removal and installation of swing circle assembly

SEN04622-00

Removal and installation of swing circle assembly

Removal

Installation

Remove the revolving frame assembly. For details, see “Removal and installation of revolving frame assembly”.

Disconnect grease hoses (1) and (2).

Remove 18 mounting bolts (3).

Install hanging bolts and lift off swing circle assembly (4). [*2]

[*1]

50-300

Swing circle assembly: 25 kg

Carry out installation in the reverse order to removal. 2 3

[*1]

[*2]

Mounting bolt: Adhesive (LT-2) Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm} (Target: 65.7 Nm {6.7 kgm})

When installing the swing circle assembly, set inner race soft zone (a) (mark S) and outer race soft zone (b) as shown in the above figure. 2 Inner race tooth surface: Grease (G2-LI)

PC18MR-3

300 Power train Removal and installation of swing circle assembly

PC18MR-3

SEN04622-00

50-300

SEN04622-00

PC18MR-3 Hydraulic excavator Form No. SEN04622-00

50-300

SEN04623-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 400 Undercarriage and frame Removal and installation of track shoe assembly ........................................................................................... 2 Disassembly and assembly of idler assembly ................................................................................................ 3 Disassembly and assembly of recoil spring .................................................................................................... 5 Disassembly and assembly of track roller assembly ...................................................................................... 7 Assembly of travel motor assembly ................................................................................................................ 9 Removal and installation of floor frame assembly ........................................................................................ 18 Removal and installation of revolving frame ................................................................................................. 22

PC18MR-3

50-400

400 Undercarriage and frame Removal and installation of track shoe assembly

SEN04623-00

Removal and installation of track shoe assembly 1

Lower the floated track frame a little and remove track shoe assembly (2) from idler (J) side first, then from sprocket (S) side.

Pull out track shoe assembly (2) to this side and lift it off.

Removal 1.

Swing the upper structure by 90° and raise the machine by using the work equipment.

Loosen valve (1) to discharge the grease and loosen track shoe tension. [*1] k Since valve (1) may jump out because of the internal high-pressure grease, do not loosen it more than 1 turn.

Rubber shoe 1. Loosen the track shoe assembly (2).

Rubber shoe: 55 kg Steel shoe: 85 kg

Steel shoe 1. Move master link (3) forward. 2.

Remove cutter pin (4) and master pin (5).

Spread the link.

Installation q

[*1]

50-400

Carry out installation in the reverse order to removal. a

Adjust the track shoe tension. For details, see Testing and adjusting, “Testing and adjusting track shoe tension”.

PC18MR-3

400 Undercarriage and frame Disassembly and assembly of idler assembly

SEN04623-00

Disassembly and assembly of idler assembly

Assembly

Using tool L1, press fit 2 bearings (6) to idler (7). 2 Inside of bearing: Grease (G2-LI)

Install shaft (5) and fix it with snap ring (4).

Using tool L2, install 2 oil seals (3) to the idler. 2 Oil seal lip: Grease (G2-LI) a Take care that dirt will not stick the oil seals. a After installing the oil seal to either side, supply grease into the idler. 2 Inside of idler: Grease (G2-LI), Approx. 36 cc

Push tool KIT

790-101-5131

• Plate

790-101-5021

• Grip

01010-50816

• Bolt

791-201-2720

Spacer

Disassembly 1.

Remove plate (1).

Remove supports (2).

Remove oil seal (3).

Remove snap ring (4) and shaft (5).

Remove bearings (6) from idler (7).

PC18MR-3

Sketch

790-101-5001

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

50-400

400 Undercarriage and frame Disassembly and assembly of idler assembly

SEN04623-00 4.

Install supports (2) to shaft (5) of the idler. 2 Mounting bolt: Adhesive (LT-2)

Install plate (1). 2 Mounting bolt: Adhesive (LT-2)

Install idler cushion assembly. specification)

50-400

(Steel shoe

PC18MR-3

400 Undercarriage and frame Disassembly and assembly of recoil spring

SEN04623-00

Disassembly and assembly of recoil spring

Using tool M, set the recoil spring to the press. k Since the installed load of the spring is large and dangerous, set the spring securely.

Apply hydraulic pressure gradually to compress the spring and remove nut (6). a Compress the spring until you can loosen the nut. a Installed load of spring: 6,860 N {700 kg}

Release the hydraulic pressure gradually to release spring (8), and then remove stopper (7) and spring (8) from cylinder (9). a Free length of spring: 200 mm

a The recoil spring is used for only the steel shoe specification.

792-371-1400

Sleeve

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

Disassembly 1.

Piston 1) Remove grease fitting (1) and valve (2) from rod (3). 2) Remove rod (3) from cylinder assembly (4).

Recoil spring a Only steel shoe specification 1) Remove cotter pin (5) from nut (6).

PC18MR-3

Cylinder 1) Remove dust seal (10) from cylinder (9). 2) Remove backup ring (11). 3) Remove O-ring (12).

50-400

400 Undercarriage and frame Disassembly and assembly of recoil spring

SEN04623-00

Assembly 1.

Cylinder 2 O-ring (12), backup ring (11), and dust seal (10): Grease (G2-LI) 1) Install O-ring (12) to cylinder (9). 2) Install backup ring (11). 3) Install dust seal (10).

Recoil spring a Only steel shoe specification 1) Assemble cylinder assembly (4), spring (8), and stopper (7).

4) 3.

50-400

Using tool M, set the recoil spring to the press. k Since the installed load of the spring is large and dangerous, set the spring securely. Apply hydraulic pressure gradually to compress the spring to installed height (a), and then install nut (6). a Installed height (a) of spring: 168 mm a Installed load of spring: 6.86 kN {700 kg}

Fix nut (6) with cotter pin (5).

Piston 1) Fill cylinder (9) with grease (G2-LI). 2 Inside of cylinder (9): Grease (G2-LI) 2) Install valve (2) and grease fitting (1) to rod (3). a After tightening the valve and grease fitting, return them about 2 turns. 3) Install rod (3) and push it into cylinder assembly (4), and then press the grease out of valve (2) and bleed air from cylinder (9). 4) Tighten valve (2). 3 Valve (2): 59 â&#x20AC;&#x201C; 74 Nm {6 â&#x20AC;&#x201C; 7.5 kgm} 5) Tighten grease fitting (1). a Direct grease fitting (1) toward outside (the side panel) of the machine.

PC18MR-3

400 Undercarriage and frame Disassembly and assembly of track roller assembly

Disassembly and assembly of track roller assembly

SEN04623-00

Assembly

Assembly parts

Using tool L3, press fit bearings (5) to track roller (6). 2 Inside of bearing: Grease (G2-LI)

Push tool KIT

790-101-5081

• Plate

790-101-5021

• Grip

01010-50816

• Bolt

790-201-2710

Spacer

Sketch

790-101-5001

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

Disassembly 1.

Remove plates (1).

Remove oil seals (2).

Remove snap rings (3) and shaft (4).

Remove bearings (5) from track roller.

PC18MR-3

50-400

SEN04623-00 2.

Install shaft (4) and fix it with snap rings (3).

Using tool L4, install oil seals (2) to the track roller (6). 2 Oil seal lip: Grease (G2-LI) a Take care that dirt will not stick to the oil seals. a After installing the oil seal to either side, supply grease into track roller (6). 2 Inside of track roller (6): Grease (G2-LI), Approx. 44 cc

Install plate (1).

400 Undercarriage and frame Disassembly and assembly of track roller assembly

Precautions for installing to machine Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 59 â&#x20AC;&#x201C; 74 Nm {6 â&#x20AC;&#x201C; 7.5 kgm} 2

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PC18MR-3

400 Undercarriage and frame Assembly of travel motor assembly

Assembly of travel motor assembly

SEN04623-00

Only the assembly procedure is described in this section. General precautions for disassembly and assembly a Check the disassembled parts for abnormal wear and seizure, and then remove burrs from them before assembling. a Replace the seals and snap rings with new ones. a Hexagonal wrenches of 5 mm and 8 mm (1 piece each) are necessary. Sectional structure drawing and introduced parts

PC18MR-3

50-400

400 Undercarriage and frame Assembly of travel motor assembly

SEN04623-00

Assembly 1.

Hydraulic motor section Body 1 (1) a 1) – 6): The parts other than the O-rings are supplied only as the parts of body 1 sub-assembly.

50-400

Insert spool assembly (2), rings (3) (both sides), and springs (4) (both sides) in body 1 (1) in order. Fit O-rings (5) to plugs (6) (both sides) and tighten the plugs. a O-ring (5): See sectional structure drawing. a Plug (6): See photo in 4). a Spool assembly (2) cannot be disassembled. 3 Tightening torque for plug (both sides): 127 – 167 Nm {13 – 17 kgm} (Width across flats of hexagon socket head: 27 mm)

Install spool (8), spool (9), and spring (10) to 2nd gear spool (7).

Insert 2nd gear spool (7) assembly in body 1 (1). a Take care of the positions of the spool and spring. (See the sectional structure drawing.)

PC18MR-3

400 Undercarriage and frame Assembly of travel motor assembly

SEN04623-00

Fit O-rings (11) to plugs (12) (both sides) and tighten the plugs. a O-ring (11): See sectional structure drawing. 3 Tightening torque for plug (both sides): 46 – 51 Nm {4.7 – 5.3 kgm} (Width across flats of hexagon socket head: 8 mm)

Press fit bearing (17) and spring pin (16) to body 1 (1).

Install O-rings (18) and (19) to body 1.

Insert shaft spool (13) and rollers (14) (both sides) in body 1 (1) and tighten plugs (15) (both sides). 3 Tightening torque (both sides): 12 – 18 Nm {1.2 – 1.8 Nm} (Width across flats of hexagon socket head: 5 mm)

PC18MR-3

50-400

SEN04623-00 Body 2 (20) Press fit oil seal (21) to body 2 (20). 2 Space between lips of oil seal (21): Grease (G2-LI)

400 Undercarriage and frame Assembly of travel motor assembly

12) Install control piston (25) to body 2 (20).

13) Install shaft assembly (26) to body 2 (20). a Take care not to damage oil seal (21) with the shaft. 10) Install parallel pin (22) to body 2 (20).

14) Install balls (27) (2 pieces) to body 2 (20). 11) Press fit bearing (24) to shaft (23). a The shaft is not supplied loose. Only the bearing is supplied loose.

50-400

PC18MR-3

400 Undercarriage and frame Assembly of travel motor assembly

15) Install rocker cam (28) to body 2 (20). 2 Sliding surface of rocker cam (28): Hydraulic oil 2 Back side of rocker cam (28): Grease (G2-LI) (If rocker cam (28) comes off)

16) Insert cylinder barrel assembly (30) in body 2 (20) so that shoe (29) will meet rocker cam (28). 2 7 piston holes on cylinder barrel: Hydraulic oil a The parts of cylinder barrel assembly (30) are supplied only in an assembly.

SEN04623-00 18) Set steel plate (32) in body 2 (20), matching it to the groove.

19) Fit O-rings (34) and (35) and backup rings (36) and (37) to brake piston (33) to make up brake piston assembly (38). a Take care of the positional relationship between the O-rings and backup rings.

17) Set disc plate (31) in body 2 (20), matching it to the groove.

PC18MR-3

50-400

400 Undercarriage and frame Assembly of travel motor assembly

SEN04623-00 20) Insert brake piston assembly (38) in body 2 (20). 2 O-ring: Grease (G2-LI) a When assembling, take care that the seals will not be caught.

Inside of body 2 (20):

Reduction gear unit 1) Install floating seal (42) and O-ring (43) to hydraulic motor (41). 2 O-ring: Grease (G2-LI) a Install floating seal (42) with the sealing surface up.

Hydraulic oil (approx.100 cm3) 21) Install valve plate (39) and springs (40) (14 pieces) to body 1 (1) and combine them with body 2 (20). a Install the valve plate with the copper side up (on the cylinder barrel side). 2 Sliding surface (Copper side) of valve plate: Hydraulic oil 2 Back side (Steel side) of valve plate: Grease (G2-LI) (for prevention of fall) a Install springs (40) (14 pieces) to the places marked with q in the following figure.

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PC18MR-3

400 Undercarriage and frame Assembly of travel motor assembly

Install bearing inner race (44) and steel balls (45) having the retainer to hydraulic motor (41) in order. (1 set) a Take care of the directions of the bearing inner race and retainer. (See the sectional structure drawing.) a The steel balls may come off the retainer. Take care not to lose them.

SEN04623-00 4)

Install body (47) to hydraulic motor (41). a Clamp the reduction gear unit flange and hydraulic motor flange with a Cclamp, a hydraulic press, etc.

Install steel balls (48) having the retainer and bearing inner race (49) to the hydraulic motor in order. a Take care of the directions of the bearing inner race and retainer. (See the sectional structure drawing.) a The steel balls may come off the retainer. Take care not to lose them.

Set the O-ring to seal ring (46) and install them to body (47). 2 O-ring: Grease (G2-LI) a Insert seal ring (46) with the sealing surface up.

PC18MR-3

50-400

400 Undercarriage and frame Assembly of travel motor assembly

SEN04623-00 6)

Fix the bearing with snap ring (50). a Adjust the preload on the bearing by the thickness of the snap ring.

Install ring (51), thrust washer (52), B1 gear (53), and needle (54) to B1 pin of the hydraulic motor. a Install these parts to all of the 4 places.

Install thrust plate (55) and fix it with snap ring (56). a Install the thrust plate with the convex side up. (See the sectional structure drawing.) a The snap ring has different sides. Install it with the edge part up (on the cover side). a If the snap ring is expanded too much, its clamping force is lost. If it does not have sufficient clamping force, replace it.

Install sun gear and carrier 2 assembly (58) to body (47). a Sun gear: (57) --- See the sectional structure drawing. a Sun gear and carrier 2 assembly (58) is supplied only as an assembly. (Including sun gear (57).)

10) Install O-ring (59) to body (47). 2 O-ring (59): Grease (G2-LI)

11) Insert slide ring (61) in cover (60). 2 Slide ring: Grease (G2-LI) (For fitting the slide ring to the cover)

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PC18MR-3

400 Undercarriage and frame Assembly of travel motor assembly

12) Supply hydraulic oil and install cover (60). 5

a a

Hydraulic oil (330 cc)

Take care not to damage the O-ring. Match the letters of "DRAIN" on the cover to the cut of the body. (A)

SEN04623-00 14) Tighten socket head plugs (63) (G3/8). a Tighten the plug on the side of the letters of DRAIN first. (Lock the cover with the flange of the plug.) 3 Socket head plug (63): 46 â&#x20AC;&#x201C; 51 Nm {4.7 â&#x20AC;&#x201C; 5.2 kgm} (Width across flats of hexagon socket head: 8 mm)

13) Install O-snap ring (62) to fix cover (60). a Apply a flat-head screwdriver to the end of O-snap ring (62) and drive the snap ring in the circumferential direction.

PC18MR-3

50-400

400 Undercarriage and frame Removal and installation of floor frame assembly

SEN04623-00

Removal and installation of floor frame assembly 1

Disconnect connector (4).

Disconnect clips (5) – (7).

Disconnect connectors (8) – (11).

Removal 1.

Tilt up the floor frame. For details, see “Removal and installation of radiator assembly”.

Lift off roof (1). 4 Roof: 17 kg

Lift off canopy pole (2). 4 Canopy pole: 50 kg 4 Canopy: 68 kg

[*1]

Remove battery (3).

50-400

PC18MR-3

400 Undercarriage and frame Removal and installation of floor frame assembly

Remove cover (12).

Disconnect connectors (13) â&#x20AC;&#x201C; (15) and terminals (16) and (17).

SEN04623-00 13. Disconnect connectors (22) â&#x20AC;&#x201C; (24). a Since the connectors do not have No. labels, record their destinations.

14. Disconnect clip (25) and ground wire (26). 10. Remove clip (18). 15. Disconnect 8 work equipment PPC hoses (27). [*2] a Hose band colors q White, green, brown, and orange Blue, yellow, red, and black

11. Disconnect connector (19) and terminal (20) from the starting motor. 12. Disconnect terminal (21). 16. Disconnect blade control cable (28).

PC18MR-3

50-400

400 Undercarriage and frame Removal and installation of floor frame assembly

SEN04623-00 17. Disconnect PPC hoses (29) and (30). a Hose band colors q (29): Red and green q (30): No band a Prepare plugs before disconnecting the hoses. a Prepare tags to record the destinations of the hoses.

18. Disconnect 4 travel PPC hoses (31). a Hose band colors: Right front: Black and yellow, Right rear: Yellow and green, Left front: Yellow and brown, Left rear: Yellow and orange

[*3]

20. Disconnect PPC hoses (34) and (35) from the control valve. [*5]

21. Disconnection of fuel control cable (38) 1) Remove pin (36). a Record the position of the pin hole. 2) Loosen locknuts (37). [*6] a Before loosening the locknuts, record the installed dimension. 3) Pull out fuel control cable (38) toward the floor frame. a Check the route of the cable.

19. Disconnect 2 swing PPC hoses (32) and (33). [*4] a Hose band colors: Left side: Red and white, Right side: Blue and white

22. Sling floor frame assembly (39) temporarily.

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PC18MR-3

400 Undercarriage and frame Removal and installation of floor frame assembly

23. Remove 2 upper mounting bolts (40) of damper (41). k Since damper (41) is pressed strongly, it may jump out to the right or left. Take care. After removing the upper mounting bolts, do not stand near the damper.

24. Pull out lock pin (42) and remove pin (43).

SEN04623-00 27. Lift off floor frame assembly (39). 4

Floor frame assembly: 132 kg Before lifting off the assembly, check that all the wires and pipes are disconnected.

Installation q

[*1]

Carry out of installation in the reverse order to removal. 3

Canopy mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}

[*2] [*3] [*4] [*5] a When connecting the hoses, check their band colors. [*6]

25. Sling up floor frame assembly (39) a little to expand damper (41) fully. (Damper (41) jumps out.)

26. Remove right and left pins (44).

Adjust the cable tension. For details, see Testing and adjusting, “Adjusting fuel control lever”.

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

PC18MR-3

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, see Testing and adjusting, “Bleeding air from each part”.

50-400

400 Undercarriage and frame Removal and installation of revolving frame

SEN04623-00

Removal and installation of revolving frame

Remove hose (4).

Disconnect hoses (E), (F), (G), and (H). a The hoses other than hose (H) have labels on them. a Hoses of the control valve having labels (1) – (6) were removed in the section of the work equipment assembly.

Disconnect hoses (A), (B), (C), and (D) from the control valve assembly. a The hoses have labels on them. a (A) – (H) of the hose labels are the name of the connecting ports of the center swivel joint.

Removal 1.

Stop the machine with the work equipment extended. a When draining the hydraulic oil, swing the upper structure 30° to the left. (Do not swing 90°.)

Drain the hydraulic oil. 6

Hydraulic oil: 15.2 l

Remove the floor frame assembly. For details, see “Removal and installation of floor frame assembly”.

Remove the work equipment assembly. For details, see “Removal and installation of work equipment assembly”.

Remove plate (1).

Pull out pin (2) and remove boom cylinder assembly (3). [*1] a Hoses (H) were disconnected from the control valve in the section of the work equipment assembly. 4

50-400

Boom cylinder: 25 kg

PC18MR-3

400 Undercarriage and frame Removal and installation of revolving frame

10. Disconnect hose (T) from the hydraulic tank.

SEN04623-00 14. Sling revolving frame assembly (10) temporarily. a Wind the sling onto the rear part. 15. Remove 16 revolving frame mounting bolts (11). [*3] 16. Lift off revolving frame assembly (10). a Check that all the pipes are disconnected and take care not to damage the center swivel joint. 4

Revolving frame assembly: 750 kg

11. Disconnect hose (H) and nipple (5) from center swivel joint assembly (7). 12. Remove lever (6) from center swivel joint assembly (7). [*2]

13. Disconnect lubrication hoses (8) and (9).

PC18MR-3

50-400

SEN04623-00

400 Undercarriage and frame Removal and installation of revolving frame

Installation q

[*1]

Carry out installation in the reverse order to removal. k

When aligning the pin holes, never insert your fingers in them. 2 Pin and sliding surface on swing bracket side: Molybdenum disulfide lubricant (LM-P) 2 Grease after installation: Grease (Hyper White Grease)

[*2]

2 3

[*3]

2 3

Revolving frame assembly mounting bolt: Adhesive (LT-2) Revolving frame assembly mounting bolt: 59 – 74 Nm {6 – 7.5 kgm} (Target: 65.7 Nm {6.7 kgm})

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

Lever mounting bolt: Adhesive (LT-2) Lever mounting bolt: 157 – 196 Nm {16 – 20 kgm}

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, see Testing and adjusting, “Bleeding air from each part”.

50-400

PC18MR-3

400 Undercarriage and frame Removal and installation of revolving frame

PC18MR-3

SEN04623-00

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SEN04623-00

PC18MR-3 Hydraulic excavator Form No. SEN04623-00

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SEN04624-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 500 Hydraulic system Disassembly and assembly of hydraulic pump assembly............................................................................... 2 Disassembly and assembly of control valve assembly ................................................................................. 12 Removal and installation of hydraulic system and center swivel joint assembly........................................... 18 Disassembly and assembly of center swivel joint assembly......................................................................... 20 Removal and installation of swing motor assembly ...................................................................................... 22 Disassembly and assembly of swing motor assembly .................................................................................. 23 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 30 Disassembly and assembly of hydraulic breaker assembly.......................................................................... 34

PC18MR-3

50-500

SEN04624-00

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Disassembly and assembly of hydraulic pump assembly

Sectional structure drawing and introduced parts

a Packing (14), oil seal (37), seal washer (9), and O-rings must be replaced when the pump assembly is assembled again. Accordingly, be sure to prepare new ones before disassembling. (Supplied parts: Seal kit) a Hexagonal wrench: 4, 5, 8 and 10 mm (1 piece each) are necessary. a Bolt: M10 x 80 (2 pieces) are necessary.

50-500

Special tool q

Oil seal driving jig: Tool S

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

SEN04624-00

Disassembly k

Never adjust or remove the set screw (ADJ). If it is adjusted or removed, the engine may stall. Removal of gear pump assembly (1) 1) Remove hexagon head bolts (2) M8 x 20 (2 pieces).

Remove gear pump assembly (1), collar (3), coupling (4), and O-rings (5) and (6).

PC18MR-3

50-500

SEN04624-00 2.

Removal of adjustment unit (ADJ) a If it is obliged to disassemble adjustment unit (ADJ), record projection (K) of the screw in advance. Loosen hexagon nut (7) fully and remove set screw (8) and seal washer (9).

Removal of LS valve Remove LS valve (11) from body H (10). a The spool may fall from the LS valve. Take care.

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

50-500

Separation of body S (12) and body H (10) 1) Remove 2 of 7 hexagon socket head bolts (13) M10 x 60. 2) Install 2 temporary mounting bolts M10 x 80 instead of the removed bolts, and then loosen the other 5 bolts. a This work is required since there is an internal spring. 3) Loosen the 2 temporary mounting bolts and separate the bodies.

Hit the spring insertion part of body H (10) lightly with a plastic hammer, and the bodies are separated easily.

Disassembly of body H (10) 1) Remove packing (14) from body H (10).

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Remove spring guide (15) and valve plate (16) from body H (10). a Record the direction (each side) of valve plate (16).

3) 4)

Pull control piston (18) out of sleeve (17). Remove sleeve (17). a An O-ring is fitted.

Remove plug (20), O-ring (21), and choke (22) from body H (10). Remove plug (23), O-ring (24), and choke (25) from body H (10).

PC18MR-3

SEN04624-00 7)

Remove plug (26), O-ring (27), steel ball (28), and filter (29) from body H (10). a Turn the filter counterclockwise with a flat-head screwdriver to remove it from the body.

Disassembly of body S (12) assembly 1) Remove spring T1 (30) from body S (12). 2) Remove spring holder (31).

Remove cylinder barrel assembly (32).

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SEN04624-00 4)

Remove rocker cam (33) and rocker pins (34).

Remove snap ring (35) on the shaft drive shaft side from body S (12). Hit shaft (36) lightly with a plastic hammer to pull oil seal (37) and the assembly of shaft (36) and bearing (38) out of body S (12).

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Cylinder barrel assembly (32) a Only cylinder barrel assembly (32) or assembly of piston (40) and shoe (41) is supplied. 1) Remove shoe holder (42) from cylinder barrel (39). (Piston (40) and shoe (41) are removed together.)

2) 3)

50-500

Inspection and measurement Check of wear of oil seal mounting part Wear Z 0.025 mm

Remove barrel holder (43) and retainer (44). Remove needle (45).

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

SEN04624-00

Inspection and measurement of piston assembly and cylinder barrel Check visually that piston assembly and cylinder barrel are free from a flaw, scuff mark, abnormal wear, etc. (Check the sliding parts in particular.) Check clearance between outside diameter (d) of piston (40) and inside diameter (D) of cylinder barrel (39). (D) â&#x20AC;&#x201C; (d) Z 0.050 mm

Remove snap ring (46) from inside of cylinder barrel (39), and then remove retainer (47), spring C (48), and retainer (47) in order.

Assembly k

PC18MR-3

Axial moving distance of piston (40) and shoe (41) (E) Z 0.2 mm

If foreign matter enters the pump, the pump will be broken. Take care. Carry out installation in the reverse order to removal. Cylinder barrel assembly (32) 1) Install retainer (47), spring C (48), retainer (47), and snap ring (46) in order. a See the figure above. 2) Install needle (45), retainer (44), and barrel holder (43) to cylinder barrel (39). a Take care of installing position of retainer (44).

50-500

SEN04624-00 3)

Install shoe holder (42), in which piston (40) and shoe (41) assembly is inserted, to cylinder barrel (39).

Body S (12) assembly 1) Install shaft (36) and bearing (38) assembly to body S (12). a Be sure to replace oil seal (37) with new one. 2 Oil seal (37): Apply a little quantity of grease (G2-LI) to lip and outside.

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Install snap ring (35) to body S (12) on the shaft drive shaft side. a Check that snap ring (35) is fitted to the groove of body S. (If the snap ring is not fitted perfectly, oil seal (37) will come off.)

Put rocker pin (34) in the spherical hole of rocker cam (33) and install them to the spherical hole of body S (12). 2 Spherical hole of rocker cam (33) and rocker pin (34): Grease (G2-LI) Install cylinder barrel assembly (32). Install spring holder (31) to spring T1 (30) and set spherical part (B) of the spring holder in the hole of rocker cam (33).

5) 6)

50-500

Drive oil seal (37) with oil seal driving jig TOOL S. Hit the jig lightly with a hammer. a Place body S (12) on body H (10) temporarily for the ease of work.

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Body H 1) Install choke (22), O-ring (21), and plug (20) to body H (10). 2) Install choke (25), O-ring (24), and plug (23) to body H (10).

Install filter (29) to body H (10). 3 Tightening torque for filter (29): 0.60 – 0.78 Nm {0.061 – 0.079 kgm} Install steel ball (28), O-ring (27), and plug (26). a Be sure to replace O-ring (27). 3 Tightening torque for plug (26): 58.8 – 68.6 Nm {6 – 7 kgm}

PC18MR-3

SEN04624-00 5)

Install O-ring (19) and sleeve (17) to body H (10). 3 Tightening torque for sleeve (17): 49.0 – 58.8 Nm {5 – 6 kgm}

6) 7)

Install control piston (18) to sleeve (17). Install spring guide (15).

Position valve plate (16) with spring pin (49) of body H (10) and place it carefully. a The face of valve plate (16) having a fine groove will slide against the cylinder barrel. Take care not to mistake the direction of the valve plate.

50-500

SEN04624-00 9)

Install 2 pins (50) to body H (10).

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Installation of body S (12) and body H (10) 1) Install 2 temporary mounting bolts M10 x 80 to 2 holes on the upper side and tighten them gradually. 2) When the clearance between the mating faces becomes 5 – 10 mm, install hexagon socket head bolts (13) M10 x 60 to the other 5 holes. 3) Remove the temporary mounting bolts and install hexagon socket head bolts (13) M10 x 60 instead. a While checking that pin (50) is engaged with bodies S and H, tighten the bolts. 3 Hexagon socket head bolt (13): 51.0 – 64.7 Nm {5.2 – 6.6 kgm}

Installation of LS valve Install LS valve (11) to body H (10). a The spool may fall from the LS valve. Take care. 3 Tightening torque for LS valve (11): 49.0 – 58.8 Nm {5 – 6 kgm}

10) Install packing (14) to face to be mated with body S (12). a Be sure to replace packing (14) with new one.

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic pump assembly

Installation of adjustment unit 1) Fix set screw (8) and seal washer (9) with hexagon nut (7) to projection (K) measured before disassembling. a Replace seal washer (9) with new one. 3 Hexagon nut (7): 19.6 – 20.6 Nm {2 – 2.1 kgm}

Installation of gear pump assembly (1) Install O-rings (5) and (6), coupling (4), collar (3), and gear pump assembly (1). a Be sure to replace the O-rings with new ones. a See the drawing for disassembly. 3 Gear pump (1) mounting bolt: 19.6 – 23.5 Nm {2 – 2.4 kgm} a Rotate the shaft and check that it revolves smoothly.

PC18MR-3

SEN04624-00

50-500

SEN04624-00

500 Hydraulic system Disassembly and assembly of control valve assembly

Disassembly and assembly of control valve assembly

In this section, only precautions for assembling the control valve assembly are explained. 8-spool valve

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of control valve assembly

SEN04624-00

a Work in a clean indoor place where there is no dirt and dust. a Clean the parts in clear solvent, and then dry them with compressed air. a Replace a part having burrs with new one. a Coat the sliding surfaces of each part with engine oil before installing. a Degrease the female threads of the plugs and screws with denatured alcohol, etc. and dry them in advance. Do not apply pressure for 2 hours after tightening them. 2 Mating face of block: Apply Sealend 242 or equivalent. 3 PA1 – PA8, PB1 – PB8 (M14 x 1.5): 29.4 – 39.2 Nm {3 – 4.0 kgm}

PC18MR-3

50-500

SEN04624-00

500 Hydraulic system Disassembly and assembly of control valve assembly

Section B-B a Take care of the installed direction of each spool. a For 8 places of 07-1L on the right side and left side, apply the following. a When tightening and loosening the bolts of 07-1L, be sure to keep the spool in the valve chamber. 2 07-1L: Apply a drop (about 0.02 g) of LOCTITE (No. 638) to threads. 3 07-1L: 6.9 â&#x20AC;&#x201C; 9.8 Nm {0.7 â&#x20AC;&#x201C; 1.0 kgm}

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of control valve assembly

SEN04624-00

Section C-C 15-2L: Apply a drop (about 0.02 g) of LOCTITE (No. 638) to threads. 3 15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} a After orifice (1) is installed, its head must not project from the mating face of the block. q

PC18MR-3

50-500

SEN04624-00 q

a a

500 Hydraulic system Disassembly and assembly of control valve assembly

Sections K-K, L-L, M-M, and AA-AA Section AA-AA is under the top cover in the section of the 9-spool valve (attachment valve). (See the sectional structure drawing.) All sections (07-1L): See the explanation of section B-B.

15-2L: Apply a drop (about 0.02 g) of LOCTITE (No. 638) to threads.

15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of control valve assembly

SEN04624-00

Sections F-F, G-G, and J-J a All sections (07-1L): See the explanation of section B-B.

2 3

15-2L: Apply a drop (about 0.02 g) of LOCTITE (No. 638) to threads. 15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}

PC18MR-3

50-500

SEN04624-00

500 Hydraulic system Removal and installation of hydraulic system and center swivel joint assembly

Removal and installation of hydraulic system and center swivel joint assembly

Removal 1.

Place blocks under the blade and raise the chassis with the blade and work equipment.

Place blocks under the tracks and place the chassis on those blocks.

Remove undercover (1).

Tilt up the floor frame. For details, see “Removal and installation of radiator assembly”.

Remove rubber cover (4) and disconnect hoses (E), (F), (G), and (H). a The hoses other than hose (H) have labels on them.

Drain the hydraulic oil. 6

Hydraulic oil: 15.2 l

Disconnect hoses (2) and (3) from the center swivel joint. q Hoses (2) are labeled (A), (C), (E), (G), and (I) from the bottom. q Hoses (3) are labeled (B), (D), (F), (H), and (J) from the bottom. a (A) – (J): Hoses are labeled. a Before disconnecting the hoses, prepare plugs. a Prepare tags to record the destinations of the hoses.

50-500

PC18MR-3

500 Hydraulic system Removal and installation of hydraulic system and center swivel joint assembly

Disconnect hose (T) from the hydraulic tank.

SEN04624-00

Installation q

[*1]

Carry out installation in the reverse order to removal. 2 3

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

10. Disconnect hose (5). q

Lever mounting bolt: Adhesive (LT-2) Lever mounting bolt: 59 – 74 Nm {6 – 7.6 kgm}

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, see Testing and adjusting, “Bleeding air from each part”.

11. Disconnect hose (H) and nipple (6) from center swivel joint assembly (8). 12. Remove lever (7) from center swivel joint assembly (8). [*1] 13. Remove center swivel joint assembly (8).

PC18MR-3

50-500

500 Hydraulic system Disassembly and assembly of center swivel joint assembly

SEN04624-00

Disassembly and assembly of center swivel joint assembly

Push puller

790-101-2510

• Block

790-101-2520

• Screw

791-112-1180

• Nut

790-101-2540

• Washer

790-101-2630

• Leg

790-101-2570

• Plate

790-101-2560

• Nut

790-101-2660

• Adapter

Sketch

New/Remodel

Q'ty

790-101-2501

Necessity

Symbol T

Part name

Remove dust seal (6) and 5 plugs (7) from swivel shaft (5).

Remove 4 plugs (8) from swivel shaft (5). a There are 2 types of the plugs.

Remove ring (10), O-ring (11), backup ring (12), and 10 slipper seal (13).

Special tools

Part No.

Disassembly 1.

Remove bolts (1) and plate (2).

Remove O-ring (3) and snap ring (4).

Using tool T, pull rotor (9) out of swivel shaft (5).

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of center swivel joint assembly

SEN04624-00

Assembly 1.

Install O-ring (11), backup ring (12), and 10 slipper seals (13) to rotor (9).

Install dust seal (6) to swivel shaft (5). 2 Dust seal lip: Grease (G2-LI).

Install 5 plugs (7) and 4 plugs (8) to swivel shaft (5). a Thoroughly degrease, clean, and dry the threads. 2 All threads of mounting plug: Adhesive (LG-5) (LOCTITE 542) a After installing, check that the end of each plug is below the end of the shaft. 2 Plug (7): 4.90 – 6.86 Nm {0.5 – 0.7 kgm} 2 Plug (8): 16.7 ± 2.9 Nm {1.7 ± 0.3 kgm}

Set swivel shaft (5) to the block. Using the push tool, install rotor (9). Hit the push tool lightly with a plastic hammer. a Take care extremely not to damage the slipper seals and O-ring. 2 Contact faces of rotor and swivel shaft: Grease (G2-LI)

Install ring (10), snap ring (4), and O-ring (3).

Install plate (2). 3 Mounting bolt (1): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

PC18MR-3

50-500

500 Hydraulic system Removal and installation of swing motor assembly

SEN04624-00

Removal and installation of swing motor assembly 1

Installation q

Carry out installation in the reverse order to removal.

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

Removal 1.

Tilt up the floor frame. For details, see “Removal and installation of radiator assembly”.

Disconnect hoses (1) – (5). a Before disconnecting the hoses, prepare plugs. a Prepare tags to record the destinations of the hoses.

Remove 4 mounting bolts (6). a Push hose (H) with the hand to set it apart from the swing motor assembly.

Lift off swing motor assembly (7). 3 Swing motor assembly: 25 kg

50-500

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, see Testing and adjusting, “Bleeding air from each part”.

PC18MR-3

500 Hydraulic system Disassembly and assembly of swing motor assembly

SEN04624-00

Disassembly and assembly of swing motor assembly

Sectional structure drawing and introduced parts

a Only seal kit and timer valve mounting bolts are supplied.

Disassembly a Before disassembling the swing motor, clean it. In particular, clean the ports carefully and remove dirt and paint from each joint with a wire brush, etc. 1.

Remove timer valve (1) from the body. a Assemble the timer valve only when necessary.

PC18MR-3

50-500

500 Hydraulic system Disassembly and assembly of swing motor assembly

SEN04624-00 q

2. 3.

Motor Grip the flange with the pinion gear down.

Remove drive (10).

Remove the mounting bolts of valve housing assembly (2).

Brake assembly section 10. Remove hexagon socket head bolts (11).

11. Remove flange mounting (12). 4.

Remove valve housing assembly (2). a At this time, take care not to lose spring (3) and pin (4).

Remove spring (3), pin (4), balancing plate (5), and valve (6).

12. Remove springs (13) from flange mounting (12).

Remove valve plate (7).

Remove valve drive (8).

Remove geroler (9).

50-500

13. Remove snap ring (Ă¸ 47) (14), bearing (15), and shaft face seal (16) from flange mounting (12). a Assemble only when necessary.

PC18MR-3

500 Hydraulic system Disassembly and assembly of swing motor assembly

14. Remove piston (17). 15. Remove ring (18).

SEN04624-00 19. Remove snap ring (Ă¸ 45) (24), collar (25), bearing (26) from pinion gear assembly (23). a Assemble only when necessary. 20. Remove X-ring (27) from bearing housing (21).

16. Remove 7 plates (19) and 6 discs (20).

17. Remove snap ring (Ă¸ 100) (22) from bearing housing (21). 18. Using a press and push tools [1] and [2], remove pinion gear assembly (23) from bearing housing (21).

PC18MR-3

50-500

500 Hydraulic system Disassembly and assembly of swing motor assembly

SEN04624-00

Assembly

Install X-ring (27) to bearing housing (21).

Install pinion gear assembly (23) to bearing housing (21). a Press the pinion side with a press or a plastic hammer.

Install plate (19) to the bearing housing.

a Clean all the parts with cleaning oil. Take care not to scratch or bruise them. Degrease the tap holes, in particular. a Replace the seals with new ones. a Apply grease to the seals in advance. q

Assembly of brake assembly Install bearing (26), collar (25), and snap ring (Ă¸ 45) (24) to pinion gear (23). a Install bearing (26) with the shield side toward the pinion. a Install collar (25) with the chamfered side toward the snap ring.

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of swing motor assembly

Install discs (20) to the bearing housing. a Install plates (19) and discs (20) alternately so that last plate (19) will be on the top.

SEN04624-00 10. Install shaft face seal (16) to flange mounting (12). 11. Install bearing (15) and fix it with snap ring (14). 12. Coat spring (13) with grease and stick it to flange mounting (12). 2 Spring (13): Grease (G2-LI) 13. Install the O-ring to flange mounting (12).

Install the 2 O-rings (inside and outside) to ring (18). Install ring (18) to bearing housing (21).

14. Install flange mounting (12) to bearing housing (21). a Take care that the spring will not fall. a When assembling, set the drain hole as shown in the following illustration.

Install the O-ring to piston (17).

Install piston (17) to bearing housing (21).

PC18MR-3

50-500

SEN04624-00

500 Hydraulic system Disassembly and assembly of swing motor assembly

15. Tighten bolts (11) evenly in the diagonal order. a Degrease bolts (11) in advance. 2 Hexagon socket head bolt (11): LOCTITE #242 3 Hexagon socket head bolt (11): 34.3 Nm {3.5 kgm}

Assembly of motor section

16. Install the O-rings (2 types) to the grooves of flange mounting (12). 17. Install drive (10). 18. Install geroler (9). a Match drain hole (D) to the flange mounting.

22. Install valve (6), taking care of the following. a 1) Match the spline teeth of valve (6) (equivalent to the position of the side hole of valve (6)) to the deeper teeth of valve drive (8) (there are 6 teeth) so that they will not be engaged. 2) Turn valve (6) to the left by 15Â° from the state of 1) above to engage it. k When valve (6) is installed, if it is turned to the right by 15Â° from the position where it is matched to the teeth of valve drive (8), the motor will revolve in reverse, and that will be very dangerous.

19. Install valve drive (8). 20. Install the O-rings (2 types) to the grooves of valve plate (7). 21. Install valve plate (7). a Match the drain hole to the geroler (9).

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of swing motor assembly

SEN04624-00

23. Install spring (3) and pin (4) to hose (H) of valve housing (2) in order.

26. Install balancing plate (5) to valve housing assembly (2), matching its cut part to pin (4).

24. Install the O-rings (2 types) to valve housing (2).

27. Install valve housing assembly (2). a While inserting thin rod (3) such as a screwdriver in port (B) of the valve housing (See illustration in 28) to hold balancing plate (5), install the valve housing. a Match drain hole (DD) to the valve plate. a Degrease the hexagon socket head bolts in advance. 2 Hexagon socket head bolt: LOCTITE #242 3 Hexagon socket head bolt: 53 Nm {5.4 kgm} a Tighten the bolts evenly in the diagonal order.

25. Install inner face seal (28) and outer face seal (29) to balancing plate (5).

28. Install the timer valve to the motor body. 3 Hexagon socket head bolt: 15 Nm {1.5 kgm}

PC18MR-3

50-500

500 Hydraulic system Disassembly and assembly of hydraulic cylinder assembly

SEN04624-00

Disassembly and assembly of hydraulic cylinder assembly

Assembly

790-101-1102

Hydraulic pump

790-330-1100

Wrench assembly

Commercially available

Socket (Width across flats: 32 mm)

Commercially available

Socket (Width across flats: 36 mm)

Commercially available

Socket (Width across flats: 41 mm)

790-201-1702

Push tool KIT

t t

1 1

790-101-5021

• Grip

01010-50816

• Bolt

790-201-1721

• Push tool (For bucket, boom swing, and variable gauge)

790-201-1731

• Push tool (For arm and blade)

790-201-1500

Push tool KIT

790-101-5021

• Grip

01010-50816

• Bolt

790-201-1530

• Plate (For bucket, boom swing, and variable gauge)

790-201-1540

• Plate (For boom, arm, and blade)

790-720-1000

Expander

796-720-1740

Ring piston ø 65 (For blade)

07281-00709

Clamp (For blade)

796-720-1630

Ring piston ø 60, 55 (For boom, arm, and boom swing)

796-720-1620

Ring piston ø 50 (For bucket and variable gauge)

07281-00609

Clamp piston ø 50 60 (For boom, arm, boom swing, bucket, and variable gauge)

50-500

Sketch

New/Remodel

Cylinder repair stand

790-502-1003

Q'ty

Part name

Necessity

Symbol

Special tools

Part No.

a In this section, only the assembly procedure is explained.

a The following steps are common to all the cylinders, unless otherwise specified. a Take care not to damage the packings, dust seals, O-rings, etc. a Clean all the parts. After assembling, cover the piping ports and pin holes to prevent dirt from entering them. a Do not insert each backup ring forcibly, but warm it in water at 50 – 60°C and then insert it. 1.

Cylinder 1) Press fit bushing (24). 2) Press fit 2 dust seals (23).

Piston rod 1) Press fit bushing (22) to piston rod (6). 2) Press fit 2 dust seals (21).

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic cylinder assembly

SEN04624-00 a

Cylinder head assembly 1) Using tool U4, press fit bushing (20) to cylinder head (14). a Do not perform this step for boom cylinder.

Using tool U5, press fit dust seal (18).

3) 4) 5) 6) 7)

Install snap ring (17). Install rod packing (19). Install O-ring (15) and backup ring (16). Install O-ring (30). Install O-ring (12) and 2 backup rings (13). a Perform this step for only the boom cylinder.

PC18MR-3

Boom cylinder.

Install cylinder head assembly (11) to piston rod (6).

50-500

SEN04624-00 4.

Piston assembly 1) Install cushion plunger (10) to piston rod (6). a Perform this step for only the boom cylinder.

Set piston ring (9) to tool U6 and give 8 – 10 turns to the handle to expand the piston ring.

3) 4) 5)

Install piston ring (9) to piston (8). Using tool U7, contract piston ring (9). Install wear ring (7).

50-500

500 Hydraulic system Disassembly and assembly of hydraulic cylinder assembly

Install piston assembly (5) to piston rod (6).

7) 8)

Set piston rod assembly (2) to tool U1. Using tool U3, install piston nut (4). q Width across flats of piston nut Boom cylinder: 36 mm Arm cylinder: 41 mm Bucket cylinder: 32 mm Boom swing cylinder: 32 mm Blade cylinder: 36 mm Variable gauge cylinder: 32 mm 2 Piston nut: Adhesive (LOCTITE 262 or equivalent) 3 Piston nut: Boom cylinder: 422 ± 42.0 Nm {43 ± 4.3 kgm} Arm cylinder: 618 ± 61.8 Nm {63 ± 6.3 kgm} Bucket cylinder: 324 ± 32.5 Nm {33 ± 3.3 kgm} Boom swing cylinder: 343 ± 34.0 Nm {35 ± 3.5 kgm} Blade cylinder: 412 ± 41.0 Nm {42 ± 4.2 kgm} Variable gauge cylinder: 324 ± 32.5 Nm {33 ± 3.3 kgm}

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic cylinder assembly

SEN04624-00

Piston rod assembly 1) Install piston rod assembly (2) to cylinder (3).

2) 3)

Set cylinder assembly (1) to tool U1. Using tool U2, tighten cylinder head. 3 Cylinder head: Boom cylinder: 785 ± 78.5 Nm {80 ± 8.0 kgm} Arm cylinder: 569 ± 57.0 Nm {58 ± 5.8 kgm} Bucket cylinder: 539 ± 54.0 Nm {55 ± 5.5 kgm} Boom swing cylinder: 441 ± 44.0 Nm {45 ± 4.5 kgm} Blade cylinder: 490 ± 49.0 Nm {50 ± 5.0 kgm} Variable gauge cylinder: 539 ± 54.0 Nm {55 ± 5.5 kgm}

PC18MR-3

50-500

SEN04624-00

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

Disassembly and assembly of hydraulic breaker assembly

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

SEN04624-00

Breaker arm parts list No.

Part name

Q'ty

1 Cap

2 Bolt, cap

3 Washer, seal

4 Cover

5 Diaphragm

6 Shell

7 Ring, valve

8 O-ring

9 Bolt

10 Body, valve

11 Plug

12 Bolt

13 Valve, control

14 Plug

15 Spring

16 Ball, steel

17 Tube, inner

18 Piston

19 O-ring

20 Pin

21 Cylinder

22 Plug

23 Packing

24 Seal, dust

25 Front end

26 Washer

27 Nut

28 Fitting, grease

29 Pin, lock

30 Pin, ring

31 Bushing, chisel

32 Bushing, chisel

33 Chisel

34 Plug

35 O-ring

36 Seal

37 Bushing

PC18MR-3

50-500

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

SEN04624-00

796T-170-2420

Stand

796T-170-2430

Shaft

796T-170-2440

Shaft

V 4

796T-170-2450

Shaft

796T-170-2460

Shaft

796-170-2160

Handle

796-170-2170

Valve assembly

t t t t t t t

Disassembly of valve body assembly 1. Pull out control valve (13) from valve body (10). Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

Q Q Q Q Q

1 1

Disassembly of cylinder assembly 1. Pull out inner tube (17) and piston (18) from the cylinder assembly. a Do not remove plug (14), spring (15) and steel ball (16) from inner tube (17). 2.

Remove O-ring (19) from the cylinder assembly.

Remove dust seal (24) and packing (23) from cylinder assembly (21). a Stick a thin screwdriver or a needle into the packing to remove.

Disassembly a Work in a clean place free from dirt and dust. a Erect the hydraulic breaker assembly on a stand when disassembling it. a For each part, see the drawing on the previous page.

Remove draw bolt (12). a Heat the draw bolt stud with a burner and burn out the screw lock to remove.

Disassembly of breaker unit 1. Remove 4 mounting bolts (9) and accumulator assembly (6). 2.

Remove nuts (27) and washers (26) to disconnect valve body assembly (10) and cylinder assembly (21) from front end assembly (25).

Disassembly of accumulator assembly 1. Grip shell (6) in vise [1] and remove cap (1). 2.

Loosen cap bolt (2) slowly to discharge the gas in the accumulator.

Using tool V6, remove cover (4) from shell (6).

Remove diaphragm (5), cap bolt (2) and seal washer (3) from cover (4).

Remove O-ring (8) and backup ring (9) from shell (6).

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

Disassembly of front end assembly 1. Chisel bushing 1) Set front end assembly (25) to tools V1 and V2 and pull out bushings (31) and (32) simultaneously, using the hydraulic press. a Hydraulic press capacity: Min. 294 kN {30 ton}

SEN04624-00

Assembly a For each part, see the drawing on the previous page. Assembly of front end assembly 1. Dust seal and bushing 1) Using tool V4 and the hydraulic press, press fit bushing (37) to front end assembly (25). 2) Using tool V5, press fit dust seal (36). a Use a new dust seal. a Hydraulic press capacity: Min. 196 kN {20 ton}

Dust seal and bushing Push out dust seal (36) and bushing (37) with a round bar 36 â&#x20AC;&#x201C; 39 mm in diameter.

Chisel bushings 1) Using tool V3 and the hydraulic press, press fit chisel bushing (31) to front end assembly (25). a Hydraulic press capacity: Min. 294 kN {30 ton} a Apply lubricating oil to the outside of chisel bushing (31) and inside of front end assembly (25) and press fit slowly. a Press fitting force: Min. 98 kN {10 ton} 2) Using tool V3 and the hydraulic press, press fit chisel bushing (32). a Apply lubricating oil to the outside of chisel bushing (32) and inside of front end assembly (25) and press fit slowly. 2 Lubricating oil: Engine oil (EO10-CD) a

PC18MR-3

Press fitting force: Min. 78 kN {8 ton}

50-500

SEN04624-00 Assembly of cylinder assembly 1. Install packing (23) and dust seal (24) to cylinder assembly (21). a Clean the packing and dust seal grooves. 2 Packing and dust seal grooves, packing and dust seal: Engine oil (EO10-CD) a Using a screwdriver, the corners of which are rounded off, install the packing and dust seal in the directions shown in the figure, while preventing twist, etc. a Take care not to damage the packing lip. a Use a new packing and a new dust seal. 2.

If plug (22) was removed, tighten it to the following torque. 3 Plug: 58.8 Nm {6 kgm} Install O-ring (19) to the groove of cylinder (21).

Insert piston (18) in cylinder assembly (21). 2 Outside of piston: Engine oil (EO10-CD)

Insert inner tube (17) in cylinder assembly (21).

50-500

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

Assembly of valve body 1. Insert control valve (13) in valve body (10). a Check that the control valve is moved by its weight. 2.

Install draw bolt (12). a Clean and degrease the threaded parts of valve body (10) and draw bolt (12). a Install the shorter threaded part of draw bolt (12). 2 Draw bolt: Adhesive (THREEBOND 1303B) 3 Draw bolt: 150 ± 15 Nm {15 ± 1.5 kgm}

If plug (11) was removed, tighten it to the following torque. 3 Plug: 30 Nm {3 kgm}

Assembly of accumulator 1. Grip shell (6) in vise [1]. 2.

Fit diaphragm (5) to cover (4). a Press around the diaphragm until its lip is fitted perfectly to the groove of the cover. 2 Inside of shell (6) and outside of diaphragm (5): Engine oil (EO10-CD) 2 Threaded part of shell: Red lead

Using tool V6, tighten cover (4). a Taking care of the threaded parts of the shell and cover, tighten the cover slowly until it becomes almost flush with the shell. 3 Cover: 206 ± 9.8 Nm {21.0 ± 1.0 kgm}

Tighten washer (3) and cap bolt (2) temporarily. a Tighten these parts permanently after charging the accumulator with gas.

Install backup ring (7) and O-ring (8) to accumulator assembly (6).

Install cap (1) fitted with O-ring (35).

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

SEN04624-00

Assembly of breaker unit 1. Set front end assembly (25) on the stand and insert cylinder assembly (21) in the front end assembly. a Set the cylinder assembly so that the dowel pin (20) will be positioned as shown in the following figure.

Install valve body assembly (10) to cylinder assembly (21). a Set dowel pin (20) to the hole of valve body assembly (10) and set draw bolt (12) to the hole of front end assembly (25). a Press the valve body assembly from above to fit O-ring (19). 2 O-ring: Engine oil (EO10-CD)

Install washers (26) and nuts (27) to draw bolt (12). a Install the each washer with the concave side up. a Tighten the 4 nuts evenly. a Clean and degrease the threaded part of the draw bolt. 2 Threaded part of draw bolt: Adhesive (THREEBOND 1342) 3 Nut: 130 Nm {13 kgm}

Insert your finger in the hole at the center of valve body assembly (10) and check that you can move inside control valve (13) with the finger. a Stroke of control valve: 10 mm

Install accumulator assembly (6) and tighten 4 mounting bolts (9). a Taking care not to damage O-ring (8) and backup ring (7), install the accumulator assembly to the valve body assembly. 2 O-ring (8): Engine oil (EO10-CD) 3 Mounting bolt: 98.1 Nm {10 kgm}

PC18MR-3

50-500

SEN04624-00

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

Charging accumulator with gas 1. Preparation for charging 1) Remove cap (1) from the top of accumulator assembly (6). 2) Fit tool V7 to a screw provided on the accumulator upper surface. 3) Connect the valve of nitrogen gas cylinder (F) to tool V7 by gas supply rubber hose (B). 4) Close escape valve (C) of tool V7. 2.

Charging 1) Check that cap bolt (2) of the accumulator is tightened. Turn the valve of nitrogen gas cylinder (F) counterclockwise to open the gas cylinder and check with pressure gauge (D) that the nitrogen gas pressure is higher than 5.9 MPa {60 kg/cm 2 }. Immediately after checking, turn handle (E) clockwise to close the gas cylinder. 2) Under this condition, check for gas leakage with pressure gauge (D). 3) While watching pressure gauge (D), turn handle (E) of tool V7 counterclockwise slowly, and the supply hole of the accumulator opens and the pressure gauge indication lowers. Stop turning handle (E) at this time. 4) While watching pressure gauge (D), turn the valve of nitrogen gas cylinder (F) counterclockwise to open. Open and close the valve until the pressure gauge indicates 5.4 MPa {55 kg/cm2}. 5) When the pressure gauge indicates the above pressure, close the valve of nitrogen gas cylinder (F) and leave it for about 1 minute to stabilize the pressure gauge indication. 6) If the pressure lowers, open the valve of nitrogen gas cylinder (F) to supply gas. If the pressure is high, open escape valve (C) of tool V7 to adjust the pressure. 7) Close nitrogen gas cylinder (F) fully and turn handle (E) of tool V7 clockwise to close the accumulator. 8) Open escape valve (C) of tool V7 to discharge the gas in the rubber hose into the atmosphere. 9) After pressure gauge (D) indication lowers, remove tool V7. 10) Install the accumulator protection nut.

50-500

PC18MR-3

500 Hydraulic system Disassembly and assembly of hydraulic breaker assembly

PC18MR-3

SEN04624-00

50-500

SEN04624-00

PC18MR-3 Hydraulic excavator Form No. SEN04624-00

50-500

SEN04625-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 600 Work equipment Removal and installation of work equipment assembly .................................................................................. 2

PC18MR-3

50-600

600 Work equipment Removal and installation of work equipment assembly

SEN04625-00

Removal and installation of work equipment assembly 1 k

Remove cover (8).

Sling boom cylinder (9) temporarily and remove plates (10) and pin (11). [*1] a Lower boom cylinder onto stand [1].

Sling work equipment assembly (12) temporarily.

Release the residual hydraulic pressure from the hydraulic circuit. For details, see “Releasing residual pressure from hydraulic circuit”. Extract the boom cylinder and bucket cylinder to the stroke end and lower the work equipment to the ground. Set the lock lever in the lock position.

Removal 1.

Tilt up the floor frame. For details, see “Removal and installation of radiator assembly”. Disconnect 6 hoses (1) – (6). a (3) and (5) are for the boom cylinder. a The hoses are labeled.

Disconnect connector (7).

50-600

PC18MR-3

600 Work equipment Removal and installation of work equipment assembly

Remove plate (13) and boom foot pin (14). [*2]

SEN04625-00

Installation q

[*1]

Carry out installation in the reverse order to removal. k

When aligning the pin holes, never insert your fingers in them. 2 Pin and sliding surface on boom side: Molybdenum disulfide lubricant (LM-P) 2 Grease after installation: Grease (Hyper White Grease)

[*2]

When aligning the pin holes, never insert your fingers in them. 2 Pin and sliding surface on swing bracket side: Molybdenum disulfide lubricant (LM-P)

Lift off work equipment assembly (12). 4

Work equipment assembly: 150 kg

Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

PC18MR-3

Grease after installation: Grease (Hyper White Grease)

Hydraulic oil: 15.2 l

Bleeding air a Bleed air. For details, see Testing and adjusting, â&#x20AC;&#x153;Bleeding air from each partâ&#x20AC;?.

50-600

SEN04625-00

PC18MR-3 Hydraulic excavator Form No. SEN04625-00

50-600

SEN04626-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 700 Cab and its attachments Removal and installation of canopy ................................................................................................................ 2

PC18MR-3

50-700

700 Cab and its attachments Removal and installation of canopy

SEN04626-00

Removal and installation of canopy

Installation

Carry out of installation in the reverse order to removal.

Removal 1.

Tilt up the floor frame. For details, see â&#x20AC;&#x153;Removal and installation of radiator assemblyâ&#x20AC;?.

Lift off roof (1). 4 Roof: 17 kg

Lift off canopy pole (2). 4 Canopy pole: 50 kg 4 Canopy: 68 kg

50-700

[*1]

PC18MR-3

700 Cab and its attachments Removal and installation of canopy

PC18MR-3

SEN04626-00

50-700

SEN04626-00

PC18MR-3 Hydraulic excavator Form No. SEN04626-00

50-700

SEN04627-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

50 Disassembly and assembly1 800 Electrical system Removal and installation of KOMTRAX terminal ............................................................................................ 2

PC18MR-3

50-800

800 Electrical system Removal and installation of KOMTRAX terminal

SEN04627-00

Removal and installation of KOMTRAX terminal

Installation

Carry out installation in the reverse order to removal.

Removal 1.

Turn the starting switch to the OFF position.

Remove the cover, garnish, etc. to expose KOMTRAX terminal (1).

Remove the cab wiring harness from KOMTRAX terminal (1). a Be sure to remove the cab wiring harness before the antenna cable (described in step 4).

Remove the communication antenna cable and GPS antenna cable from KOMTRAX terminal (1).

Remove all mounting bolts (2) and washers (3) of the KOMTRAX terminal. Reference: The mounting bolt size is M8.

Remove KOMTRAX terminal (1) from bracket. a When handling the KOMTRAX terminal, take care not to give an impact on it. (Never hit it against another part or drop it.)

50-800

PC18MR-3

800 Electrical system Removal and installation of KOMTRAX terminal

PC18MR-3

SEN04627-00

50-800

SEN04627-00

PC18MR-3 Hydraulic excavator Form No. SEN04627-00

50-800

SEN04327-00

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

90 Diagrams and drawings

100 Hydraulic diagrams and drawings Hydraulic circuit diagram................................................................................................................................. 3

PC18MR-3

90-100

SEN04327-00

90-100

100 Hydraulic diagrams and drawings

PC18MR-3

Hydraulic circuit diagram PC18MR-3

PC18MR-3

Hydraulic circuit diagram PC18MR-3

SEN04327-00 90-100

100 Hydraulic diagrams and drawings

PC18MR-3

SEN04327-00

90-100

SEN04327-00

PC18MR-3 Hydraulic excavator Form No. SEN04327-00

90-100

SEN04328-01

HYDRAULIC EXCAVATOR PC18MR-3

Machine model

Serial number

PC18MR-3

20001 and up

90 Diagrams and drawings

200 Electrical diagrams and drawings Electrical circuit diagram ................................................................................................................................. 3 Connector list and stereogram........................................................................................................................ 5

PC18MR-3

90-200

SEN04328-01

90-200

200 Electrical diagrams and drawings

PC18MR-3

Electrical circuit diagram

PC18MR-3

Electrical circuit diagram PC18MR-3

SEN04328-01 90-200

Connector list and stereogram PC18MR-3

Connector list and stereogram Connector No.

Model

Number of pins

Rotary lamp for swing pressure switch (Revolution left) (If equipped)

—

Rotary lamp for swing pressure switch (Revolution right) (If equipped)

—

Travel alarm for domestic (STD)

—

Travel pressure switch (STD)

—

Travel pressure switch (STD)

—

Travel pressure switch (STD)

—

Travel pressure switch (STD)

—

AMP

KOMTRAX controller

A-5

AMP

KOMTRAX controller

A-5

—

Diode

A-5

Relay

Relay for KOMTRAX

D-5

Intermediate connector (For KOMTRAX)

B-5

Intermediate connector (For KOMTRAX)

B-4

—

Diode

C-3

—

Diode

K-1

VCH

Blade variable gauge change switch

M-7

PPC lock switch (Left)

M-8

Intermediate connector (Spare)

K-9

Rotary lamp

K-9

YAZAKI

Horn switch

J-9

Component name

Address of stereogram

PPC lock switch (Right)

I-8

AMP

Machine monitor

I-9

Buzzer

I-9

KES

Light switch

M-8

F10

Auto-accel switch

J-9

F13

YAZAKI

Timer for engine stop solenoid

B-5

F17

DT-T

Resistor

H-8

FB1

—

Fuse box

C-6

YAZAKI

Horn

H-1

—

Fusible link (45A)

M-7

YAZAKI

Starting motor (ST terminal)

M-7

Engine stop solenoid

L-9

YAZAKI

Fuel pump

H-8

Engine coolant temperature sensor

L-9

SUMITOMO

Alternator (L, IG, P terminal)

L-9

—

Fuel level sensor

M-5

PPC lock solenoid valve

H-8

M10

Travel speed acceleration solenoid valve

H-8

M11

Intermediate connector (For variable gauge change solenoid)

—

M12

Intermediate connector (Spare)

I-1

M13

Connector (If equipped)

—

M14

—

Variable gauge change solenoid valve

J-1 — —

—

Additional outer power source socket (+) (EU STD)

—

Additional outer power source socket (–) (EU STD)

Relay

Relay for engine start circuit

C-6

Relay

Relay for PPC lock solenoid

C-5

Relay

Relay for acceleration solenoid

C-6

YAZAKI

Engine safety relay

D-6

YAZAKI

Engine stop solenoid relay

C-4

Relay

Relay for drive (If equipped)

—

T-F1

Terminal

Starting switch (B terminal)

C-8

F-F2

Terminal

Starting switch (BR terminal)

C-7

F-F3

Terminal

Starting switch (ACC terminal)

B-8

F-F4

Terminal

Starting switch (C terminal)

B-8

F-F5

Terminal

Starting switch (R1 terminal)

C-8

F-F6

Terminal

Starting switch (R2 terminal)

C-7

T-M1

Terminal

Battery

M-6

T-M2

Terminal

Starting motor (B Terminal)

M-7

T-M3

Terminal

Engine pressure switch

L-9

T-M4

Terminal

Alternator (B terminal)

I-8

T-M5

Terminal

Glow plug

M-8

T-M6

Terminal

Revolving frame earth

H-1

Intermediate connector (For work lamp)

J-1

Work lamp

E-6

Additional work lamp

H-1

PC18MR-3

SEN04328-01 90-200

200 Electrical diagrams and drawings

PC18MR-3

SEN04328-01

90-200

SEN04328-01

PC18MR-3 Hydraulic excavator Form No. SEN04328-01

90-200