PC18MR2

SEBM038404
Machine model Serial number
PC18MR-2 15001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
• PC18MR-2 mount the 3D67E-1A engine.

For details of the engine, see the 67E-1 Series Engine Shop Manual.
© 2007
All Rights Reserved 00-1
Printed in Japan 06-07 (02) (4)
Contents
No. of page
01 General .......................................................................................................................... 01-1
10 Structure, function and maintenance standard ........................... 10-1
20 Testing and adjusting ........................................................................................ 20-1
30 Disassembly and assembly .......................................................................... 30-1
90 Others ............................................................................................................................. 90-1
00-2 PC18MR-2
(2)
List of revised pages
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page revision Mark Page revision Mark Page revision Mark Page revision Mark Page revision
q 00-1 (4) 01-3 10-22 10-51 10-83
00-2 (2) 01-4 10-23 10-52 10-85
q 00-2-1 (4) 01-5 10-24 10-53 10-86
q 00-2-2 (4) 01-6 10-25 10-54 10-87
q 00-2-3 (4) 01-7 10-26 10-55 10-88
00-3 01-8 10-27 10-56 10-89
00-4 01-9 10-28 10-58 10-90
00-5 10-29 10-59 10-91
00-6 10-30 10-60 10-92
00-7 10-1 10-31 10-61 10-93
00-8 10-2 10-32 10-62 10-94
00-9 10-4 10-33 10-63 10-95
00-10 10-5 10-34 10-64 10-96
00-11 10-6 10-35 10-65 10-97
00-12 10-7 10-36 10-66 10-98
00-13 10-8 10-37 10-67 10-99
00-14 10-9 10-38 10-68 10-100
00-15 10-10 10-39 10-69 10-101
00-16 10-11 10-40 10-70 10-102
00-17 10-12 10-41 10-72 10-103
00-18 10-13 10-42 10-73 10-104
00-19 10-14 10-43 10-74
00-20 10-15 10-44 10-76
00-21 10-16 10-45 10-77 20-1 (1)
00-22 10-17 10-46 10-78 20-2 (1)
10-18 10-47 10-79 20-3 (1)
10-19 10-48 10-80 20-4 (1)
01-1 10-20 10-49 10-81 20-5 (1)
01-2 10-21 10-50 10-82 20-6 (1)
PC18MR-2 00-2-1
(4)

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
20-7 (1) 20-138 (1) 20-243 (1) 20-341 (1) q 30-1 (4)
20-8 (1) 20-201 (1) 20-244 (1) 20-342 (1) 30-2 (2)
20-9 (1) 20-202 (1) 20-245 (1) 20-343 (1) 30-3 (2)
20-10 (1) 20-203 (1) 20-301 (1) 20-344 (1) 30-4 (2)
20-11 (1) 20-204 (1) 20-302 (1) 20-345 (1) 30-5 (2)
20-101 (1) 20-205 (1) 20-303 (1) 20-346 (1) 30-6 (2)
20-102 (1) 20-206 (1) 20-304 (1) 20-347 (1) q 30-7 (4)
20-103 (1) 20-207 (1) 20-305 (1) q 20-401 (4) Q 30-7-1 (4)
20-104 (1) 20-208 (1) 20-306 (1) 20-402 (1) Q 30-7-2 (4)
20-105 (1) 20-209 (1) 20-307 (1) 20-403 (1) Q 30-7-3 (4)
20-106 (1) 20-210 (1) 20-308 (1) 20-404 (1) 30-8 (2)
20-107 (1) 20-211 (1) 20-309 (1) 20-405 (1) 30-9 (2)
20-108 (1) 20-212 (1) 20-310 (1) 20-406 (1) 30-10 (2)
20-109 (1) 20-213 (1) 20-312 (1) 20-407 (1) 30-11 (2)
20-110 (1) q 20-214 (4) 20-313 (1) 20-408 (1) 30-12 (2)
20-111 (1) 20-215 (1) 20-314 (1) 20-409 (1) 30-13 (3)
20-112 (1) 20-216 (1) 20-315 (1) 20-410 (1) 30-14 (3)
20-113 (1) 20-218 (1) 20-316 (1) 20-411 (1) 30-15 (3)
20-114 (1) 20-219 (1) 20-317 (1) 20-412 (1) 30-16 (2)
20-115 (1) 20-220 (1) 20-318 (1) 20-413 (1) 30-17 (2)
20-116 (1) 20-221 (1) 20-319 (1) 20-414 (1) 30-18 (2)
20-117 (1) 20-222 (1) 20-320 (1) 20-415 (1) 30-19 (2)
20-118 (1) 20-223 (1) 20-321 (1) 20-416 (1) 30-20 (2)
20-119 (1) 20-224 (1) 20-322 (1) 20-417 (1) 30-21 (2)
20-120 (1) 20-225 (1) 20-323 (1) 20-418 (1) 30-22 (2)
20-121 (1) 20-226 (1) 20-324 (1) 20-419 (1) 30-23 (2)
20-122 (1) 20-227 (1) 20-325 (1) 20-420 (1) 30-24 (2)
20-123 (1) 20-228 (1) 20-326 (1) 20-421 (1) 30-25 (2)
20-124 (1) 20-229 (1) 20-327 (1) 20-422 (1) 30-26 (2)
20-125 (1) 20-230 (1) 20-328 (1) 20-423 (1) 30-27 (2)
20-126 (1) 20-231 (1) 20-329 (1) 20-424 (1) 30-28 (2)
20-127 (1) 20-232 (1) 20-330 (1) 20-425 (1) 30-29 (2)
20-128 (1) 20-233 (1) 20-331 (1) 20-426 (1) 30-30 (2)
20-129 (1) 20-234 (1) 20-332 (1) 20-427 (1) 30-31 (2)
20-130 (1) 20-235 (1) 20-333 (1) Q 20-428 (4) 30-32 (2)
20-131 (1) 20-236 (1) 20-334 (1) Q 20-429 (4) 30-33 (2)
20-132 (1) 20-237 (1) 20-335 (1) 20-501 (1) 30-34 (2)
20-133 (1) 20-238 (1) 20-336 (1) 20-502 (1) 30-35 (2)
20-134 (1) 20-239 (1) 20-337 (1) 20-503 (1) 30-36 (2)
20-135 (1) 20-240 (1) 20-338 (1) 20-504 (1) 30-37 (2)
20-136 (1) 20-241 (1) 20-339 (1) 20-505 (1) 30-38 (2)
20-137 (1) 20-242 (1) 20-340 (1) 30-39 (2)
00-2-2 PC18MR-2
(4)

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
30-40 (2)
30-41 (2)
30-42 (2)
30-43 (2)
30-44 (2)
30-45 (2)
30-46 (2)
30-47 (2)
30-48 (2)
30-49 (2)
30-50 (2)
30-51 (2)
30-52 (2)
30-53 (2)
30-54 (2)
30-55 (2)
30-56 (2)
30-57 (2)
30-58 (2)
30-59 (2)
30-60 (2)
30-61 (2)
30-62 (2)
30-63 (2)
30-64 (2)
30-65 (2)
30-66 (2)
30-67 (2)
30-68 (2)
30-69 (2)
Q 30-70 (4)
Q 30-71 (4)
Q 30-72 (4)
Q 30-73 (4)
Q 30-74 (4)
Q 30-75 (4)
Q 30-76 (4)
90-1
90-3
90-5
PC18MR-2 00-2-3
(4)
Safety Safety notice
Safety
Safety notice
Important safety notice

Proper service and repair is 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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
General precautions
6. Decide a place in the repair workshop to keep
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work.
9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
Safety Safety notice
Precautions during work 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or
Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
• When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out.
that they will not be damaged by contact with
Before disconnecting or removing components
other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the
that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get
dangerous, so be extremely careful when install-
burned.
ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carrying
that connecting parts are correctly installed.
out any work on the oil or water circuits.
21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the
the specified tightening torques. When installing
battery. Always remove the lead from the nega-
protective parts such as guards, or parts which
tive (–) terminal first.
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
Check that the wire rope, chains and hooks are
22. When aligning two holes, never insert your fin-
free from damage.
gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample
caught in a hole.
capacity.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16. When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.
17. 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, or can even start fires.
18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gas-
oline when washing electrical parts.
00-4
Foreword General
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
Testing and adjusting

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword General
How to read the shop manual Revised edition mark

W he n a m an ua l i s r ev i se d, an e di t i on m a r k
Volumes ((1)(2)(3)....) is recorded on the bottom of the pages.
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Revisions
Chassis volume: Issued for every machine model Revised pages are shown in the List of revised
Engine volume: Issued for each engine series pages next to the Contents page.
Each issued as one
Electrical volume:
volume to cover all
Attachments volume: Symbols
models
So that the shop manual can be of ample practical
use, important safety and quality portions are
These various volumes are designed to avoid dupli- marked with the following symbols.
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
Symbol Item Remarks
sis, engine, electrical and attachment volumes be
available. Special safety precautions
k Safety are necessary when
performing the work.
Distribution and updating Special technical
Any additions, amendments or other changes will be precautions or other
sent to KOMATSU distributors. Get the most up-to- a Caution precautions for preserving
date information before you start any work. standards are necessary
when performing the work.
Filing method Weight of parts of systems.
1. See the page number on the bottom of the page. Caution necessary when
4
File the pages in correct order. Weight selecting hoisting wire, or
when working posture is
2. Following examples show how to read the page
important, etc.
number.
Places that require special
3
Example 1 (Chassis volume): Tightening
attention for the tightening
torque
10 - 3 torque during assembly.
Places to be coated with
2
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
Places where oil, water or
5
each item.
Oil, water fuel must be added, and
Example 2 (Engine volume): the capacity.
12 - 5 Places where oil or water
6
Drain must be drained, and
Unit number (1. Engine) quantity to be drained.
Item number
(2. Testing and Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indi-

cated by a hyphen (–) and number after the
page number. File as in the example.
Example:
10-4 20-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
1) Check for removal of all bolts fastening the
part to the relative parts. 100% 88% 79% 71% 41%
2) Check for existence of another part causing SAD00479
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release Type 1
the residual pressure from the hydraulic tank.
For details, see “Testing and adjusting”,
Releasing residual pressure from hydraulic tank.
k 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.
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
a The adapter can be pushed in about 3.5 mm.
a Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See 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. (See 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. (See 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.
00-8
Foreword Method of disassembling, connecting push-pull type coupler
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding and push body (2) in straight until sliding
prevention ring (1) contacts contact surface a of prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever 2) Hold in the condition in Step 1), and push until
(4) to the right (clockwise). cover (3) contacts contact surface a of the
hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and pull 3) Hold in the condition in Steps 1) and 2), and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it. hexagonal portion at the male end to connect it.
Connection
00-9
Foreword Coating materials
Coating materials
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
Foreword Standard tightening torque
Standard tightening torque

Standard tightening torque table (when using torque wrench)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
Tightening torque for 102 and 114 engine series

1) Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
Nominal type
Width
size of Nominal thread size
across flats Thread size – Threads per inch, Root diameter
hose Range Target (mm) Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} — – 18UN 14.3
16
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 — —
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} — – 16UN 17.5
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —
00-14
Foreword Electric wire code
Electric wire code

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness
Copper wire
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Classification by color and code

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White Blue
00-15
Foreword Conversion table
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), 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 two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
1) The number 550 does not appear in the table, so divide 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 (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
Foreword Units
Units
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 General
Specification dimension drawing ....................01- 2

Working range drawing ..................................01- 3
Specifications .................................................01- 4
Weight table ...................................................01- 7
Lubricants, fuel and coolant specifications.....01- 9
PC18MR-2 01-1
General Specification dimension drawing
Specification dimension drawing
Item Unit PC18MR-2
Operating weight Canopy specification kg 1,855

3
Bucket capacity m 0.044
Komatsu 3D67E-1A
Engine model —
Diesel engine
Rated engine output kW{HP}/rpm 11.2 {15.0} / 2,600
A Overall length mm 3,650
B Overall height mm 2,410
C Overall width mm Min. 980 / Max. 1,300
D Shoe width mm 230
E Tail swing radius Canopy specification mm 705
F Overall length of track mm 1,555
G Distance between tumbler centers mm 1,212
Minimum ground clearance mm 170
Travel speed (Low / High) km/h 2.3 / 4.3
Continuous swing speed rpm 8.9
01-2 PC18MR-2
General Working range drawing
Working range drawing
Working range (mm) PC18MR-2
A Max. digging radius 4,025

B Max. digging depth 2,160
C Max. digging height 3,615
D Max. vertical wall depth 1,785
E Max. dumping height 2,610
Swing radius of work equipment 1,670
F
<Values in ( ) are boom swing radii> (1,355)
G Max. reach at ground level 3,935
H Blade lifting height 280
I Blade lowering depth 255
PC18MR-2 01-3
General Specifications
Specifications
PC18MR-2
Machine model
Canopy specification
Serial number 15001 and up
Bucket capacity m3 0.044

1,855
Operating weight kg
[1,940]
Max. digging depth 2,160
Max. vertical wall depth 1,785
Max. digging reach 4,025
Working ranges
Max. reach at ground level 3,935

Max. digging height mm 3,615
Max. dumping height 2,610
Bucket offset 465 (L.H.), 785 (R. H.)
Performance
Max. blade lifting height 280

Max. blade lowering depth 250
Max. digging force (bucket) kN {kg} 15.9 {1,620}
Continuous swing speed rpm 8.9
Swing max. slope angle deg. 19.0
Travel speed km/h 2.3 (Lo) / 4.3 (Hi)
Gradeability deg. 30
2
Ground pressure kPa {kg/cm } 29.4 {0.30}
[31.4 {0.32}]
Overall length (for transport) 3,650
Overall width Min. 980 / Max. 1,300
Overall height (for transport) 2,410 [2,410]
Ground clearance of conterweight 430 [430]
Min. ground clearance 170 [170]
Tail swing radius 705
Dimensions
Min. swing radius of work equipment 1,670 (1,355)

(at boom swing) mm
Min. swing radius of work equipment 2,705
Overall width (crawler) Min. 980 / Max. 1,300
Overall length (crawler) 1,555
Length of track on ground 1,212
Track gauge Min. 750 / Max. 1,070
Machine cab height 1,195
Blade width x height Min.980/Max.1,300 × 250
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specifi-
cation are shown.)
a Values in [ ] are for the steel shoe specification.
01-4 PC18MR-2
PC18MR-2
Machine model
Model 3D67E-1A
Type 4-cycle, water cooled, in-line direct injection type,
swirl chamber type
No. of cylinders - bore x stroke mm 3 – 36 × 74
Piston displacement l {cc} 0.778 {778}
Flywheel horsepower kW {HP}/rpm 11.2 {15.0} / 2,600
Performance
Maximum torque Nm {kgm}/rpm 45.6 {4.65} / 2,000

Engine
High idling speed rpm 2,780

Low idling speed rpm 1,475
Min. fuel consumption ratio g/kWh {g/HPh} 265 {198}
Starting motor 12V, 1.2 kW
Alternator 12V, 40A
Battery (*1) 12V, 41Ah × 1 (44B19L)
Radiator
AL louver type fin
• Core type
Carrier plate 1 on each side
Under-carriage
Track roller 3 on each side

Track shoe (Rubber shoe) Unit-type rubber crawler
Track shoe (Steel shoe) Assembly-type double grouser: 35 each side
Hydraulic pump
Type x no. Variable displacement piston type x 1, gear type x 1

3
Theoretical capacity cm /rev 16 + 4.9
Set pressure
For travel, work equipment, blade MPa {kg/cm2} 23.0 {235}
For swing MPa {kg/cm2} 19.1 {195}
Hydraulic system
Type x no. 9-spool type x 1

Control
valve
Control method Hydraulic assist type
Variable-displacement piston motor (with counterv-

Hydraulic
Travel motor
motor
alance valve, parking brake) x 2

Fixed-displacement orbit-roll type motor (with brake
Swing motor
valve, swing shaft brake) x 1
Hydraulic tank Box-shaped, open type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (Drawn-cup)
*1: The battery capacity (Ah) is based on 5-hour rate.
PC18MR-2 01-5
PC18MR-2
Machine model
Cylinder type Double acting piston

Boom cylinder
Inside diameter of cylinder ø60

Outside diameter of piston rod ø35
mm
Stroke 355
Max. distance between pins 985
Min. distance between pins 630
Arm cylinder

mm
Stroke 447
Max. distance between pins 1,153
Bucket cylinder

mm
Stroke 378
Work equipment cylinder
Max. distance between pins 1,027

Hydraulic system

Boom swing cylinder

mm
Stroke 282

Blade cylinder

mm
Stroke 100
Variable gauge cylinder

mm
Stroke 293
01-6 PC18MR-2
General Weight table
Weight table
k This weight table is a guide for use when transporting or handing components.
Unit: kg
PC18MR-2
Machine model
Engine assembly (excluding coolant and oil) 126

• Engine (excluding coolant and oil) 86
• Engine mount 11
• PTO 10
• Hydraulic pump 19
Cooling assembly (excluding coolant and oil) 14
Battery 10
Revolving frame 199
Floor frame 125
Canopy assembly 63
Handrail 6
Operator's cab (with floor frame) —
Operator's seat 12
Fuel tank (excluding fuel) 2
Hydraulic tank (excluding hydraulic oil) 23
Control valve 33
Counterweight 157
X-weight (Additional counterweight) 122
Swing motor (with brake valve and machinery) 23
Track frame assembly (excluding track shoe) 360
• Track frame 196
• 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 24
• Center swivel joint 10
PC18MR-2 01-7
General Weight table
Unit: kg
PC18MR-2
Machine model
Track shoe assembly

• Rubber shoe (230 mm) 51 × 2
• Double grouser shoe (230 mm) 82 × 2
Boom swing bracket assembly 18
Boom assembly 48
Arm assembly 25
Bucket link assembly 8
Bucket assembly (with side cutter) 29
Blade assembly 91
Boom cylinder assembly 13
Arm cylinder assembly 12
Bucket cylinder assembly 10
Boom swing cylinder assembly 9
Blade cylinder assembly 8
Variable gauge cylinder assembly 7
01-8 PC18MR-2
General Lubricants, fuel and coolant specifications
Lubricants, fuel and coolant specifications
Ambient temperature Capacity ( )

Reservoir Kind of
fluid -22 -4 14 32 50 68 86 104 122°F
-30 -20 -10 0 10 20 30 40 50°C Specified Refill
SAE 30
SAE 10W
Engine oil pan 3.6 3.3
SAE 10W-30
SAE 15W-40
Engine oil
Final drive case (each) SAE 30 0.3 0.3
SAE 10W
Hydraulic system SAE 10W-30 23.8 15.2
SAE 15W-40
Idler (each) 0.036 0.036

Grease G2-LI
Track roller (each) 0.044 0.044
ASTM D975 No.2

Fuel tank Diesel fuel 19
*1
Cooling system Coolant Add antifreeze 3.1
* 1 : ASTM D975 No.1
PC18MR-2 01-9
10 Structure, function and
maintenance standard
PTO .............................................................. 10- 2

Cooling system............................................. 10- 4
Power train ................................................... 10- 6
Swing circle .................................................. 10- 7
Track frame .................................................. 10- 8
Idler cushion................................................. 10- 9
Idler .............................................................. 10- 11
Track roller ................................................... 10- 12
Sprocket ....................................................... 10- 13
Track shoe.................................................... 10- 14
Hydraulic components layout drawing ......... 10- 16
Hydraulic tank .............................................. 10- 17
Center swivel joint ........................................ 10- 18
Travel motor ................................................. 10- 19
Hydraulic cylinder......................................... 10- 28
Solenoid valve.............................................. 10- 31
Variable gauge valve.................................... 10- 34
Multi-control valve ........................................ 10- 35
Hydraulic pump ............................................ 10- 36
Control valve ................................................ 10- 42
CLSS............................................................ 10- 54
Operation for each function and valve ......... 10- 58
Swing motor ................................................. 10- 72
PPC valve .................................................... 10- 76
Work equipment ........................................... 10- 85
Dimensions of each part of work equipment.. 10- 88
Floor ............................................................. 10- 91
Engine control .............................................. 10- 92
Electric control system ................................. 10- 94
Component parts of system ......................... 10- 99
Monitor system............................................. 10-100
Monitor panel ............................................... 10-101
Sensors ........................................................ 10-103
PC18MR-2 10-1
Structure, function and maintenance standard PTO
PTO
1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump
10-2 PC18MR-2
Structure, function and maintenance standard Cooling system
Cooling system
1. Radiator cap 7. Oil cooler

2. Fan guard 8. Reservoir tank
3. Shroud 9. Drain valve
4. Oil cooler inlet 10. Radiator inlet hose
5. Radiator 11. Radiator outlet hose
6. Oil cooler outlet
10-4 PC18MR-2
Structure, function and maintenance standard Cooling system
Specifications
Radiator Oil cooler
Core type AL louver type fin AL drawn-cup
Fan pitch mm 3.0 / 2 4.0 / 2
Total heat dissipation surface m2 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-2 10-5
Structure, function and maintenance standard Power train
Power train
1. Idler 7. Hydraulic pump (For PPC control)

2. Swing motor 8. Left travel motor
3. Center swivel joint 9. Control valve
4. Right travel motor 10. Travel Hi-Lo speed selector valve
5. Engine 11. PPC lock solenoid valve
6. Hydraulic pump (For work equipment, travel, 12. Swing circle
swing, blade and variable gauge)
10-6 PC18MR-2
Structure, function and maintenance standard Swing circle
Swing circle
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

1 Clearance between bearing Replace
0.03 – 0.15 0.25
2. Swing circle bearing lubricator Specifications

3. Swing circle pinion lubricator
Reduction ratio 110 / 17 = 6.47
4. Outer race
5. Inner race Grease G2-LI
6. Ball
7. Seal
PC18MR-2 10-7
Structure, function and maintenance standard Track frame
Track frame
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier plate 8. Idler cushion
4. Travel motor 9. Idler guard
5. Sprocket (Steel shoe and road liner spec.)
10-8 PC18MR-2
Structure, function and maintenance standard Idler cushion
Idler cushion
Steel shoe spec.
Unit: mm
Standard size Repair limit

Installed Installed Installed
Free length Free length
1 Recoil spring length load load Replace
6.9 kN 6.0 kN
200 168 195.6
{700 kg} {612 kg}
2. Front support Specifications

3. Recoil spring
Grease G2-LI
4. Cylinder
5. Rear support Amount of grease cc 70
6. Rod
7. Lubricator
PC18MR-2 10-9
Structure, function and maintenance standard Idler cushion
Rubber shoe spec.
1. Cylinder Specifications
2. Rod
Grease G2-LI
3. Lubricator
Amount of grease cc 70
10-10 PC18MR-2
Structure, function and maintenance standard Idler
Idler
Unit: mm
Standard clearance Repair limit

Outside diameter of
1
protruding portion 266 259.5
2 Outside diameter of tread 227 221

Rebuild or
3 Width of protruding portion 23 17 replace
4 Overall width 60 55
5 Width of tread 18.5 21.5
Standard Tolerance Standard Clearance

Clearance between idler and size Shaft Hole clearance limit Replace
6
bearing bushing
+0.030 +0.030
62 0 – 0.030 1.5
+0.030 +0.030
Clearance between shaft and –0.025 +0.039
7 30 0 – 0.064 1.5 Replace
support –0.025 +0.030
PC18MR-2 10-11
Structure, function and maintenance standard Track roller
Track roller
Unit: mm

Outside diameter of
1
protruding portion 96 90
2 Outside diameter of tread 80 74 Rebuild or

replace
3 Width of tread 31 34
4 Width of protruding portion 26 23
Tolerance Standard
Standard size
Interference between shaft Shaft Hole clearance
5
and bearing Replace
–0.025 –0.20
25 0.179 – 0.40 bushing
–0.021 –0.40
Interference between roller +0.40 +0.039
6 35 0.161 – 0.40
and bearing +0.20 +0.030
10-12 PC18MR-2
Structure, function and maintenance standard Sprocket
Sprocket
Unit: mm
Standard size Tolerance Repair limit

1 Wear of root circle diameter +1.0
ø255 ø251
–2.0
2 Wear of tip circle diameter ø290 ±1.5 ø278 Repair by

overlaying
3 Wear of tip width 17 — 15 welding or
replace
+1.0
4 Wear of bottom width 23 21
–2.0
+1.0
5 Thickness of bottom 57.5 55.5
–2.0
PC18MR-2 10-13
Structure, function and maintenance standard Track shoe
Track shoe
Rubber shoe
Unit: mm
Standard size Repair limit

1 Wear of lug height
17 5
Replace
2 Wear of roller guide 30 33
Wear of meshing parts of

3 23 27
sprocket
10-14 PC18MR-2
Structure, function and maintenance standard Track shoe
Steel shoe
Unit: mm
Standard size Repair limit Replace

1 Link pitch bushing and
90 92 pin or link
assembly
2 Height of grouser 15 5
3 Height of link 46 41
4 Outside diameter of bushing 22 18
Standard Tolerance Standard Interference

Interference between link and size Shaft Hole interference limit
5 Replace
regular pin
+0.155 +0.050 0.100 –
14 —
+0.150 +0.150 0.105
Interference between link and +0.154 +0.050 0.100 –
6 22 —
bushing +0.150 +0.150 0.104

Clearance between master size Shaft Hole clearance limit
7
pin and bushing
–0.020 +0.050 0.020 –
14 0.8
–0.050 +0.150 0.100
PC18MR-2 10-15
Structure, function and maintenance standard Hydraulic components layout drawing
Hydraulic components layout drawing
1. Variable gauge valve 13. Control valve

2. Boom swing PPC valve 14. Attachment PPC valve (If equipped)
3. Multi-control valve (If equipped) 15. Travel PPC valve
4. Swing motor 16. Arm cylinder
5. 2-spool solenoid valve 17. Boom cylinder
6. Right work equipment PPC valve 18. Oil cooler
7. Blade PPC valve 19. Center swivel joint
8. Right travel motor 20. Variable gauge cylinder
9. Left travel motor 21. Boom swing cylinder
10. Hydraulic pump 22. Blade cylinder
11. Left work equipment PPC valve 23. Bucket cylinder
12. Hydraulic tank
10-16 PC18MR-2
Structure, function and maintenance standard Hydraulic tank
Hydraulic tank
1. Filler cap Specifications

2. Hydraulic tank
Tank capacity l 18.5
3. Sight gauge
4. Drain plug Oil amount l 15.2
5. Bypass valve Bypass valve set 150 ± 30
kPa {kg/cm2}
6. Filter element pressure {1.53 ± 0.31}
7. Strainer Pressure valve 70 ± 15
kPa {kg/cm2} {0.71 ± 0.15}
cracking pressure
Vacuum valve 0–5
kPa {kg/cm2} {0 – 0.05}
cracking pressure
PC18MR-2 10-17
Structure, function and maintenance standard Center swivel joint
Center swivel joint
A1: From R.H. travel control valve 1. Cover

A2: To R.H. travel motor 2. Rotor
B1: From L.H. travel control valve 3. Slipper seal
B2: To L.H. travel motor 4. Shaft
C1: From R.H. travel control valve
C2: To R.H. travel motor
D1: From L.H. travel control valve
D2: To L.H. travel motor
E1: From variable gauge solenoid valve
E2: To blade cylinder head
F1 : From variable gauge solenoid valve
F2 : To blade cylinder bottom
G1: From variable gauge solenoid valve
G2: To variable gauge cylinder bottom
H1: From variable gauge solenoid valve
H2: To variable gauge cylinder head
I1 : To hydraulic tank
I2 : From travel motor drain port
J1 : From solenoid valve B
J2 : To travel Hi-Lo speed selector valve
Unit: mm
Standard size Standard clearance Clearance limit

Clearance between rotor and
5 Replace
shaft ø45 0.055 – 0.085 0.090
10-18 PC18MR-2
Structure, function and maintenance standard Travel motor
Travel motor
Model: PHV-1B-12B-PT-8517A
A : From travel control valve Specifications

B : From travel control valve Model: PHV-1B-12B-PT-8517A
PP : From travel speed Hi-Lo selector solenoid valve Delivery of motor: (1st) 12.4/(2nd) 6.2 cm3/rev
DR : To tank Max. output speed: (1st) 1,683/(2nd) 3,367 rpm
Max. flow rate: 21.3 l/min
PC18MR-2 10-19
1. Cover 13. Disc

2. No. 2 planetary gear 14. Shaft
3. No. 2 sun gear 15. Rocker cam
4. Ring gear 16. Control piston
5. No. 2 planetary carrier 17. No. 1 planetary gear
6. Housing 18. No. 1 sun gear
7. Piston 19. Drain plug
8. Cylinder 20. Oil level plug
9. Valve plate 21. Check valve
10. Brake valve 22. Counterbalance valve
11. Brake piston 23. Check valve
12. Plate 24. Automatic speed changing valve
10-20 PC18MR-2
Principle of operation
• The PVH 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).
a b1 consists of 4 planetary gears and b2 consists 1. Simple planetary reduction gear unit
of 3 planetary gears. (Double reduction)
2. Hydraulic motor
3. Automatic 1st valve
4. Counterbalance valve
5. Carrier 2
PC18MR-2 10-21
1. Reduction gear unit • The reduction ratio of the 2 stages of the simple
planetary gears is generally given by the follow-
Function ing expression.
• The reduction gear unit consists of 2 stages of R = Zs1 (Zs1 + Za1) x Zs2 (Zs2 + Za2)
simple planetary gears. It converts the high- Zs1, Zs2 : Number of teeth of gears s1 and s2
speed revolution from the hydraulic motor into Za1, Za2 : Number of teeth of gears a1 and a2
low-speed higher torque to obtain revolution of • Since the body of the PHV Series travel motor
the case. revolves, the above reduction ratio is given by
the following expression.
Operation R' = 1/(1-1/R)
• In the following figure, gear s2 is coupled with
the hydraulic motor output shaft by spline (of by
a shaft). The revolution of gear s2 is reduced
through gears s2, b2, and a2.
• The reduced revolution is further reduced
through gears s1, b1, and a1 coupled with car-
rier 2 (5) by spline.
• This revolution is transmitted through internal
gears a1 and a2 to the rotary part and used for
travel.
10-22 PC18MR-2
2. Hydraulic motor
Function
• 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
• The hydraulic oil flowing in through the hydraulic
valve is supplied to valve plate (3).
• The hydraulic oil supplied to port A flows into the
cylinder port in cylinder barrel (2) corresponding
to port A and pushes piston (1).
• The pushing force of the above hydraulic oil is
converted through rocker cam (4) into rotary
force and output to shaft (5) coupled with cylin-
der barrel (2).
• The return oil in the cylinder port flows out
through port B of valve plate (3).
• When the motor revolves in reverse, the hydrau-
lic oil flows in through port B and the return oil
flows out through port A.
PC18MR-2 10-23
Operation of 2nd motor • If the 2nd gear lever is set, hydraulic oil P is led
• Rocker cam (4) has 2 faces of A and B on the through the 2nd spool into control chamber (10).
opposite side to the face on which shoe (6) • Control piston (11) moves until face B of rocker
slides. It is supported on 2 balls (7) fixed to body cam (4) reaches body (8), and then rocker cam
(8). (4) is fixed at swash plate angle b. At this time,
• Balls (7) are installed a little higher than the axis. the delivery of the motor is reduced.
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 deliv-
ery of the motor is increased.
• 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
g ear sp eed i s al way s s el ec ted wh en th e
machine starts travel.
10-24 PC18MR-2
3. Hydraulic valve
1) Counterbalance valve
Operation • Even if the hydraulic oil from port A is stopped,

• If the hydraulic oil is supplied through port A, it the hydraulic motor continues revolution by iner-
pushes check valve (2) open and flows in port A' tia.
on the inlet side of the hydraulic motor. • At this time, the return oil is controlled gradually
• On the other hand, the hydraulic oil flows by the changing speed and shape of the cut of
through choke C into chamber D and moves spool (3) to stop the hydraulic motor smoothly.
spool (3) to the right against spring (4).
• 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 rotates the hydraulic motor.
• If the hydraulic oil is supplied through port B,
each part operates in the opposite direction and
the hydraulic motor revolves in reverse.
• If the hydraulic oil from port A is stopped, spool
(3) moved to the (3) is returned to the left by the
force of spring (4).
• At this time, the oil in chamber D controls the
speed of spool (3) returning to the left with choke
C.
PC18MR-2 10-25
2) Automatic 1st valve
Operation • If the drive pressure lowers from the 1st gear

• If the 2nd pilot switch is turned ON, the 2nd pilot speed level to the set pressure of the 2nd gear
pressure is led through port PP into hydraulic speed, the total of rightward forces F1 and F2
pressure pilot (1) and force F1 is generated. applied to automatic 1st valve (5) decreases the
• Force F1 moves automatic 1st valve (5) to the total of left ward forces F3 and F4. As a result,
right against force F4 and sets the system in the automatic 1st valve (5) moves to the right and
2nd gear speed. set the system in the 2nd gear speed.
• On the other hand, the drive pressure is led into
pilots (2) and (3) to generate forces F2 and F3.
• 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.
• 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.
10-26 PC18MR-2
4. Parking brake • If the hydraulic oil is supplied to port A or B,

hydraulic oil P is led into chamber (5). Hydraulic
Function oil P moves brake piston (6) to the right against
• When the travel motor is stopped, the parking the force of spring (7).
brake fixes the hydraulic motor output shaft • As a result, disc plate (3) and steel plate (4) is
mechanically. released and the friction force is lost and cylin-
der barrel (1) can revolve.
Operation
• While the hydraulic oil is not supplied to port A or
B, spring (7) presses brake piston (6) to the left.
• 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).
• 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-2 10-27
Structure, function and maintenance standard Hydraulic cylinder
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
10-28 PC18MR-2
Boom swing cylinder
Blade cylinder
Variable gauge cylinder
PC18MR-2 10-29
Unit: mm
Cylinder Standard Tolerance Standard Clearance

name size Shaft Hole clearance limit
–0.025 +0.039 0.025 –
Boom ø35 –0.064 +0.080 0.103 0.403
–0.025 +0.132 0.031 –
Arm ø35 –0.064 +0.006 0.196 0.496
Clearance
between piston –0.020 +0.133 0.013 – Replace
1 Bucket ø30 0.486
rod and bush- –0.053 –0.007 0.186 bushing
ing –0.020 +0.133 0.013 –
Boom swing ø30 0.486
–0.053 –0.007 0.186
Blade ø35 –0.025 +0.132 0.031– 0.496
–0.064 +0.006 0.196
Variable ø30 –0.020 +0.133 0.013 – 0.486
gauge –0.053 –0.007 0.186
–0.025 +0.134 0.097 –
Boom ø35 –0.064 +0.072 0.198 1.0
–0.010 +0.111 0.046 –
Arm ø30 –0.050 +0.036 0.161 1.0
Clearance
Bucket ø30 –0.090 +0.099 0.130 – 1.0
between piston –0.130 +0.040 0.229
2 rod supporting
shaft and bush- Boom swing ø30 –0.010 +0.111 0.046 – 1.0
–0.050 +0.036 0.161
ing
Blade ø35 –0.010 +0.134 0.082 – 1.0
–0.050 +0.072 0.184
Variable –0.010 +0.111 0.046 –
gauge ø30 –0.050 +0.036 0.161 1.0
Replace pin
–0.025 +0.134 0.097 – and bushing
Boom ø35 –0.064 +0.072 0.198 1.0
–0.025 +0.111 0.061 –
Arm ø30 –0.064 +0.036 0.175 1.0
Clearance
–0.090 +0.099 0.130 –
between cylin- Bucket ø30
–0.130 +0.040 0.229
1.0
3 der bottom sup-
porting shaft Boom swing ø30 –0.010 +0.111 0.046 – 1.0
–0.050 +0.036 0.161
and bushing
Blade ø35 –0.010 +0.134 0.082 – 1.0
–0.050 +0.072 0.184
Variable –0.010 +0.111 0.046 –
gauge ø30 –0.050 +0.036 0.161 1.0
Boom 785 ± 78.5 Nm {80 ± 8.0 kgm}
Arm 569 ± 57.0 Nm {58 ± 5.8 kgm}
Tightening Bucket 539 ± 54.0 Nm {55 ± 5.0 kgm}

4 torque of cylin-
der head 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}
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)
Tightening Bucket 324 ± 32.5 Nm {33 ± 3.3 kgm} (Width across flats: 32 mm)
5 torque of cylin-
der piston 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)
10-30 PC18MR-2
Structure, function and maintenance standard Solenoid valve
Solenoid valve
A: To PPC valve
B: To 2nd travel speed selector valve
P: From hydraulic pump
T: To hydraulic tank
1. PPC lock solenoid valve

2. 2nd travel speed selector solenoid valve
3. Control relief valve
Solenoid valve Control relief valve

4. Coil (ON/OFF type) 9. Adjustment screw
5. Push pin 10. Locknut
6. Valve spool 11. Plug
7. Return spring 12. Return spring
8. Valve body 13. Cover
14. Plunger
PC18MR-2 10-31
2nd travel speed selector solenoid valve

PPC lock solenoid valve
Operation
When solenoid is turned OFF When solenoid is turned ON
(When circuit is shut off) (When circuit is connected)
• While the signal current is not flowing from the • While the signal current is flowing from the PPC
PPC lock solenoid valve or travel speed selector lock solenoid valve or travel speed selector
switch, solenoid (1) is turned OFF. switch to solenoid (1), solenoid (1) is turned ON.
Accordingly, spool (2) is pressed up by spring • Accordingly, spool (2) is pressed down by push
(3). pin (4).
• As a result, ports P and A are shut off from each • As a result, ports P and A are connected to each
other and the pilot pressure does not flow into other and the pilot pressure flows into the actua-
the actuator. tor.
At the same time, the oil from the actuator flows At the same time, the port T is closed and the oil
through ports A and T to the hydraulic tank. does not flow to the hydraulic tank.
10-32 PC18MR-2
Control relief valve

Operation
• 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}
PC18MR-2 10-33
Structure, function and maintenance standard Variable gauge valve
Variable gauge valve
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)
10-34 PC18MR-2
Structure, function and maintenance standard Multi-control valve
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).
PC18MR-2 10-35
Structure, function and maintenance standard Hydraulic pump
Hydraulic pump
Main pump
Model: PVK-OB-163-K-4827Z
P1 : Main pump discharge 1. Main pump (piston pump)

P2 : Gear pump discharge 2. Gear pump
PLS : LS pressure inlet 3. LS valve
S1 : Pump suction
10-36 PC18MR-2
1. Input shaft
2. Rocker pin
3. Swash plate
4. Piston
5. Cylinder block
6. Valve plate
7. Spring
8. Control piston
PC18MR-2 10-37
Function Operation
• This pump converts the engine torque transmit- • As shaft (5) revolves, cylinder block (1) revolves
ted to its shaft into hydraulic pressure and sup- and pistons (2) in it reciprocate according to the
plies the hydraulic oil according to the load. movement of rocker cam (4) to suck and dis-
• The delivery can be changed by changing the charge the oil.
swash plate angle. • Accordingly, 9 pistons (2) perform 1 cycle of suc-
• This pump has the constant-horsepower control tion and discharge each time cylinder block (1)
function and the load-sensitive control function revolves. If shaft (5) revolves continuously, the
oil is sucked and discharged continuously.
Structure • Since the displacement of pistons (2) depends
• Cylinder block (1) has 9 pistons (2) in it and its on the inclination of rocker cam (4), the dis-
end is in contact with valve plate (3). Valve plate charge can be changed by changing the inclina-
(3) has suction port A and discharge port B. tion of rocker cam (4).
• Rocker cam (4) is fixed to body S at a certain
angle. Piston (2) revolves along rocker cam (4).
a: Suction stroke
b: Discharge stroke
c: Suction
d. Discharge
10-38 PC18MR-2
1. Constant-horsepower control • If the discharge pressure increases further, the

• Rocker pin (6) is installed to rocker cam (4) and inclination of rocker cam (4) is decreased.
they are so installed to body S that the angle of • At this time, the length of the arm receiving com-
rocker cam (4) can be changed. bined force F1 of the pistons is reduced from a
• Spring (7) and pistons (2) of cylinder block are to a'. Accordingly, larger force F1 is necessary
so arranged that they will be against each other for the inclination of rocker cam (4).
through rocker cam (4). Discharge pressure P1
is applied to pistons (2).
• 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).
• 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.
• As a result, the P – Q curve is so changed that

the engine horsepower will be used efficiently
(constant-horsepower control).
PC18MR-2 10-39
2. Load-sensitive control 3. All-horsepower control

• In the load-sensitive control mode, the signal • Rod (8) is arranged in the position against spring
pressure from the LS valve is transmitted to con- (7) and discharge pressure P2 is applied to it.
trol piston (9), which presses rocker cam (4). • As discharge pressure P2 is increased, the incli-
• Rocker cam (4) is slanted to change the dis- nation of rocker cam (4) is reduced.
charge until the above pressure, spring force, • Accordingly, the horsepower used by the whole
and combined force F1 of the pistons are bal- pump is kept constant, even if pressure P2 rises.
anced.
• Since the load-sensitive control gives the con-
stant-horsepower control priority, the discharge
is controlled within the flow range of the con-
stant-horsepower control.
10-40 PC18MR-2
4. LS valve
• The LS valve controls the pump discharge
according to the stroke of the control lever, or
the demand flow for the actuator.
• The LS valve detects the demand flow for the
actuator from differential pressure PLS
between pump discharge pressure P1L and
control valve outlet pressure PLS and controls
pump discharge Q (P1L is called the pump dis-
charge pressure, PLS the LS pressure, and
PLS the LS differential pressure).
• In other words, the pressure loss caused by
flowing of oil through the opening of the control
valve spool (= LS differential pressure PLS) is
detected, and then pump discharge Q is con-
trolled to keep that pressure loss constant and
supply the pump discharge according to the
demand of flow for the actuator.
PC18MR-2 10-41
Structure, function and maintenance standard Control valve
Control valve
a The control valve is an add-on type where one
service valve each can be added, so it is possi-
ble to add valves or remove valves if necessary.
a The service valve is installed additionally
between the top cover and lower valve.
a As for the 9-spool USA apec. valve, only the
parts different from the 9-spool KUK spec. valve
are shown.
9-spool valve (without port relief valve):
For KUK specification
9-spool valve (with port relief valve):
For USA specification
C : Cooler port (To oil cooler)

P : Pump port (From main pump)
S : Swing motor suction port [To swing motor port (S)]
T : Tank port (To hydraulic tank)
A1 : To arm cylinder bottom
A2 : To swing motor (MA)
A3 : To left travel motor (forward)
A4 : To right travel motor (forward)
A5 : To boom cylinder head
A6 : To bucket cylinder bottom
A7 : To blade cylinder head
A8 : To boom swing cylinder head
A9 : To attachment actuator
B1 : To arm cylinder head
B2 : To swing motor (MB)
B3 : To left travel motor (reverse)
B4 : To right travel motor (reverse)
B5 : To boom cylinder bottom
B6 : To bucket cylinder bottom
B7 : To blade cylinder bottom
B8 : To boom swing cylinder bottom
B9 : To attachment actuator
LS : Port (LS) (To pump LS valve)
PP : To pump LS valve
PS : To swing brake (Swing holding brake release port)
TS : Seal drain port (To tank)
PA1: From arm dump PPC valve
PA2: From swing right PPC valve
PA3: From left travel forward PPC valve
PA4: From right travel forward PPC valve
PA5: From boom raise PPC valve
PA6: From bucket curl PPC valve
PA7: From blade raise PPC valve
PA8: From boom swing right PPC valve
PA9: From attachment PPC valve
PB1: From arm in PPC valve
PB2: From swing left PPC valve
PB3: From left travel reverse PPC valve
PB4: From right travel reverse PPC valve
PB5: From boom lower PPC valve
PB6: From bucket dump PPC valve
PB7: From blade lower PPC valve
PB8: From boom swing left PPC valve
PB9: From attachment PPC valve
10-42 PC18MR-2
1. 9 spool valve (For KUK specification)

(1/5)
PC18MR-2 10-43
(2/5)
10-44 PC18MR-2
1. Suction valve (attachment)

2. Suction valve (boom swing head)
3. Suction valve (bucket bottom)
4. Suction valve (boom head)
5. Suction valve (arm bottom)
6. Suction valve (boom bottom)
7. Suction valve (attachment)
8. Safety valve
9. Spool (attachment)
10. Spool (boom swing)
11. Spool (blade)
12. Spool (bucket)
13. Spool (boom)
14. Spool (R.H. travel)
15. Spool (L.H. travel)
16. Spool (swing)
17. Spool (arm)
18. Main relief valve
Unit: mm

Spool return spring
Free length Installed Installed Free Installed
(boom swing, blade, bucket,
19 x OD length load length load
boom, R.H. travel, L.H. travel
22.6 N 18.1 N Replace
and arm) 29.0 x 17.5 28.5 —
{2.30 kg} {1.84 kg} spring if dam-
aged or
Spool return spring 17.7 N 14.2 N deformed
20 20.25 x 17.6 19.85 —
(swing) {1.81 kg} {1.45 kg}
Spool return spring 68.2 N 54.6 N
21 13.1 x 16.7 7.45 —
(swing) {6.95 kg} {5.56 kg}
PC18MR-2 10-45
(3/5)
10-46 PC18MR-2
1. Buck pressure check valve 14. Pressure compensation valve

2. Unload valve (R/blade)
3. Pressure compensation valve 15. Pressure compensation valve
(F/arm) (R/bucket)
(F/swing) (R/boom)
(F/L.H. travel) (R/R.H. travel)
(F/R.H. travel) (R/L.H. travel)
(F/boom) (R/swing)
(F/bucket) (R/arm)
9. Pressure compensation valve 21. LS bypass plug
(F/blade) 22. Oil cooler bypass valve
10. Pressure compensation valve 23. Main relief valve
(F/boom swing)
11. Pressure compensation valve F: Flow control valve
(F/attachment) R: Pressure reducing valve
12. Pressure compensation valve
(R/attachment)
(R/boom swing)
Unit: mm

Pressure compensation valve
spring
(boom swing, blade, bucket,
boom and arm) 7.64 N 6.11 N
16.9 x 8.40 15.0 —
{0.78 kg} {0.62 kg}
9.75 N 7.8 N
25 spring 22.5 x 8.40 18.2 —
{0.99 kg} {0.80 kg}
(right travel and left travel) Replace
spring if dam-
4.3 N 3.44 N aged or
26 spring 20.0 x 8.40 15.0 —
{0.44 kg} {0.35 kg} deformed
(swing)
82.4 N 65.9 N
27 Unload valve spring 29.1 x 18.7 18.0 —
{8.4 kg} {6.7 kg}
78.8 N 63.04 N
28 Oil cooler bypass spring 27.2 x 13.2 21.0 —
{8.04 kg} {6.43 kg}
Buck pressure check valve 15.3 N 12.2 N
29 29.0 x 13.3 21.0 —
spring {1.56 kg} {1.25 kg}
PC18MR-2 10-47
(4/5)
10-48 PC18MR-2
1. Pressure compensation valve (F/arm)

2. Spool (arm)
3. Check valve
4. Suction valve
5. Pilot check valve
6. Pressure compensation valve (R/arm)
7. Pressure compensation valve (F/swing)
9. Spool (swing)
11. Pressure compensation valve (R/swing)
12. Pressure compensation valve (F/L.H. travel)
13. Spool (L.H. travel)
14. Pressure compensation valve (R/L.H. travel)
15. Pressure compensation valve (F/boom)
16. Suction valve
17. Spool (boom)
18. Check valve
19. Suction valve
20. Pressure compensation valve (R/boom)
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Replace
Check valve spring spring if dam-
(boom and arm) aged or
1.96 N 1.57 N deformed
21.9 x 5.0 15.8 —
{0.20 kg} {0.16 kg}
PC18MR-2 10-49
(5/5)
10-50 PC18MR-2
1. Pressure compensation valve (F/bucket)

2. Spool (bucket)
3. Check valve
4. Suction valve
5. Pressure compensation valve (R/bucket)
6. Pressure compensation valve (F/blade)
7. Spool (blade)
8. Pressure compensation valve (R/blade))
9. Pressure compensation valve (F/boom swing)
10. Spool (boom swing)
11. Suction valve
12. Pressure compensation valve (R/boom swing)
13. Suction valve
14. Suction valve
15. Spool (attachment)
16. Pressure compensation valve (R/attachment)
17. Pressure compensation valve (F/attachment)
18. Safty valve
19. Air bleeding plug
20. Safty valve circuit filter
F : Flow control valve

R : Pressure reducing valve
Unit: mm

Replace
Check valve spring spring if dam-
(bucket) aged or
1.96 N 1.57 N deformed
21.9 x 5.0 15.8 —
{0.20 kg} {0.16 kg}
PC18MR-2 10-51
2. 9 spool valve (For USA specification)

a Port names, part names, criteria of springs, tightening torque, sectional drawings, etc. which are not shown
in this drawing are the same as those of the KUK specification.
10-52 PC18MR-2
A9: To attachment actuator

B9: To attachment actuator
PA9: To attachment PPC valve
PB9: To attachment PPC valve
1. Pressure compensation valve (F/attachment)

2. Pressure compensation valve (R/attachment)
3. Spool (Attachment)
4. Port relief valve
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Pressure compensation valve Replace
spring spring if dam-
6.86 N 5.49 N aged or
20.0 x 8.40 12.0 —
Spool return spring 22.6 N 18.1 N
6 29.0 x 17.5 28.5 —
(Attachment) {2.30 kg} {1.80 kg}
PC18MR-2 10-53
Structure, function and maintenance standard CLSS
CLSS
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- • The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
• Fine control not influenced by load • The pump body consists of the main pump, TCC
• Control enabling digging even with fine control valve and LS valve.
• Ease of compound operation ensured by flow
divider function using area of opening of spoll
during compund operations
• Energy saving using variable pump control
10-54 PC18MR-2
Basic principle • If LS differential pressure PLS becomes lower

than the set pressure of the LS valve (when the
1. Control of pump swash plate angle
actuator load pressure is high), the pump swash
• The pump swash plate angle (pump discharge
plate moves towards the maximum position; if
amount) is controlled so that LS differential pres-
the set pressure becomes higher than the set
sure PLS (the difference between pump (dis- pressure of the LS valve (when the actuator load
charge) pressure PP and control valve outlet pressure is low), the pump swash plate moves
port LS pressure PLS) load pressure of actua- towards the minimum position.
tor) is constant.
(LS pressure PLS=Pump discharge pressure LS differential pressure PLS and pump swash
PP-LS pressure PLS) plate angle
a For details of the operation, see HYDRAULIC

PUMP.
PC18MR-2 10-55
2. Pressure compensation control

• A pressure compensation valve is installed to
the inlet port side of the control valve spool to
balance the load.
When to actuators are operated together, this
valve acts to make pressure difference P
between the upstream (inlet port) and down-
stream (outlet port) the same, regardless of the
size of the load (pressure). In this way, 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.
10-56 PC18MR-2
Structure, function and maintenance standard Operation for each function and valve
Operation for each function and valve

Hydraulic circuit diagram and name of valve
1. 9 Spool valve (For KUK specification)
10-58 PC18MR-2
1. Unload valve
Set pressure : LS pressure + 2.9 MPa {30 kg/cm2}
2. Safety valve
Set pressure : 27.9 MPa {285 kg/cm2}
4. Suction valve
5. Main relief valve
Set pressure : 23 MPa {235 kg/cm2}
6. Back pressure check valve
Set pressure : 0.14 MPa {1.4 kg/cm2}
7. Oil cooler bypass valve
Set pressure : 0.4 MPa {4 kg/cm2}
8. Check valve (For swing holding brake release system)
9. Pilot pressure check valve
2. 9 spool valve (For USA specification)

a All except the attachment valve circuit are the same as the hydraulic circuit of the KUK specification.
1. Port relief valve

Set pressure: 17.2 MPa {175 kg/cm2}
PC18MR-2 10-59
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. Spool
2. Spring
Function Operation
• When the control valve is at neutral, pump dis- • On the left side of spool (1), pump discharge
charge amount Q discharged by the minimum pressure PP is applied to the area of S1. On the
swash plate angle is released to the tank circuit. right side, pump discharge pressure PP is
When this happens, pump discharge pressure applied to the area of S2 and LS pressure PLS
PP is set at 1.9 MPa {19.7 kg/cm2} by spring (2) is applied to the area of S3.
inside the valve. (LS pressure PLS : 0 MPa {0 • When the control valve is at neutral, LS pressure
kg/cm2}. PLS is 0, so only pump discharge pressure PP
has any effect, and PP is set only by the load of
spring (2).
• Spool (1) moves to the right until pump dis-
charge pressure PP rises and PP x S1 = PP x
S2 + force of spring (2). Pump circuit PP is con-
nected to tank circuit T through the hole of spool
(1).
• In this way, pump discharge pressure PP is set
to 1.9 MPa {19.7 kg/cm2}.
10-60 PC18MR-2
2. When control valve is in fine control
A : To each valve
T : Tank circuit
PP : Pump circuit
PLS: LS circuit
1. Spool
2. Spring
Function Operation
• When the control valve is in the fine control • When the control valve is operated finely, LS
mode, if the demand flow for actuator is less pressure PLS is generated and applied to area
than the value corresponding to the minimum S3 at the right end of spool (1). At this time, dif-
swash plate angle of the pump, pump pressure ference between LS pressure PLS and pump
PP is set to LS pressure PLS + 1.9 MPa {19.7 discharge pressure PP is large, since the open-
kg/cm 2 }. If the difference pressure between ing area of the control valve spool is narrow.
pump pressure PP and LS pressure PLS • When the difference between pump discharge
becomes equal to the load of spring (2) (1.9 pressure PP and LS pressure PLS reaches the
MPa {19.7 kg/cm 2 }), the unload valve opens. load of spring (2), spool (1) moves to the right
Accordingly, LS differential pressure PLS is and pump circuit PP and tank circuit T are con-
(1.9 MPa {19.7 kg/cm2}) at this time. nected to each other.
• 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 PLS becomes 1.9 MPa
{19.7 kg/cm2}.
PC18MR-2 10-61
3. When control valve is being operated (work equipment)
A : To each valve
T : Tank circuit
PP : Pump circuit
PLS: LS circuit
1. Spool
2. Spring
Function
• When the control valve is operated, if the
demand flow for actuator exceeds the value cor-
responding to the minimum swash plate angle of
the pump, the outflow to tank circuit T is shut off
and all of pump discharge amount Q is sent to
the actuator circuit.
Operation
• 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, dif-
ference between LS pressure PLS and pump
discharge pressure PP is small, since the open-
ing area of the control valve spool is wide.
• 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/cm 2 }), so spool (1) is
pushed to the left by spring (2).
• As a result, pump circuit PP and tank circuit T
are shut off, and all the pump discharge amount
Q flows to the actuator circuit (3).
10-62 PC18MR-2
Introduction of LS pressure
1. Work equipment valve (boom, arm, bucket, boom swing, blade, swing)
Function Operation
• The LS pressure is the actuator load pressure at • When spool (1) operated, pump pressure PP
the outlet port end of the control valve. flows from flow control valve (2) and notch a in
• With the control valve, it actually reduces pump the spool (1) through bridge passage b to actua-
pressure PP at reducing valve (3) of the pres- tor circuit A.
sure compensation valve to the same pressure • At the same time, reducing valve (3) also moves
as actuation circuit pressure A, and sends it to to the right, so pump pressure PP is reduced by
the LS circuit PLS. the pressure loss at notch c, and then applied
though LS circuit PLS to spring chamber PLS1.
• When this happens, LS circuit PLS is connected
to tank circuit T from LS bypass plug (4) (see the
section on the LS bypass plug).
• 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.
• 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.
PC18MR-2 10-63
LS bypass plug
T : Tank circuit
PP : Pump circuit
PLS: LS circuit
1. LS bypass plug
2. Valve cover
Function
• This releases the residual pressure of LS pres-
sure PLS.
• 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.
Operation
• The pressurized oil for LS circuit PLS passes
from filter a of bypass plug (1) through orifice b
and flows to the tank circuit T.
10-64 PC18MR-2
Function Operation
• During compound operations, if the load pres- • If the load pressure on the other actuator side
sure becomes lower than the other actuator and (right side) is increased during compound opera-
the oil flow tries to increase, compensation is tion, the flow in actuator circuit A on this side
received. (left side) is increased.
(When this happens, the other actuator being • At this time, LS pressure PLS of the other actua-
used for compound operation (right side) is at a tor acts on spring chamber PLS1 and pushes
higher load than the actuator on this side (left reducing valve (1) and flow control valve (2) to
side).) the left.
• 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.
• 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 con-
trol valve (2) and PPA.
• 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-2 10-65
1. Area ratio of pressure compensation valve
Function Area ratio (S1:S2) and compensation character-

• The pressure compensation valve finely adjusts istics
the ratio of (left) area S1 of flow control valve (2) • When 1.00: [Pump (discharge) pressure PP –
to (right) area S2 of reducing valve (1) and Spool cut upstream pressure PPA]
decides the compensation characteristics C LS circuit pressure PLS - Actua-
according to the characteristics of each actuator. tor circuit pressure PA (= A)] As a
S1: Area of flow control valve (2) – Area of pis- result, the oil is divided according to
ton (3) the opening area ratio of the spool.
S2: Area of reducing valve (1) – Area of piston • When above 1.00: PP – PPA > PLS – PA (= A)
(3) As a result, less oil is supplied
to the compensated side by
the area ratio of the spool.
• When below 1.00: PP – PPA < PLS – PA (= A)
As a result, more oil is sup-
plied to the compensated side
by the area ratio of the spool.
10-66 PC18MR-2
2. LS introduction throttle of pressure compensation valve
Function
• If the other actuator is relieved during compound
operation, more oil is supplied through LS intro-
duction throttle b of reducing valve (1).
Operation
• If the other actuator side (right side) is relieved
during compound operation, each circuit pres-
sure (PPA, PA) of the other actuator becomes
the same as the pump circuit pressure (PP =
Relief pressure).
• 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).
• PLS2 is led through LS introduction throttle b of
reducing valve (1) and it becomes PLS. Since
PLS is connected through LS bypass plug (4) to
tank circuit T, a pressure loss is made in LS
introduction throttle b (PLS < PLS2).
• 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 die (left side).
PC18MR-2 10-67
L.H., R.H. travel junction circuit
1. When traveling in a straight line
Function Operation
• To compensate for any difference in the oil flow • When left and right travel spools (1) are oper-
in the left and right travel circuits when traveling ated, the pump discharge flows from pump cir-
in a straight line, the junction circuit opens when cuit PP and circuits PA to actuator circuits B.
the left and right travel spools are operated. • When traveling in a straight line, to make actua-
• In this way, the flow of oil to the left and right tor circuits PA equal, left and right reducing
travel motors is almost the same when traveling valves (2) are pushed to the right by the same
in a straight line, so there is no travel deviation. amount, and notch a and the travel junction cir-
• When steering the machine, the difference in the cuit are opened.
load pressure returns the reducing valve of the • In this way, the left and right travel actuator cir-
travel valve on the inside of the turn and the cuits are interconnected by the travel junction
opening of the notch in the travel junction valve circuit, so if any difference occurs in the flow of
spool becomes smaller, so the machine can be oil to the left and right travel motors, the com-
steered. pensation is carried out to prevent any deviation
in travel.
10-68 PC18MR-2
2. Steering when traveling
Operation
• 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.
• 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.
• 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.
PC18MR-2 10-69
Swing holding brake cancel system
Function Operation
• This system resets the swing holding brake by • The left and right swing PPC pressure and the
using left and right swing PPC pressures and arm IN PPC pressure each pass through check
arm IN PPC pressure as signals. valve (2) inside spring case (1), are output to
port BR and the swing holding brake is can-
celed. (The highest pressure is output to port
BR).
• The arm and swing are connected by the pilot
circuit inside the control valve.
10-70 PC18MR-2
Structure, function and maintenance standard Swing motor
Swing motor
Model: 104-6404-005+V2TD3A
A : From control valve Specifications

B : From control valve Model : 104-6404-005+V2TD3A
L : From control valve (PPC valve pressure signal) Delivery of motor : 195 cm3/rev
P : Pilot port Max. using speed : 57.8 rpm
T : To tank 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}
10-72 PC18MR-2
1. Pinion gear 12. Valve

2. Front bearing 13. Suction valve
3. Housing 14. Valve drive shaft
4. Plate 15. Spring
5. Disc 16. Piston
6. Flange 17. Ring
7. Rear bearing 18. Drive shaft
8. Geroller 19. Safety valve
9. Valve plate 20. Safety valve
10. Outer face seal 21. Timer valve
11. Inner face seal
PC18MR-2 10-73
Operation
Note) When the motor revolves in the opposite direction, the oil flows in the opposite direction to the above fig-
ure.
1. Output shaft 5. Valve plate

2. Main drive 6. Valve drive
3. Giroller 7. Disc valve
4. Star 8. Check valve
• The oil from the pump through the control valve • In other words, output shaft (1) is rotated by
flows through disc valve (7) to geroler (3), and main drive (2). At the same time, rotation of star
then start (4) of the geroler makes planetary (4) of geroler (3) is taken out by valve drive (6)
movements. and transmitted to disc valve (7), thus the motor
• Only the rotation of the planetary movements is is rotated by the oil flowing in the geroler.
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.
10-74 PC18MR-2
Structure, function and maintenance standard PPC valve
PPC valve
1. For work equipment, swing PPC valve
P : From solenoid valve

T : To tank
P1 : L.H. PPC Arm IN / R.H. PPC Boom RISE
P2 : L.H. PPC Arm OUT / R.H. PPC Boom LOWER
P3 : L.H. PPC Swing RIGHT / R.H. PPC Bucket DUMP
P4 : L.H. PPC Swing LEFT / R.H. PPC Bucket CURL
10-76 PC18MR-2
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
Unit: mm

Centering spring
(for P3, P4 port)
9.81 N 7.85 N Replace
38.7 x 15.5 34.0 — spring if dam-
{1.0 kg} {0.8 kg}
aged or
Centering spring 17.7 N 14.1 N deformed
13 42.5 x 15.5 34.0 —
(for P1, P2 port) {1.8kg} {1.44 kg}
16.7 N 13.7 N
14 Metering spring 26.5 x 8.15 24.9 —
{1.70 kg} {1.40 kg}
PC18MR-2 10-77
Operation • The relationship in the position of spool (1) and

1. At neutral body (10) (fine control hole f is at a point midway
• Ports A and B of the control valve and ports P1 between drain hole D and pump pressure cham-
and P2 of the PPC valve are connected to drain ber PP) does not change until retainer (9) con-
chamber D through fine control hole f in spool tacts spool (1).
(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 bal-
anced.
2. During fine control (neutral o fine control)

• 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.
• 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, so pilot pressure oil from the control pump
passes through fine control hole f and goes from
port P1 to port A.
• 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.
• When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1.
10-78 PC18MR-2
3. During fine control 4. At full stroke

(when control lever is returned) • When disc (5) pushes down piston (4), and
• When disc (5) starts to be returned, spool (1) is retainer (9) pushes down spool (1), fine control
pushed up by the force of centering spring (3) hole f is shut off from drain chamber D, and is
and the pressure at port P1. connected with pump pressure chamber PP.
• When this happens, fine control hole f is con- • Therefore, the pilot pressure from the control
nected to drain chamber D and the pressure oil pump passes through fine control hole f and
at port P1 is released. flows to chamber A from port P1, and pushes
• If the pressure at port P1 drops too far, spool (1) the control valve spool.
is pushed down by metering spring (2), and fine • The oil returning from chamber B passes from
control hole f is shut off from drain chamber D. port P2 through fine control hole f' and flows to
At almost the same time, it is connected to pump drain chamber D.
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever posi-
tion.
• 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-2 10-79
2. For travel PPC valve

a For operation, see the sections of the work equipment and swing PPC valve.
P : From solenoid valve

T : To tank
P1 : Right forward
P2 : Right reverse
P3 : Left forward
P4 : Left reverse
10-80 PC18MR-2
1. Piston
2. Plate
3. Collar
4. Body
5. Valve
6. Metering spring
7. Centering spring
8. Bolt
PC18MR-2 10-81
3. For blade, boom swing PPC valve

a For operation, see the sections of the work equipment and swing PPC valve.
P : From solenoid valve 1. Spool

T : To tank 2. Metering spring
P1 : To blade RAISE, boom swing RIGHT valve 3. Centering spring
P2 : To blade LOWER, boom swing LEFT valve 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
9. Filter
10-82 PC18MR-2
For blade PPC valve

Unit: mm

10 Centering spring x OD length load length load Replace
spring if dam-
147 N 118 N aged or
42.4 x 15.5 32.5 —
{15 kg} {12 kg} deformed
16.7 N 13.3 N
{1.70 kg} {1.36 kg}
For boom swing PPC valve

Unit: mm

10 Centering spring x OD length load length load Replace
spring if dam-
125 N 100 N aged or
33.9 x 15.3 28.4 —
16.7 N 13.3 N
{1.70 kg} {1.36 kg}
PC18MR-2 10-83
Structure, function and maintenance standard Work equipment
Work equipment
PC18MR-2 10-85
10-86 PC18MR-2
Unit: mm

Clearance between mounting size clearance limit
Shaft Hole
1 pin of revolving frame and
swing bracket and bushing –0.036 +0.153 0.115 –
ø55 1.0
–0.090 +0.079 0.243
Clearance between mounting
–0.025 +0.115 0.078 –
2 pin of swing bracket and ø35 1.0
–0.064 +0.053 0.179
boom and bushing
–0.025 +0.086 0.061 –
3 pin of boom and arm and ø30 1.0
–0.064 +0.036 0.15
bushing
–0.090 +0.087 0.124 – Replace pin
4 pin of arm and bucket and ø30 1.0
–0.130 +0.034 0.217 and bushing
bushing
–0.090 +0.087 0.124 –
5 pin of link and bucket and ø30 1.0
–0.130 +0.034 0.217
bushing
Clearance between mounting –0.090 +0.087 0.124 –
6 ø30 1.0
pin of links and bushing –0.130 +0.034 0.217
–0.090 +0.087 0.124 –
7 pin of arm and link and bush- ø30 1.0
–0.130 +0.034 0.217
ing
–0.010 +0.070 0.05 –
8 pin of track frame and blade ø30 1.0
–0.050 +0.040 0.12
and bushing
PC18MR-2 10-87
Structure, function and maintenance standard Dimensions of each part of work equipment
Dimensions of each part of work equipment

Arm section
10-88 PC18MR-2
Unit: mm
Tolerance
No. Measuring point Standard size
Shaft Hole
–0.01 +0.039
1 — ø30
–0.05 +0.000
–0
Arm side 42
–1
2
–0.5
Cylinder head side 40
–0.5
–0.09 +0.086
3 — ø30
–0.13 +0.036
Boom side 97 ±0.25

4
+0.0
Arm side 96.5
–0.5
5 — 235.2 ±0.5
6 — 84.2 ±0.5
7 — 242.2 ±0.5
8 — 1,114.7 ±3
9 — 56.8 ±0.5
10 — 149.7 —
11 — 5 ±1
12 — 210 ±0.5
13 — 193 ±0.1
14 — 124 ±1
15 — 527 —
–0.090 +0.087
16 — ø30
–0.130 +0.034
0.
Link side 118
–0.5
17
+1.0
Bucket side 119
–0.5
–0.090 +0.087
18 — ø30
–0.130 +0.034
0.
Arm side 118
–0.5
19
+1.0
Bucket side 119
–0.5
Min. 706 ±1
20
Max. 1,153 —
21 — 965 ±3
PC18MR-2 10-89
Bucket section
Unit: mm
No. Measuring point Standard size Tolerance
1 — 124 ±1
2 — 4 ±1
3 — 440.6 ±1
4 — 33 —
5 — 33 —
6 — 25° —
7 — 45° —
8 — ø11 —
+1.0
9 — 119
–0.5
10 — 44 —
11 — 25 —
12 — 176 ±1
13 — ø50 —
14 — ø50 —
— ø30 +0.033
15 +0.009
10-90 PC18MR-2
Structure, function and maintenance standard Floor
Floor
Tilt floor
1. Hinge pin Outline

2. Torsion bar • The tilt floor can be tilted open for the ease of
3. Lock pin adjusting of the fan belt, inspection and mainte-
4. Gas spring nance such as replacement of the hydraulic
5. Reset lever hoses, etc.
6. Wire Tilt open angle a: Approx. 50°
7. Tilt lock bracket
8. Floor assembly
PC18MR-2 10-91
Structure, function and maintenance standard Engine control
Engine control
1. Battery
2. Starting switch
3. Fuse box
4. Engine stop solenoid
5. Safety lock lever
6. PPC lock switch
7. Neutral-engine start relay
8. Safety relay
9. Starting motor
10. Fuel control lever
10-92 PC18MR-2
Structure, function and maintenance standard Engine control
Starting engine
• 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.
• If starting switch (2) is set to the START position
while safety lock lever (5) is in the LOCK posi-
tion, the start signal flows in starting motor (9)
and the engine starts. If safety 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.
Engine speed control

• If fuel control lever (10) is operated, the cable is
extended or retracted to control the engine
speed.
Stopping engine
• If starting switch (2) is set in the OFF position,
engine stop solenoid (4) sets the governor stop
lever in the STOP position to stop the engine.
PC18MR-2 10-93
Structure, function and maintenance standard Electric control system
Electric control system

General system drawing
10-94 PC18MR-2
1. Battery
2. Starting switch
3. Fuse box
4. Monitor panel
5. 2nd travel speed selection switch
6. 2nd travel speed selection solenoid relay
7. Safety lock lever
8. PPC lock switch
9. PPC lock solenoid relay
10. 2nd travel speed selection solenoid valve
11. PPC lock solenoid valve
12. Right work equipment PPC valve
13. Travel PPC valve
14. Left work equipment PPC valve
15. Boom swing PPC valve
16. Blade PPC valve
17. Travel motor
18. Engine
19. Hydraulic pump
19a. Servo valve
19b. LS valve
19c. PC valve
20. Control valve
20a. Self-reducing pressure valve
PC18MR-2 10-95
Travel control function
1. Battery Input and output signals

2. Starting switch a. Solenoid power supply
3. Fuse box b. 2nd travel speed selection signal
4. 2nd travel speed selection switch c. Solenoid valve drive signal
5. 2nd travel speed selection solenoid relay
6. 2nd travel speed selection solenoid valve
7. Left travel motor
8. Right travel motor
9. Control valve
10. Engine
11. Hydraulic pump
10-96 PC18MR-2
Function
Changing travel speed
2nd travel speed
• If the travel speed selector switch of the monitor Low speed High speed
selection switch
panel is operated, the motor capacity changes,
2nd travel speed
thus the travel speed changes. OFF ON
selection monitor
2nd travel speed
a Even while the machine is traveling at the high selection solenoid OFF ON
speed (High), if the load changes largely on a valve
soft ground or on a slope, the travel speed is set
Motor capacity cm3/rev 12.4 6.2
to the low speed (Low) automatically. At this
time, the 2nd travel speed selection monitor Travel speed km/h 2.3 4.3
keeps lighting up.
Travel motor
Max. Min.
swash plate angle
17.8 ± 1 MPa
A
{181 ± 10 kg/cm2}
19.2 ± 1 MPa
B
{196 ± 10 kg/cm2}
PC18MR-2 10-97
PPC lock function
Function
1. Battery • The PPC lock switch is interlocked with the
2. Starting switch safety lock lever. If the safety lock lever is set in
3. Fuse box the LOCK position, the PPC lock switch is turned
4. Safety lock lever OFF.
5. PPC lock lever • If the PPC lock switch is turned OFF, the current
6. PPC lock solenoid relay flowing to the PPC lock solenoid valve is shut
7. PPC lock solenoid valve off. Then, the work equipment and machine unit
8. Left PPC valve do not move even if any control lever or pedal is
9. Right PPC valve operated.
10. Travel PPC valve
11. Boom swing PPC valve
12. Blade PPC valve
13. Engine
14. Hydraulic pump
15. Control valve
Input and output signals

a. PPC lock signal
b. Solenoid power supply
c. Solenoid valve drive signal
10-98 PC18MR-2
Structure, function and maintenance standard Component parts of system
Component parts of system

PPC lock solenoid valve
2nd travel speed selection solenoid valve

a See Solenoid valve.
Monitor panel
a See Monitor system.
PC18MR-2 10-99
Structure, function and maintenance standard Monitor system
Monitor system
1. Monitor panel Outline

2. Battery • The machine monitor system uses the net work
3. Each sensor circuit between the controllers and sensor
4. Working lamp installed to all parts of the machine to observe
5. Alarm buzzer the condition of the machine. It processes this
information, and display it on a panel to inform
Input and output signals the operator of condition of the machine.
a. Power supply
b. Sensor signal
c. Switch signal
d. Alarm buzzer signal
10-100 PC18MR-2
Structure, function and maintenance standard Monitor panel
Monitor panel
Outline
• The monitor panel has the monitor display function, gauge display function, and service meter function.
• The monitor switch section consists of 2 flat-type sheet switches. Each time either switch is pressed, the
machine condition changes.
• There is a CPU (Center Processing Unit) in the monitor panel to process, display, and output the informa-
tion.
• If the monitor panel has a failure, it does not display normally.
Input and output signals

KFS2P [CN-F7]
Input/Output
Pin No. Signal name
signal
1 Power supply (12 V) –
2 GND –
SWP14P [CN-F8]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 ACC power supply – 8 Backup light Input
2 Engine oil pressure Input 9 Fuel level Input
3 Charge level Input 10 GND –
4 Preheating (-) Output 11 NC –
5 Preheating (+) Input 12 NC –
6 Coolant temperature (+) Input 13 NC –
7 2nd travel speed Input 14 NC –
PC18MR-2 10-101
Structure, function and maintenance standard Monitor panel
Operation
Gauge and monitor display section

Category of Displayed Display
No. Display range Display method Remarks
display item color
Time is measured while engine is running
1 Service meter 0 – 99999.9 h — —
(while alternator is generating).
Coolant Above set tempera- Caution lamp flashes and alarm buzzer
2 Caution Red LED
temperature ture 105°C sounds.
Lamp lights up when starting switch is
turned ON and goes off after engine is
started.
Engine oil Below set pressure
3 Caution When normal: Lamp goes off. Red LED
pressure 49 kPa {0.5 kg/cm2}
When abnormal: Lamp flashes.
(If condition becomes abnormal while en-
gine is running, alarm buzzer sounds.)
Lamp flashes when starting switch is in
HEAT position. Alarm buzzer sounds
4 Pilot Preheating During preheating when preheating is finished, then lamp Yellow LED
goes off. (Preheating time: Approx. 18
sec)
5 Gauge Fuel level See above figure. Pointer indicates corresponding position. — —
Lamp lights up when starting switch is

turned ON and goes off after engine
When charging is
starts.
abnormal
6 Caution Charge level When normal: Lamp goes off. Red LED
(Charge voltage
When abnormal: Lamp flashes.
(Battery voltage))
(If condition becomes abnormal while en-
gine is running, alarm buzzer sounds.)
Lamp lights up when 2nd travel speed
2nd travel
When 2nd travel selector switch is turned ON.
7 Pilot speed Yellow LED
speed is selected [While machine is traveling, travel speed
selection
can be increased (automatically).]
10-102 PC18MR-2
Structure, function and maintenance standard Sensors
Sensors
• 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 Name of sensor Type of sensor When normal When abnormal
Caution Engine oil pressure Contact OFF (Open) ON (Closed)
Coolant temperature Contact OFF (Open) ON (Closed)
Gauge
Fuel level Resistance — —
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• The engine oil pressure sensor is installed to the engine cylinder block and its diaphragm senses oil pres-
sure. If the oil pressure lowers below the set level, the switch is turned ON.
Coolant temperature sensor
1. Reed switch 4. Magnet

2. Magnet 5. Plug
3. Thermo-ferrite 6. Connector
Function
• The coolant temperature sensor is installed to the engine cylinder block and its thermo-ferrite senses tem-
perature changes. If the temperature rises above the set level, the switch is turned ON.
PC18MR-2 10-103
Structure, function and maintenance standard Sensors
Fuel level sensor
1. Float 3. Variable resistor

2. Arm 4. Connector
Function
• The fuel level sensor is installed to the side 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.
10-104 PC18MR-2
20 Testing and adjusting
Standard value table for engine related

parts ........................................................ 20- 2
Standard value table for chassis related
parts ........................................................ 20- 3
Testing and adjusting ................................... 20-101
Troubleshooting............................................ 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
k When carrying out work together with other workers, always use signals and do not let unauthorized people
pins, and use blocks to prevent the machine from moving.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
near the machine.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
the water is still hot, the water will spurt out and cause burns.
PC18MR-2 20-1
(1)
Testing and adjusting Standard value table for engine related parts
Standard value table for engine related parts
Applicable model PC18MR-2
Engine 3D67E-1A
Standard value Service limit

Item Measurement condition Unit
for new machine value
High idling 2,780 ± 50 —
Engine speed Low idling rpm 1,475 ± 50 —
Rated speed 2,600 —
At sudden acceleration Max. 5.0 5.5

Bosch
Exhaust gas color
index
At high idling Max. 1.0 2.5
Intake valve 0.145 – 0.185 —

Valve clearance Normal temperature mm
Exhaust valve 0.145 – 0.185 —
Oil temperature:
40 – 60°C Compression MPa 3.0 – 3.4 2.5
Compression pressure
Engine speed: pressure {kg/cm2} {31 – 35} {25}
200 – 300 rpm
Coolant temperature:
kPa — —
Blow-by pressure Within operating range
{mmH2O} {—} {—}
At high idling
0.196 – 0.441
Coolant temperature: At high idling —
MPa {2.0 – 4.5}
Oil pressure Within operating range
{kg/cm2} Min. 0.098 —
oil: SAE30W At low idling
{1.0} {—}
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
Fuel injection timing BTDC °(degree) 19 ± 1 —
Deflection when pressed with finger force

Fan belt tension mm Approx. 10 —
of approx. 98 N{10 kg}
20-2 PC18MR-2
(1)
Testing and adjusting Standard value table for chassis related parts
Standard value table for chassis related parts

Machine model PC18MR-2
Cate- Standard value Service limit
Item Measurement conditions Unit
gory for new machine value
• Engine coolant temperature: Within oper-
Engine
speed
Speed when pump is ating range

rpm Min. 2,320 Min. 2,320
relieved • Hydraulic oil temperature: 45 – 55°C
• Relief of pump: Relieve bucket circuit.
Boom control valve
Arm control valve

Stroke of control valve spool
Bucket control valve
Swing control valve

l = 30 l = 30
aFor details, see Fig. Control valve at the
Breaker control valve mm a=6 a=6
end of this section.
b=6 b=6
Boom swing control
valve
Blade control valve
Left travel control

valve
Right travel control
valve
N o RAISE,
Boom control lever 80 ± 10 80 ± 10
LOWER
Arm control lever N o IN, OUT 80 ± 10 80 ± 10
N o CURL,
Bucket control lever 80 ± 10 80 ± 10
DUMP
Stroke of control lever and pedal
N o Swing to
Swing control lever 80 ± 10 80 ± 10
LEFT, RIGHT
• Stop engine. N o Swing
Boom swing control • Measure at center of boom to LEFT, 25 ± 5 25 ± 5
pedal lever grip. RIGHT
• Measure at pedal tip. mm
• Read max. value to N o RAISE,
Blade control lever 50 ± 5 50 ± 5
stroke end (excluding LOWER
neutral play). N o FOR-
Travel control lever WARD, 100 ± 10 100 ± 10
REVERSE
SLOW i
o FULL
Fuel control lever 160 ± 20 160 ± 20
THROTTLE
Work equip-
Max. 5 Max. 5
ment, swing
Play of control lever
Travel Max. 5 Max. 5
PC18MR-2 20-3
(1)

15.68 ± 4.9 15.68 ± 9.8
Boom control lever
Operating effort of control levers and pedals
{1.6 ± 0.5} {1.6 ± 1}

15.68 ± 4.9 15.68 ± 9.8
Arm control lever
{1.6 ± 0.5} {1.6 ± 1}
15.68 ± 4.9 15.68 ± 9.8
Bucket control lever
{1.6 ± 0.5} {1.6 ± 1}
• Hydraulic oil temperature: 45 – 55°C 15.68 ± 4.9 15.68 ± 9.8
Swing control lever • Run engine at full throttle.
N {1.6 ± 0.5} {1.6 ± 1}
• Install push-pull scale to center of lever
Boom swing control {kg} 78.4 ± 19.6 78.4 ± 29.4
grip or pedal tip to measure.
pedal • Read max. value to stroke end. {8.0 ± 2.0} {8.0 ± 3.0}
29.4 ± 9.8 29.4 ± 19.6
Blade control lever
{3.0 ± 1.0} {3.0 ± 2}
19.6 ± 4.9 19.6 ± 9.8
Travel control lever
{2.0 ± 0.5} {2.0 ± 1}
29.4 ± 14.7 29.4 ± 29.4
Fuel control lever
{3.0 ± 1.5} {3.0 ± 3}
• Hydraulic oil temperature: 45 – 55°C + 0.98 + 0.98
• Set all levers in neutral. 2.5 0 2.5 0
Unload pressure
• Run engine at full throttle. + 10 + 10
{25 0 } {25 0 }
• Measure pump outlet pressure.
+ 0.98 + 0.98
23.0 – 0.49 23.0 – 0.49
Boom relief pressure + 10 + 10
{235 – 5 } {235 – 5 }
+ 0.98 + 0.98
23.0 – 0.49 23.0 – 0.49
Arm relief pressure + 10 + 10
{235 – 5 } {235 – 5 }
+ 0.98 + 0.98
Bucket relief pres- 23.0 – 0.49 23.0 – 0.49
sure + 10
{235 – 5 }
+ 10
{235 – 5 }
• Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle and measure
19.1 ± 0.98 19.1 ± 0.98
Swing relief pressure relief pressure (Relieve only circuit to be
{195 ± 10} {195 ± 10}
measured).
Oil pressure
+ 0.98 + 0.98
Boom swing relief 23.0 – 0.49 23.0 – 0.49
MPa
pressure + 10
{253 – 5 }
+ 10
{253 – 5 }
{kg/cm2}
23.0 ± 0.98 23.0 ± 0.98

Blade relief pressure
{253 ± 10} {253 ± 10}
+ 0.98 + 0.98
23.0 – 0.49 23.0 – 0.49
Travel relief pressure + 10 + 10
{253 – 5 } {253 – 5 }

• Run engine at full throttle. + 0.39 + 0.39
Control circuit oil 3.72 – 0.1 3.72 – 0.1
• Measure circuit oil pressure when all con-
pressure +4
{38 – 1 } {38
+4
trol levers are in neutral. –1 }
When all 2.5
+ 0.98
2.5
+ 0.98
• Hydraulic oil tempera- 0 0
levers are in
ture: 45 – 55°C + 10 + 10
neutral {25 0 } {25 0 }
LS differential pres- • Run engine at full throt-
sure tle.
When arm
• Pump outlet pressure - 1.57 ± 0.1 1.57 ± 0.1
lever is moved
LS pressure {16 ± 1} {16 ± 1}
IN (half stroke)
20-4 PC18MR-2
(1)

• No load, max. reach
• Run engine at full throttle.
• Stop after swinging 1 turn and measure
deg. Max. 40 50
Overrun of swing shifting distance of swing circle.
(mm) (–) (–)
• Value in ( ) is shifting distance of outside
of swing circle.
• For measuring posture, see Fig. Swing 1
at end of this section.
• Run engine at full throttle. 90 deg. Max. 2.0 Max. 2.2
• Hydraulic oil temperature: 45 –
55°C
Time required to start
• Measure time required to pass
swinging
90-degree and 180-degree
points after starting swinging. 180 deg. — —
• For measuring posture, see Fig.
Swing 1 at end of this section. sec.
Swing
Time required for

• Measure time required to swing 5 turns 34 ± 3 Max. 41
swinging
after swinging 1 turn.
• Max. reach
• Stop engine.
• Fill bucket with rated load or dirt and
sand. (Rated load: 706 N {72 kg})
• Stop machine on slope of 15 degrees
Hydraulic drift of and set its upper structure at 45 degrees deg. 0 0
swing upward. (mm) (0) (0)
• Make match marks on swing circle outer
race and track frame.
• Measure shifting distance of match
marks in 15 minutes.
Leakage from swing • Run engine at full throttle.
cc/min. — —
motor • Relieve swing circuit and measure leak-
age in 1 minute.
• Run engine at full throttle. Low
31.3 ± 3 31.3 ± 6
• After approach run of at least 10 speed
m on flat ground, measure time
Travel speed required to travel 20 m. sec.
• ( ): Machine with steel shoe
specification High
16.7 ± 2 16.7 ± 4
• For measuring posture, see Fig. speed
Travel
Travel 1 at end of this section.

• Run engine at full throttle. Low
Max. 500 550
• After approach run of at least 10 speed
m on hard and flat ground, mea-
Travel deviation sure travel deviation X in the mm
travel of 20 m after approach
run. High
Max. 500 550
• For measuring posture, see Fig. speed
Travel 2 at end of this section.
PC18MR-2 20-5
(1)

• Stop engine.
• Stop machine on slope of 30 degrees
Hydraulic drift of with sprocket on upper side. mm 0 0
travel • Measure hydraulic drift of travel in 5 min-
Travel
utes.
• For measuring posture, see Fig. Travel 3
Leakage from travel • Hydraulic oil temperature: 45 – 55°C

• Run engine at full throttle. l/min. — —
motor • Lock shoe to relieve travel circuit.
Whole work • Measure extension and retraction of
equipment
(Hydraulic drift of each cylinder and lowering of bucket Max. 300 450
bucket tooth tip) tooth tip from above position.
• Stop machine on level and flat ground.
Boom cylinder • Bucket: Rated load
(Retraction of (Rated load: 706 N {72 kg}) Max. 35 70
cylinder) • Hydraulic oil temperature: 45 – 55°C
• Stop engine
Arm cylinder • Set lever in neutral.
(Extension of cyl- • Start measurement just after setting. Max. 25 50
inder) • Measure hydraulic drift every 5 minutes
for 15 minutes.
Hydraulic drift
Bucket cylinder
(Retraction of • For measuring posture, see Fig. Work Max. 10 20
cylinder) equipment 1 at end of this section.
mm
• Stop engine
• Bucket: Rated load
Boom swing cyl- (Rated load: 706 N {72 kg})
inder (Retraction
and extension of • Set machine in above position on slope Max. 20 30
cylinder) of 15 degrees with upper structure at
right angle to its body and measure
retraction and extension of cylinder for
15 minutes.
Work equipment
Blade (Hydraulic • Stop engine

drift of blade tip) • Measure hydraulic drift of blade tip from Max. 50 Max. 75
maximum raising height for 15 minutes.
55°C
• Run engine at full throttle. RAISE 2.0 ± 0.2 2.6
• Measure time required to move
cylinder between extension
Boom speed stroke end and position at which
bucket tooth is in contact with
ground.
• For measuring posture, see Fig. LOWER 2.0 ± 0.2 2.6
Work equipment 2 at end of this
Work equipment speed
section.
55°C IN 2.5 ± 0.3 3.1
• Measure time required to move sec.
Arm speed cylinder between extension and
retraction stroke ends.
• For measuring posture, see Fig. OUT 2.2 ± 0.2 2.6
section.
55°C CURL 2.2 ± 0.2 2.6
Bucket speed cylinder between extension and
retraction stroke ends.
• For measuring posture, see Fig. DUMP 1.7 ± 0.2 2.3
section.
20-6 PC18MR-2
(1)

• Hydraulic oil temperature: 45 – Swing
55°C boom to 5.0 ± 1.5 8.0
• Run engine at full throttle. LEFT
Boom swing • Measure time required to move
cylinder between extension and
speed retraction stroke ends. Swing
Work equipment speed
• For measuring posture, see Fig. boom to 5.0 ± 1.5 8.0

Work equipment 5 at end of this RIGHT
section.
55°C
• Run engine at full throttle. RAISE 1.0 ± 0.3 1.6
cylinder between position at
Blade speed which blade is in contact with
ground and maximum blade
raising position.
• For measuring posture, see Fig. LOWER 1.0 ± 0.3 1.6
section.
• Run engine slow.
• Set arm to OUT stroke end, bucket to
DUMP stroke end, and boom at RAISE
Boom time lag stroke end. Then, lower bucket and Max. 2 Max. 3.9
measure time required to raise machine
after bucket touches ground.
• For measuring posture, see Fig. Work sec.
Work equipment
equipment 7 at end of this section.

• Set upper side of boom horizontally,
bucket to DUMP stroke end, and arm to
Arm time lag IN stroke end. Then, move arm IN and Max. 1 Max. 2
measure time required to start it again
after it stops temporarily.
Time lag
• For measuring posture, see Fig. Work

• Set upper side of boom horizontally, arm
to IN stroke end, and bucket to DUMP
Bucket time lag stroke end. Then, CURL bucket and Max. 1 Max. 2
measure time required to start it again
after it stops temporarily.
• Lower blade from RAISE stroke end and
Blade time lag measure time required to raise machine Max. 2 Max. 3.9
after blade touches ground.
Internal leakage
Leakage from
Max. 2 10
each cylinder • Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle. cc/min.
Leakage from • Relieve circuit to be measured.
center swivel — —
joint
Performance of
— See section of Performance of hydraulic pump.
hydraulic pump
PC18MR-2 20-7
(1)
Performance of hydraulic pump

Gear pump
Standard value for

Item Measurement conditions Unit Service limit value
new machine

Discharge of gear • Engine speed: 2,600 rpm
l/min. 12.1 10.2
pump • Measure at set pressure of relief
valve.
Piston pump
Discharge Standard
Measurement pressure of Criterion
Item Checkpoint discharge
conditions piston pump (l/min.)
(MPa{kg/cm2}) (l/min.)
• Hydraulic oil temperature:

45 – 55°C
Discharge of • Engine speed: 2,600 rpm Q Q
Any point P
piston pump aAvoid measuring near broken (See graph) (See graph)
part of graph since error
become large at that part.
20-8 PC18MR-2
(1)
Posture of machine for measuring per-

formance 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-2 20-9
(1)
Work equipment 1: Hydraulic drift of work equip- Work equipment 4: Bucket speed
ment
Work equipment 2: Boom speed Work equipment 5: Boom swing speed
Work equipment 3: Arm speed Work equipment 6: Blade speed
20-10 PC18MR-2
(1)
Work equipment 7: Boom time lag Work equipment 10: Blade time lag
Work equipment 8: Arm time lag
Work equipment 9: Bucket time lag
PC18MR-2 20-11
(1)
Testing and adjusting
List of testing, adjusting, and troubleshooting tools .................................................................................... 20-102

Measuring engine speed............................................................................................................................. 20-104
Measurement of exhaust gas color ............................................................................................................. 20-105
Adjusting valve clearance ........................................................................................................................... 20-106
Testing compression pressure .................................................................................................................... 20-108
Testing engine oil pressure ......................................................................................................................... 20-109
Testing and adjusting fuel injection timing................................................................................................... 20- 110
Adjusting engine stop solenoid ................................................................................................................... 20- 112
Bleeding air from fuel circuit........................................................................................................................ 20- 113
Testing and adjusting fan belt tension......................................................................................................... 20- 114
Adjusting fuel control lever linkage ............................................................................................................. 20- 115
Measurement of clearance in swing circle bearings ................................................................................... 20- 116
Testing and adjusting track shoe tension .................................................................................................... 20- 117
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits .......................... 20- 119
Testing and adjusting control circuit basic pressure.................................................................................... 20-122
Testing and adjusting pump LS differential pressure .................................................................................. 20-124
Measuring solenoid valve output pressure ................................................................................................. 20-126
Measuring PPC valve output pressure ....................................................................................................... 20-128
Adjusting play of work equipment and swing PPC valves .......................................................................... 20-130
Measuring swing holding brake release pressure....................................................................................... 20-130
Testing oil leakage from cylinder ................................................................................................................. 20-132
Releasing residual pressure from hydraulic circuit ..................................................................................... 20-134
Bleeding air from cylinder ........................................................................................................................... 20-134
Pressurizing hydraulic tank ......................................................................................................................... 20-135
How to open and close (tilt) floor ................................................................................................................ 20-136
Inspection procedures for diode.................................................................................................................. 20-138
PC18MR-2 20-101
(1)
Testing and adjusting List of testing, adjusting, and troubleshooting tools
List of testing, adjusting, and troubleshooting tools
Symbol
Q’ty
Testing/Adjusting item Part No. Part Name Remarks
Measuring engine speed A 799-205-1100 Tachometer kit 1 Degital display: 6 – 99,999.9 rpm
1 799-201-9001 Handy smoke 1

checker
Measuring exhaust gas B Bosch index: 0 – 9
color
2 Commercially Smoke meter 1
available
Adjusting valve clearance C Commercially Thickness gauge 1 Intake : 0.145 – 0.185 mm

available Exhaust : 0.145 – 0.185 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}

Measuring compression
pressure D 2 795-111-1120 Adapter 1 For 3D67E-1A (YC-2)
3 795-101-1571 Joint 1 For 3D67E-1A
799-101-5002 Hydraulic tester 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
1
Measuring engine oil pres-
sure E 790-261-1204 Dizital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
tester
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10kg/cm2}
Measuring swing circle F Commercially Dial gauge 1 —

bearing clearance available
{25, 60, 400, 600 kg/cm2}
Measuring and adjusting 1
oil pressures in work 790-261-1204 Dizital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
equipment, travel, boom G tester
swing, swing, and blade
circuits 799-101-5220 Nipple 1
2 Size: 10 x 1.25 mm
07002-11023 O-ring 1
{25, 60, 400, 600 kg/cm2}
1
790-261-1204 Dizital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
Measuring control circuit oil H tester
pressure
799-101-5220 Nipple 1
2 Size: 10 x 1.25 mm
07002-11023 O-ring 1
{25, 60, 400, 600 kg/cm2}
1
790-261-1204 Dizital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
tester
Measuring pump LS J
differential pressure 2 799-401-2701 Differential pressure 1 49 MPa {50 kg/cm2}
gauge
799-101-5220 Nipple 2
3 Size: 10 x 1.25 mm
07002-11023 O-ring 2
20-102 PC18MR-2
(1)
Testing and adjusting List of testing, adjusting, and troubleshooting tools
Symbol
Q’ty
Testing/Adjusting item Part No. Part Name Remarks
{25, 60, 400, 600 kg/cm2}
1
Measuring solenoid valve
output pressure K 790-261-1204 Dizital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
tester
2 799-401-3100 Adapter 1 Size : 02
{25, 60, 400, 600 kg/cm2}
1
Measuring PPC valve
output pressure L 790-261-1204 Dizital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
tester
2 799-401-3100 Adapter 1 Size : 02
{25, 60, 400, 600 kg/cm2}
1
Measuring swing holding
brake release pressure M 790-261-1204 Digital hydraulic 1 Pressure gauge: 58.8 MPa {600kg/cm2}
tester
2 799-401-3100 Adapter 1 Size : 02
Measuring leakage from N Commercially Measuring cylinder 1 —

work equipment cylinder available
Measuring water tempera- – 799-101-1502 Digital thermometer 1 - 99.9 – 1,299°C

ture and oil temperature
79A-264-0021 1 0 – 294 N {0 – 30 kg}

Measuring operating effort – Push-pull scale
and pressing force
79A-264-0091 1 0 – 490 N {0 – 50 kg}
Measuring stroke and – Commercially Scale 1 —

hydraulic drift available
Measuring work equipment – Commercially Stopwatch 1 —

speed available
Measuring voltage an resis- – Commercially Tester 1 —

tance available
a 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, list of T-boxes and T-
adapters.
PC18MR-2 20-103
(1)
Testing and adjusting Measuring engine speed
Measuring engine speed

a Measuring instruments for engine speed
Symbol Part No. Part Name

A 799-205-1100 Tachometer kit
a Measure the engine speed under the following

condition.
• Coolant temperature: Within operating range
• Hydraulic oil temperature : 45 – 55°C
1. Preparation work
1) Open the engine rear cover and stick reflec-
tor tape [1] of tachometer kit A to the end
face of fan pulley (1).
2. Measuring low idling speed
1) Start the engine and set the fuel control lever
in the low idling position.
2) Set all the control levers and pedals in neu-
tral and measure the engine speed.
3. Measuring high idling speed

in the high idling position.
2) Set all the control levers and pedals in neu-
tral and measure the engine speed.
4. Measuring engine speed when 1 pump is

relieved
2) Using stand [2], set probe [3] straight at in the high idling position.
reflector tape [1]. 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 posi-
tion under this condition and measure the
engine speed.
5. Work after finishing measurement

After finishing measurement, remove the mea-
suring instruments and return the removed parts.
3) Connect probe [3] to tachometer [4].
20-104 PC18MR-2
(1)
Testing and adjusting Measurement of exhaust gas color
Measurement of exhaust gas

color
a Exhaust gas color measurement tool
1 799-201-9001 Handy smoke checker
B Commercially
2 Smoke meter
available
a Measurement of exhaust gas color under the fol-

lowing condition.
k Be careful not to touch the highly heated parts,

Coolant temperature: Within operating range
while fitting and detaching a measurement tool.

a If no compressed air or power is not available in 2) Connect the probe hose, accelerator switch
the field, use handy smoke checker B1. For outlet and air hose to the smoke meter B2.
recording official data, use smoke meter B2. a Keep the pressure of the supplied com-
pressed air below 1.5 MPa {15 kg/cm2}.
1. Measurement with handy smoke checker B1 3) Connect the power cable to AC socket.
1) Fit a filtering paper to handy smoke checker a Confirm that the smoke meter power
B1. switch is in the OFF position, before con-
necting the power cable to an outlet.
2) Insert the exhaust gas intake pipe into the
4) Fit a filtering paper by loosening the suction
exhaust pipe (1).
pump cap nut.
3) Start the engine.
a Fit the filtering paper securely so that air
4) Accelerate the engine suddenly or run it at
may not leak.
high idling and operate the handle of smoke
5) Move the smoke meter B2 power switch to
checker B1 so that the filter paper will
the ON position.
absorb the exhaust gas.
6) Accelerate the engine suddenly or run it at

5) Remove the filter paper and compare it with
high idling and press the accelerator pedal of
the attached scale.
smoke meter B2 and collect the exhaust gas
6) After finishing measurement, remove the
into the filter paper.
measuring instruments and return the
7) Put the polluted filtering paper on non-pol-
removed parts.
luted filtering paper (more than 10 sheets) in
the filtering paper holder, and read the indi-
2. Measurement with smoke meter B2
cated value.
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.
removed parts.
PC18MR-2 20-105
(1)
Testing and adjusting Adjusting valve clearance
Adjusting valve clearance 4. While the No. 1 cylinder is at the compression

top dead center, adjust the valve clearances
a Adjusting instrument for valve clearance marked with q in the valve arrangement draw-
ing according to the following procedure.
a Valve arrangement drawing
Commercially
C available Thickness gauge
1. Tilt the floor open. For details, see How to open

and close (tilt) floor.
2. Remove cylinder head cover (1).
1) Insert thickness gauge C in clearance (c)

between rocker arm (2) and valve cap (3)
and adjust the clearance with adjustment
screw (4).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you
3. While checking through the inspection hole of can move the thickness gauge lightly.
the flywheel housing, rotate the crankshaft for-
ward to bring the stamped "1.TC" line (a) of the 2) While fixing adjustment screw (4), tighten
flywheel to stamped line (b) in the housing and locknut (5).
set the No. 1 cylinder to the compression top a After adjusting all of the valves marked
dead center. with q, go to the next procedure.
a Rotate the crankshaft with the crank 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 compres-
sion 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.
5. 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.
20-106 PC18MR-2
(1)
Testing and adjusting Adjusting valve clearance
6. 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.
7. After finishing adjusting, return the removed
3 Cylinder head cover mounting bolt:

parts.
4.9 Nm {0.5 kgm}
PC18MR-2 20-107
(1)
Testing and adjusting Testing compression pressure
Testing compression pressure

a Testing instruments for compression pressure

1 795-502-1590 Compression gauge
D 2 795-111-1120 Adapter (YC-2)
3 795-101-1571 Joint
a When testing the compression pressure, take

care not to burn yourself on the exhaust mani-
fold, muffler, etc. or get caught in a rotating part.
a Test the compression pressure under the follow-
ing condition.
• Engine oil temperature: 40 – 60°C
6. Install adapter D2 and joint D3 to the nozzle
holder mounting part and connect compression
1. Adjust the valve clearance. For details, see
gauge D1.
Adjusting valve clearance.
a Install the packing to the end of the adapter.
2. Prepare for testing the engine speed. For 3 Adapter: 58.8 Nm {6.0 kgm}
details, see Testing engine speed.
a Since the compression gauge cannot be
3. Open the cooling cover and close the valve of pulled out of the revolving frame, keep the
fuel filter (1). floor tilted open.
a If you have removed the air cleaner assem-
bly, install it before starting the test.
4. Disconnect M4 connector (2) of the engine stop

solenoid.
7. Crank the engine with the starting motor and test
5. Remove nozzle holder (3) of the cylinder to mea- the compression pressure.
sure the compression pressure. a Read the compression gauge when its
a If you remove the air cleaner assembly tem- pointer is stabilized.
porarily, you can work easily. a When testing the compression pressure, test
the engine speed, too, and check that it is in
the measurement condition range.
8. After finishing testing, remove the testing instru-
3 Nozzle holder: 58.8 Nm {6.0 kgm}

ments and return the removed parts.
20-108 PC18MR-2
(1)
Testing and adjusting Testing engine oil pressure
Testing engine oil pressure

a Testing instruments for engine oil pressure

799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Test the engine oil pressure under the following

condition.
• Engine coolant temperature: Within operat-
ing range

5. Start the engine and measure the engine oil
pressure at low idle and high idle.
2. Remove engine oil pressure switch (1).
6. After finishing testing, remove the testing instru-
3 Engine oil pressure switch

ments and return the removed parts.
Switch: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}

Screw: 1.4 – 2.0 Nm {0.14 – 0.2 kgm}
3. Install adapter [1] of hydraulic tester E1 and pull

the oil pressure test hose out of the revolving
frame.
4. Tilt down the floor and connect the oil pressure

test hose to the hydraulic tester E2.
PC18MR-2 20-109
(1)
Testing and adjusting Testing and adjusting fuel injection timing
Testing and adjusting fuel 5. Rotate the crankshaft forward slowly from this
position about 1.5 turns.
injection timing
6. Rotate the crankshaft forward slowly again.
a After the fuel injection pump is replaced or When the fuel rises at the end of No. 1 delivery
repaired, test and adjust the fuel injection timing holder hole (a) of fuel injection pump (2), stop
according to the following procedure. the crankshaft.
a Before testing and adjusting the fuel injection
timing, bleed air from the fuel circuit. 7. Watch through the inspection hole of the fly-
wheel housing and check that injection timing
Testing stamped line (b) on the flywheel is matched to
1. Tilt the floor open. For details, see How to open stamped line (c) in the housing.
and close (tilt) floor. a If you cannot see stamped line (c) easily,
check the position of stamped line (b) by the
2. Remove 3 fuel injection pipes (1). projection in the inspection hole.
a If you remove the air cleaner assembly tem-
porarily, you can work easily.
3 Fuel injection pipe sleeve nut:

8. After finishing testing, return the removed parts.
3. Set the fuel control lever in the high idle position.

24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a Keep the fuel control lever in this position
a If the fuel injection timing is abnormal, adjust
during the test.
it before connecting the fuel injection pipe.
4. 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 crank pulley
mounting bolt.
a After the fuel rises, wipe it off to check again.
20-110 PC18MR-2
(1)
Testing and adjusting Testing and adjusting fuel injection timing
Adjusting 3. Set selected shim (3) and install fuel injection

a If the fuel injection timing stamped line on the fly- pump (2).
wheel is not matched to the stamped line in the a Thinly apply gasket sealant (ThreeBond
3 Fuel injection pump mounting bolt/nut:

flywheel housing or the projection in the inspec- 1215 or 1104) to both sides of the shim.
tion hole, the fuel injection timing is abnormal. In
this case, adjust according to the following pro- 9.8 – 11.3 Nm {1.0 – 1.15 kgm}
cedure.
4. After finishing adjusting, check that the fuel
1. Remove fuel injection pump (2) and check the injection timing is normal according to the above
thickness of shim (3). testing procedure.
2. Adjust the fuel injection timing by increasing or

decreasing the thickness of shim (3).
a If the fuel injection timing is
• early, increase the shim thickness.
• 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.
• 0.20 mm shim: 2 identification holes
• 0.25 mm shim: 1 identification hole
• 0.30 mm shim: No identification hole
PC18MR-2 20-111
(1)
Testing and adjusting Adjusting engine stop solenoid
Adjusting engine stop solenoid 4. After tightening the bolts, push the rear end of
bellows (6) and check that rod (4) and stop lever
a After the engine stop solenoid is removed and (2) move smoothly.
installed, adjust it according to the following pro-
cedure.
Function
• The engine stop solenoid is a push-type sole-
noid which is normally energized (during opera-
tion) and which has a suction coil and a holding
coil.
• When the starting switch is turned ON, both of
the suction coil and holding coil are energized.
After s set time (about 1 second), the suction
coil is de-energized.
• The following figure shows the operating condi-
tion of the solenoid.
RUN: While the engine is operated (the power 5. After finishing adjusting, start and stop the
is applied), the rod is extracted. engine to check that the solenoid operates nor-
STOP: While the engine is stopped (the power is mally.
not applied), the rod is retracted.
<Precautions for checking operation>
• 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 fol-
lowing figure).
• If the operation stroke of the solenoid is insuffi-
cient, the holding power of the holding coil low-
ers 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) tem-
porarily.
2. Move stop lever (2) toward the RUN position

with the hand to extract rod (4) of the solenoid.
3. 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
3 Mounting bolt:
contact with the stopper.
9.8 – 11.3 Nm {1.0 – 1.15 kgm}
20-112 PC18MR-2
(1)
Testing and adjusting Bleeding air from fuel circuit
Bleeding air from fuel circuit

a 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 proce-
dure.
1. Fill the fuel tank with the fuel.
2. Check that the fuel filter valve is at the OPEN

position.
3. Turn the starting switch to the ON position and

keep it there for 10 – 15 seconds, and then
return it to the OFF position.
a The air in the fuel circuit is bled automatically by

the above operation.
PC18MR-2 20-113
(1)
Testing and adjusting Testing and adjusting fan belt tension
Testing and adjusting fan belt 5. Tighten adjustment bolt (2) and mounting bolt (3)
to fix alternator (1).
tension a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt and V-
Testing groove.
1. Tilt the floor open. For details, see How to open a If the V-belt is so lengthened that the adjust-
and close (tilt) floor. ment allowance is eliminated or it has a cut
or a crack, replace it.
2. Press the center of the belt between the crank
pulley and fan pulley with your finger and mea-
sure the deflection of the belt.
• Force to press belt: Approx. 98 N {10 kg}
• Deflection: 9 – 13 mm
a If the deflection is about 10 mm, the belt ten-
sion is roughly in the normal range.
6. After finishing adjusting, return the removed

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

2. 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.
3. Loosen adjustment bolt (2) and mounting bolt (3)

of the alternator.
4. Move alternator (1) to adjust the belt tension.

• Force to press belt for adjustment:
Approx. 98 N {10 kg}
• Deflection for adjustment:
Approx. 7 – 10 mm
20-114 PC18MR-2
(1)
Testing and adjusting Adjusting fuel control lever linkage
Adjusting fuel control lever

linkage
1. Adjusting low idling
1) Tilt fuel control lever (1) forward until it
reaches stopper (2) on the low idling side.
2) Under this condition, adjust low idling adjust-
ment screw (3) on the fuel injection pump
side to set the low idling speed to the speci-
fied level.
2. Adjusting high idling

1) Tilt fuel control lever (1) backward until gov-
ernor lever (4) of the fuel injection pump
reaches screw (5) on the high idling 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 idling side of the
fuel injection pump is not adjustable. If
the high idling speed or power is still low
even when the governor lever reaches
the screw on the high idling side, check
the nozzle holder, etc.
PC18MR-2 20-115
(1)
Testing and adjusting Measurement of clearance in swing circle bearings
Measurement of clearance in 4. Hold the arm nearly perpendicular to the ground,

and lower the boom until the track shoes will be
swing circle bearings lifted at the work equipment.
a The upper structure is raised at the front and
a Swing circle bearing clearance measurement tools lowered at the rear at that time.
Mark Part No. Part Name
5. Read off the value in dial gauge F in this condi-
Commercial
F Dial gauge tion.
product
a The value indicated in dial gauge F ex-
presses clearance in the bearings.
a Follow the steps explained below, when measur-
ing clearance in the swing circle bearing in the
k Be careful not to put a hand or foot under the

actual machine.
undercarriage, while taking measurement.
1. Fix dial gauge F to the track frame and apply the

probe to the underside of outer race (1) perpen-
dicularly.
a Set dial gauge F at the track frame rear.
6. 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.
7. After finishing measurement, remove the mea-

2. Keep the work equipment in the max. reach pos-

ture 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 struc-
ture rises and the rear side lowers.
3. Under this condition, set dial gauge F to the zero

point.
20-116 PC18MR-2
(1)
Testing and adjusting Testing and adjusting track shoe tension
Testing and adjusting track

shoe tension
Testing
1. Run the engine at low idling 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.
3. Measure maximum clearance (a) between bar

[1] and track shoe.
• Standard maximum clearance (a) a When steel shoe is installed
Steel shoe specification: 5 – 15 mm You may supply grease until distance (b)
Rubber shoe specification: 1 – 3 mm 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.
Adjusting
a If the track shoe tension is abnormal, adjust it
2. To lower tension
1) Loosen valve (2) to discharge the grease.
k Since the valve may jump out because
1. To heighten tension
1) Supply grease throungh grease fitting (1).
2) To check that the tension is normal, run the of the internal high-pressure grease, do
engine at low idling and move the machine not loosen it more than 1 turn.
forward by the length of track on ground, then 2) Tighten valve (2).
stop slowly. 3) To check that the tension is normal, run the
3) After finishing adjustment, check again that engine at low idling and move the machine
the tension is normal according to the above forward by the length of track on ground, then
procedure. stop slowly.
4) After adjusting, check the tension again
according to the procedure described above.
PC18MR-2 20-117
(1)
Testing and adjusting Testing and adjusting track shoe tension
20-118 PC18MR-2
(1)
Testing and adjusting oil pressures in work equipment,
Testing and adjusting travel, swing, and blade circuits
Testing and adjusting oil

pressures in work equipment,
travel, swing, and blade circuits
a Measuring instruments for oil pressures in work
equipment, travel, swing, and blade circuits

1
790-261-1204 Digital hydraulic tester
G
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Testing 4) Tilt down the floor and connect the hose to

a Test the oil pressures in the work equipment, oil pressure gauge [1] of hydraulic tester G1.
travel, swing, and blade circuits under the follow- a Use oil pressure gauges of 39.2 MPa
ing condition. {400 kg/cm2} for both hoses.
k Release the residual pressure from the hydrau-
lic 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 instru-
ments without tilting the floor open. If the
floor is tilted open, however, you can
work easily.
2) Remove pump discharge pressure pickup
5) Pressurize the hydraulic tank. For details,
plugs (1).
see Pressurizing hydraulic tank.
2. 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.
3. Measuring work equipment (boom/arm/

bucket/boom swing/blade) circuit relief pres-
sure
a The variable gauge circuit is operated by
applying the blade circuit pressure through
3) Install nipples G2 and pull the oil pressure test the variable gauge selector valve.
hose out of the revolving frame. 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-2 20-119
(1)
4. Measuring travel circuit relief pressure Adjusting

1) Start the engine and lock the travel mecha- 1. Adjusting unload pressure
nism on the side to be measured. a The unload pressure cannot be adjusted.
k Set pin [1] between the sprocket and
2. Adjusting relief pressure of work equipment
track frame to lock the travel mechanism
circuit and travel circuit
securely.
a If the relief pressure of the work equipment
circuit and travel circuit is abnormal, adjust
main relief valve (2) of the control valve
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.

travel circuit and measure the oil pressure.
a The relief pressure of the main relief
valve of the control valve is indicated.
5. Measuring swing circuit relief pressure

1) Start the engine and lock the swing mecha-
1) While fixing adjustment screw (3), loosen
nism with the work equipment securely.
k Stick the bucket into the ground or press
locknut (4).
2) Turn adjustment screw (3) to adjust the pres-
it against the blade sure.
2) Run the engine at high idle and relieve the a If the adjustment screw is
swing circuit and measure the oil pressure. • turned to the right, the pressure
a The relief pressure of the swing motor rises.
safety valve is indicated. • turned to the left, the pressure low-
a The swing motor safety valves are ers.
installed to the right and left sides. a Quantity of adjustment per turn of adjust-
Accordingly, measure the relief pres- ment screw: 12.6 MPa {128 kg/cm2}
sures on both sides respectively. 3) While fixing adjustment screw (3), tighten
a The swing motor relief pressure is lower
3 Locknut: 59 – 79 Nm {6 – 8 kgm}
locknut (4).
than the main relief pressure.
6. Work after finishing measurement

After finishing measurement, remove the mea-
20-120 PC18MR-2
(1)
4) After finishing adjustment, check again that 4) After finishing adjustment, check again that
the oil pressure is normal according to the the oil pressure is normal according to the
above described measurement procedure. above described measurement procedure.
3. Adjusting relief pressure of swing circuit

a If the relief pressure of the swing circuit is
abnormal, adjust safety valves (5) and (6)
• Safety valve (5):
For right swing relief valve (A)
• 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 How to tilt (open and close) floor.
1) While fixing adjustment screw (7), loosen

locknut (8).
2) Turn adjustment screw (7) to adjust the pres-
sure.
a If the adjustment screw is
• turned to the right, the pressure
rises.
• turned to the left, the pressure low-
ers.
a Quantity of adjustment per turn of adjust-
ment screw: Approx. 4.5 MPa {46 kg/
cm2}
3) While fixing adjustment screw (7), tighten
locknut (8).
3 Locknut: 3.92 Nm {0.4 kgm}
PC18MR-2 20-121
(1)
Testing and adjusting Testing and adjusting control circuit basic pressure
Testing and adjusting control

circuit basic pressure
a Testing and measuring instruments for control
circuit basic pressure
1
H
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Testing
a Measure the control circuit basic pressure under
the following condition. 4. Tilt down the floor and connect the hose to oil
• Hydraulic oil temperature: 45 – 55°C pressure gauge [1] of hydraulic tester H1.
a Use an oil pressure gauge of 5.9 MPa {60
kg/cm2}.
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 control circuit basic pressure pickup

plug (1).
5. Pressurize the hydraulic tank. For details, see

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

Adjusting
3. Install nipple H2 and pull the oil pressure test a If the control circuit basic pressure is abnormal,
hose out of the revolving frame. adjust relief valve (2) of the 2-spool solenoid
valve according to the following procedure.
a When adjusting the main relief valve of the con-
trol valve, tilt the floor open. For details, see
How to tilt (open and close) floor.
20-122 PC18MR-2
(1)
Testing and adjusting Testing and adjusting control circuit basic pressure
1. While fixing adjustment screw (3), loosen lock-

nut (4).
2. Turn adjustment screw (3) to adjust the pres-

sure.
a If the adjustment screw is
• turned to the right, the pressure rises.
• turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment screw: 17.54 MPa {179 kg/cm2}
3. While fixing adjustment screw (3), tighten lock-
3 Locknut: 9.8 Nm {1.0 kgm}

nut (4).
4. After finishing adjustment, check again that the

oil pressure is normal according to the above
described measurement procedure.
PC18MR-2 20-123
(1)
Testing and adjusting Testing and adjusting pump LS differential pressure
Testing and adjusting pump LS

differential pressure
a Testing and adjusting instruments for pump LS
differential pressure
1
Differential pressure
J 2 799-401-2701
gauge
799-101-5220 Nipple (10 × 1.25 mm)
3
07002-11023 O-ring
Measuring 4. Tilt down the floor and connect the hose to oil
a Measure the pump discharge pressure and LS pressure gauge [1] of hydraulic tester J1 or to
pressure (actuator load pressure) simulta- differential pressure gauge J2.
neously and calculate the difference between a When using differential pressure gauge:
them. Connect the pump discharge pressure to the
a Measure the LS differential pressure under the high pressure side (back side) and connect
following condition. the LS pressure to the low pressure side
• Hydraulic oil temperature: 45 – 55 °C (lower side).
k Release the pressure from the hydraulic tank.

Since the differential pressure gauge needs
a 12-V power source, connect it to a battery.
For details, see Releasing pressure from hy- a When using oil pressure gauge:
draulic circuit. Use the oil pressure gauge of 39.2 MPa {400
kg/cm²}.
1. Open the battery cover, then tilt the floor open. Since the differential pressure is about 2.5
For details, see How to open and close (tilt) floor. MPa {25 kg/cm²} at maximum, measure it by
a You can connect the measuring instruments installing the same gauge to the pickup
without tilting the floor open. If the floor is plugs alternately.
tilted open, however, you can work easily.
2. Remove pump discharge pressure pickup plugs

(1) and (2).
• Plug (1): Pump discharge pressure pickup
plug
• Plug (2): LS pressure pickup plug

6. Run the engine and operate the work equipment

to set the boom top horizontally.
7. While running the engine at high idling, measure

3. Install nipple J3 and pull the oil pressure mea- the pump discharge pressure and LS pressure
surement hose out of the revolving frame. (actuator load pressure) simultaneously under
the following condition.
20-124 PC18MR-2
(1)
Testing and adjusting Testing and adjusting pump LS differential pressure
• Work equipment, travel, swing, and blade 3. Turn plug (5) to adjust the differential pressure.
circuits: Set all the levers in neutral and a If the plug is
move the arm IN. • turned to the right, the differential pres-
a Move the arm lever halfway to move the arm sure rises.
IN and measure the oil pressure during this • turned to the left, the differential pres-
operation. sure lowers.
a Calculation of LS differential pressure (when a Quantity of adjustment (LS differential pres-
oil pressure gauge is used): sure) per turn of plug: 127 kPa {13 kg/cm²}
LS differential pressure = a Tighten hose sleeve nut (4) temporarily and
Pump discharge pressure – LS pressure turn the plug, while checking the LS differen-
a If the LS differential pressure is as follows, it tial pressure.
is normal.
4. Fixing plug (5), tighten locknut (6).
3 Locknut: 27.4 – 34.3 Nm {2.8 – 3.5 kgm}
Work equipment, travel,
LS differential pressure
swing, and blade levers
Unload pressure (See
Set all levers in neutral 5. Tighten hose sleeve nut (4).
standard values table)
Specified LS differential
Set arm lever in IN
pressure (See standard
position (halfway)
values table)

Adjusting
a If the LS differential pressure is abnormal, adjust
LS valve (3) according to the following proce-
dure.
a When adjusting the LS valve, remove the battery
cover.
1. Loosen hose sleeve nut (4).
2. Fixing plug (5), loosen locknut (6).
PC18MR-2 20-125
(1)
Testing and adjusting Measuring solenoid valve output pressure
Measuring solenoid valve

output pressure
a Measuring instruments for solenoid valve output
pressure
1
K 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (02)
a Before measuring the solenoid valve output

pressure, check that the basic pressure in the
control circuit is normal.
a Measure the solenoid valve output pressure 5. Tilt down the floor and connect the hose to oil
under the following condition. pressure gauge [2] of hydraulic tester K1.
• Hydraulic oil temperature: 45 – 55 °C a Use oil pressure gauge of 5.9 MPa {60 kg/
cm²}.
1. Tilt the floor open. For details, see How to tilt

(open and close) floor.
2. Disconnect outlet hoses (1) and (2) of the sole-

noid valves to be measured.
• Hose (1): PPC lock solenoid valve
• Hose (2): 2nd travel speed selection sole-
noid valve

7. Run the engine at high idling, 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 the operations table
of each solenoid valve.
a If the output pressure of each solenoid valve
is as shown in the operation table of the
solenoid valve, it is normal.
3. Install adapter K2 and connect the disconnected
hose again.
4. 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.
20-126 PC18MR-2
(1)
Testing and adjusting Measuring solenoid valve output pressure
Operation table of solenoid valves
Output pressure of
No. Solenoid valve Operating condition State of solenoid
solenoid valve
0 MPa
Lock lever: LOCK OFF
{0 kg/cm²}
1 PPC lock
+ 0.2
3.14 0 MPa
Lock lever: FREE ON
+2
{32 0 kg/cm²}
Travel speed shifting switch: Low speed mode 0 MPa

OFF
(2nd travel speed monitor: OFF) {0 kg/cm²}
2nd travel speed
2
selection Travel speed shifting switch: High speed mode 3.14
+ 0.2
MPa
0
ON
(2nd travel speed monitor: ON) {32
+2
kg/cm²}
0
PC18MR-2 20-127
(1)
Testing and adjusting Measuring PPC valve output pressure
Measuring PPC valve output

pressure
a Measuring instruments for PPC valve output pres-
sure
1
L 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (02)
a Before measuring the PPC valve output pres-

sure, check that the basic pressure in the control
circuit is normal.
a Measure the PPC valve output pressure under 5. Tilt down the floor and connect the hose to oil
the following condition. pressure gauge [2] of hydraulic tester L1.
• Hydraulic oil temperature: 45 – 55 °C a Use oil pressure gauge of 5.9 MPa {60 kg/
cm²}.
1. Tilt the floor open. For details, see How to tilt

(open and close) floor.
2. Disconnect PPC hose (1) of the solenoid valve

to be measured.
a The figure shows the hose of the ARM IN cir-
cuit.

7. Run the engine at high idling, 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 fol-
lows, it is normal.
Control lever/pedal PPC valve output pressure

3. Install adapter L2 and connect the disconnected
0 MPa
hose again. Neutral
{0 kg/cm²}
+ 0.2
4. Install nipple [1] of hydraulic tester L1 and pull 3.14 0 MPa
Stroke end
the oil pressure measurement hose out of the {32
+2
kg/cm²}
0
revolving frame.
a The figure shows the measuring instruments
connected to the hose of the ARM IN circuit.
20-128 PC18MR-2
(1)
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 ( ).
PC18MR-2 20-129
(1)
Adjusting play of work equipment and swing PPC valves,
Testing and adjusting Measuring swing holding brake release pressure
Adjusting play of work equip- Measuring swing holding brake

ment and swing PPC valves release pressure
a If the play of the left or right work equipment con- a Measuring instruments for swing holding brake
trol lever is excessive, adjust it according to the release pressure
following procedure.
1. Remove the PPC valve assembly. 799-101-5002 Hydraulic tester
1
M 790-261-1204 Digital hydraulic tester
2. Remove boot (1).
2 799-401-3100 Adapter (02)
3. Loosen locknut (2) and screw in disc (3) until it

touches the heads of 4 pistons (4). a Before measuring the swing holding brake
a At this time, do not move the pistons. release pressure, check that PPC valve output
pressure (swing LEFT, swing RIGHT, and arm
4. Fix disc (3) and tighten locknut (2) to the speci- IN) is normal.
a Measure the swing holding brake release pres-
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
fied torque.
sure under the following condition.
• Hydraulic oil temperature : 45 – 55 °C
5. Install boot (1). k Release the residual pressure from the hydrau-
6. Install the PPC valve assembly. pressure from hydraulic circuit.
1. 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.
2. 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.
3) Install adapter M2 and connect the discon-

nected hose again.
4) Install nipple [1] of hydraulic tester M1 and

pull the oil pressure measurement hose out
of the revolving frame.
20-130 PC18MR-2
(1)
Testing and adjusting Measuring swing holding brake release pressure
<Reference:
Release pressure and release signal pressure>
• The swing holding brake release pressure is the
output pressure of the PPC solenoid valve,
which is led to the swing motor.
• If the swing holding brake does not operate,
check the release pressure (output pressure of
the PPC solenoid valve) first.
• 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 con-
trol valve.
• If the release pressure is normal but the swing
holding brake is not released, check the release
5) Tilt down the floor and connect the hose to signal pressure, and then check the output pres-
oil pressure gauge [2] of hydraulic tester M1. sure of the PPC valves for swing LEFT, swing
a Use oil pressure gauge of 5.9 MPa {60 RIGHT, and arm IN.
kg/cm²}. • If the output pressure of each PPC valve is nor-
mal but the release signal pressure is not nor-
mal, the shuttle valve in the control valve may
be malfunctioning.
• 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.
6) Pressurize the hydraulic tank. For details,

see Pressurizing hydraulic tank.
7) Run the engine at high idling, set all the con-
trol levers in the neutral position and operat-
ing position, and measure the oil pressure.
a If the swing holding brake release pres-
sure is as follows, it is normal.
Swing holding brake

Control lever/pedal
release pressure
Neutral or other than 0 MPa
following positions {0 kg/cm²}
+ 0.2
Swing LEFT, Swing 3.14 0 MPa
RIGHT, Arm IN {32
+2
kg/cm²}
0

removed parts.
PC18MR-2 20-131
(1)
Testing and adjusting Testing oil leakage from cylinder
Testing oil leakage from k Take care not to disconnect the hose on
the cylinder bottom side.
cylinder a Use the following part to block the hose
side.
a Testing instruments for oil leakage from cylinder. 07376-70315 (Plug #03)
Commercially
N Measuring cylinder
available
1. 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 hy-
draulic 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 3) Run the engine at high idle and relieve the
the cylinder bottom side. arm circuit by moving the arm IN.
a Use the following part to block the hose k Take care not to "move the arm OUT".
side. 4) Measure the oil leakage for 1 minute after 30
07376-70210 (Plug #02) seconds since relieving is started.
removed parts.
3. Measuring oil leakage from bucket cylinder

1) Run the engine and move the bucket cylin-
der to the CURL stroke end.
bucket cylinder circuit. For details, see
Releasing residual pressure from hy-
draulic circuit.
3) Run the engine at high idle and relieve the k Take care not to disconnect the hose on
boom circuit by raising the boom. the cylinder bottom side.
k Take care not to "lower the boom".
a Use the following part to block the hose
side.
4) Measure the oil leakage for 1 minute after 30
07376-70210 (Plug #02)
seconds since relieving is started.
removed parts.
2. 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 Releas-
ing residual pressure from hydraulic cir-
cuit.
20-132 PC18MR-2
(1)
Testing and adjusting Testing oil leakage from cylinder
3) Run the engine at high idle and relieve the a Raise the track shoe to a degree that the
bucket circuit by curling the bucket. blade will not touch the ground when it is
k Take care not to "dump the bucket".
lowered to the stroke end.
2) Lower the blade cylinder to the stroke end.
5) After finishing measurement, remove the blade cylinder circuit. For details, see
measuring instruments and return the Releasing residual pressure from hy-
removed parts. draulic circuit.
4. Measuring oil leakage from boom swing cyl- side and block the hose side with a plug.
k Take care not to disconnect the hose on
inder
1) Run the engine and move the boom swing
cylinder to the left stroke end.
side.
boom swing cylinder circuit. For details, 07367-70210 (Plug #02)
see Releasing residual pressure from
hydraulic circuit.
k Take care not to disconnect the hose on
side.
07367-70210 (Plug #02)

blade circuit by lowering the blade.
k Take care not to "raise the blade".
removed parts.

boom swing circuit by swinging the boom to
the left.
k Take care not to "swing the boom to the
right".
removed parts.
5. 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.
PC18MR-2 20-133
(1)
Releasing residual pressure from hydraulic circuit,
Testing and adjusting Bleeding air from cylinder
Releasing residual pressure Bleeding air from cylinder

from hydraulic circuit a If a cylinder was removed and installed or its pip-
1. Releasing residual pressure from hydraulic ing was disconnected and reconnected, bleed
tank air according to the following procedure.
k The hydraulic tank is enclosed and pressur-

a If a cylinder was replaced, bleed air from it
before connecting the work equipment. In par-
ized. When removing a hose or a plug con- ticular, the boom cylinder does not move to the
nected to the hydraulic tank, release the lowering stroke end, if it is installed to the work
residual pressure from the hydraulic tank equipment.
1) Lower the work equipment to the ground in a 1. Run the engine at low idling for about 5 minutes.
stable posture and stop the engine.
2) Remove bolt (1) and plate (2). 2. Running the engine at low idling, raise and lower
3) Slowly loosen oil filler cap (3) of the hydrau- the boom 4 – 5 times.
lic tank to release the air from the tank. a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3. Running the engine at high idling, perform step

2).
4. Running the engine at low idling, move the pis-

ton rod to the stroke end and relieve the oil.
5. Bleed air from the arm cylinder, bucket cylinder,

boom swing cylinder, and blade cylinder accord-
ing to steps 2 – 4.
2. Releasing residual pressure from hydraulic

cylinder circuit
k When disconnecting the piping between a
hydraulic cylinder and the control valve, re-
lease the residual pressure from the piping
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 hy-
draulic 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.
20-134 PC18MR-2
(1)
Testing and adjusting Pressurizing hydraulic tank
Pressurizing hydraulic tank

a If the oil filler cap is removed from the hydraulic
tank, pressurize the hydraulic tank according to
the following procedure.
1. Run the engine at low idling, set the work equip-

ment in the pressurizing position, and stop the
engine.
a Extract the boom, arm, and bucket cylinders
fully.
2. Remove bolt (1) and plate (2).
3. Remove oil filler cap (3) of the hydraulic tank,

and then tighten it again.
4. Start the engine and lower the work equipment

to the ground.
a The hydraulic tank is pressurized by the
above procedure.
PC18MR-2 20-135
(1)
Testing and adjusting How to open and close (tilt) floor
How to open and close (tilt)

floor
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 follow-
ing 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 shoe

to stop the machine.
7. After the floor rises, push up handrail (5) until
3. Open and fix engine rear cover (1). lock pin (6) is fitted to lock groove (a) of lock
plate (7).
4. Remove 2 floor fixing bolts (2). a When the lock pin moves to the lock groove,
the 1st locking is completed.
5. Roll up floor mat (3).

8. Insert 2nd lock pin (8) in lock hole (b) securely
6. While pulling floor lock release lever (4) toward and rotate it until lock hook (c) is hitched on fix-
the rear of the machine with the left hand, hold ing pin (9) securely.
handrail (5) with the right hand and push up the a Check that the lock pin is hitched on the fix-
floor toward the front of the machine (about 45 ing pin and it does not come off.
degrees). a The 2nd locking is completed and the floor
k Do not put any part of your body under the

opening (tilting open) work is finished.
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.
20-136 PC18MR-2
(1)
Testing and adjusting How to open and close (tilt) floor
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.
2. 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
degrees).
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.
3. Install 2 floor fixing bolts (2).

a If the fixing bolts are damaged, replace them
3 Fixing bolt:
with new ones.
156.8 – 196 Nm {16 – 20 kgm}
4. Close engine rear cover (1).

a The floor closing (tiling close) work is fin-
ished.
PC18MR-2 20-137
(1)
Testing and adjusting Inspection procedures for diode
Inspection procedures for

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

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
a The conductive direction of each diode is ii) Put the red probe (+) of the test lead to
marked on its surface as shown below. 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.
• 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)
• If the needle swings in either case of i)
and ii): Defective (short-circuited inter-
nally)
• If the needle does not swing in any case
of i) and ii): Defective (short-circuited
internally)
1. 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 dis-
played value.
3) Determine if a specific diode is good or no
good with the indicated value.
• No change in the indicated value: No
continuity (defective).
• Change in the indicated value: Continu-
ity established (normal) (Note)
Note: A silicon diode shows a value be-
tween 460 and 600.
20-138 PC18MR-2
(1)
Troubleshooting
Points to remember when troubleshooting.................................................................................................. 20-202

Sequence of events in troubleshooting ....................................................................................................... 20-203
Points to remember when carrying out maintenance.................................................................................. 20-204
Checks before troubleshooting ................................................................................................................... 20-212
Classification and procedures of troubleshooting ....................................................................................... 20-213
Connectors list and connectors arrangement stereogram .......................................................................... 20-215
Connection table for connector pin numbers .............................................................................................. 20-220
T-adapter - boxes and T-adapter table........................................................................................................ 20-243
Troubleshooting of electrical system (E mode) ........................................................................................... 20-301
Troubleshooting of hydraulic and mechanical system (H mode) ................................................................ 20-401
Troubleshooting of engine (S mode)........................................................................................................... 20-501
PC18MR-2 20-201
(1)
Troubleshooting Points to remember when 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 two 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 water 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 (–) 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, and important point is of course to understand the structure and func-
tion.
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 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PC18MR-2
(1)
Troubleshooting Sequence of events in troubleshooting
Sequence of events in troubleshooting
PC18MR-2 20-203
(1)
Troubleshooting Points to remember when carrying out maintenance
Points to remember when carrying out maintenance

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).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing 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 care-
ful when handling wiring harnesses.
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 ox-
idization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC18MR-2
(1)
(3) 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 bro-
ken.
(4) 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 connec-
tor, depending on the direction of the water
jet.
As already said, 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-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take other
appropriate action before passing electricity
through it.
(5) 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
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.
PC18MR-2 20-205
(1)
2) Removing, installing, and drying connectors

and wiring harnesses
(1) Disconnecting connectors

• Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For connec-
tors which have a lock stopper, press down
the stopper with your thumb and pull the con-
nectors apart.
Never pull with one hand.
• When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
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 wa-
ter from getting in the connector portion.
If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC18MR-2
(1)
(2) Connecting connectors

• 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 connec-
tor pins.
Check that there is no damage or breakage
to the outside of the connector.
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 connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
If there is any damage or breakage, re-
place the connector.
• Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in the
connector until the stopper clicks into posi-
tion.
• 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 wir-
ing harness is misaligned, or the clamp is out
of position, adjust it to its correct position.
If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
• If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
(3) Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC18MR-2 20-207
(1)
(4) 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 fol-

lows.
• Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
• Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
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 re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
• Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC18MR-2
(1)
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box un-
less necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand).
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
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.
If there is any change, there is probably defective contact in that circuit.
PC18MR-2 20-209
(1)
3. 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 cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) 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.
2) 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 confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) 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 enter-
ing. 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 on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 PC18MR-2
(1)
5) 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 con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC18MR-2 20-211
(1)
Troubleshooting Checks before troubleshooting
Checks before troubleshooting

Judgement
Item Action
value
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
Lubricating oil,
5. Check for clogging of engine oil filter — Replace

coolant
6. Check coolant level — Add water

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
mechanical equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical
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
equipment
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 10 – 15V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
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 Disconnect
—
water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
After
running for
7. Check alternator voltage (engine running at 1/2 throttle or above) several Replace
minutes :
13.5 – 14.5V
20-212 PC18MR-2
(1)
Troubleshooting Classification and procedures of troubleshooting
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 "Phe-
nomena looking like troubles and troubleshooting Nos.", and then go to explanation of the troubleshooting.
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like troubles
E-mode H-mode S-mode
Phenomena related to engine

1 Engine does not start E-1 q
2 Engine does not stop E-2 q
3 Engine hunts q
4 Exhaust gas color is white or blue q
5 Exhaust gas color is black or dark gray and output is insufficient q
6 Oil is consumed much q
7 Fuel is mixed in oil q
8 Oil pressure is low q
9 Oil pressure is high q
10 Engine overheats q
11 Battery is discharged quickly (Battery is dead) q
12 Glow lamp (Preheater monitor) does not light up E-7 q
13 Charge lamp (Charge level monitor) doe snot light up E-4 q
14 Charge lamp (Charge level monitor) doe snot go off E-4 q
Phenomena related to work equipment, travel, swing, and blade
15 Speed or power of whole work equipment, travel, swing, and blade is low H-1
16 Engine speed lowers extremely or engine stalls H-2
17 Work equipment, travel, swing, and blade systems do not work E-10 H-3
18 Abnormal sound comes out from around hydraulic pump H-4
19 Fine control performance or response is low H-5
Phenomena related to work equipment
20 Speed or power of boom is low H-6
21 Speed or power of arm is low H-7
22 Speed or power of bucket is low H-8
23 Speed or power of boom swing is low H-9
PC18MR-2 20-213
(1)
Troubleshooting Classification and procedures of troubleshooting
Troubleshooting
No. Phenomena looking like troubles
E-mode H-mode S-mode
24 Work equipment does not move singly H-10

25 Hydraulic drift of work equipment is large H-11
26 Time lag of work equipment is large H-12
Phenomenon related to compound operation
27 During compound operation of work equipment, speed of part loaded more is low H-13
Phenomena related to travel
28 Machine deviates during travel H-14
29 Speed or power of travel is low H-15
30 Machine is not steered well or steering power is low H-16
31 Travel speed does not change E-8 H-17
32 Travel motor does not work (only 1 side) H-18
33 Travel alarm does not sound or does not stop sounding E-13
Phenomena related to swing
34 Speed or power of swing is low H-19
35 Machine does not swing H-20
36 Swing acceleration is low H-21
37 Machine overruns largely when it stops swinging H-22
38 Large shock is made when machine stops swinging H-23
39 Large sound is made when machine stops swinging H-24
40 Hydraulic drift of swing is large H-25
Phenomena related to blade and variable gauge
41 Speed or power of blade is low H-26
42 Blade does not move E-11 H-27
43 Hydraulic drift of blade is large H-28
44 Variable gauge does not move E-11 H-29
Phenomena related to hydraulic breaker
45 Troubleshooting for hydraulic breaker H-30
Phenomena related to monitor panel
46 Engine oil pressure monitor does not indicate normally E-3
47 Charge level monitor does not indicate normally E-4
48 Fuel level gauge does not indicate normally E-5
49 Service meter does not operate normally E-6
50 Preheating system does not operate normally E-7
51 Travel speed shifting system does not operate normally E-8 H-17
52 Engine coolant temperature monitor does not indicate normally E-9
Other phenomena
53 Lock lever does not operate normally E-10 H-3
H-27
54 Blade/Variable gauge selector system does not operate normally E-11
H-29
55 Night lamp of machine monitor and working lamp do not light up E-12
20-214 PC18MR-2
(4)
Troubleshooting Connectors list and connectors arrangement stereogram
Connectors list and connectors arrangement stereogram

Connectors list
a The addresses roughly show the places of the connectors in the connectors arrangement stereogram.
Address in
Connector No. Type No. of pins Name of device stereogram
A5 DT-T 2 Travel alarm L-2
A6 X 2 Travel oil pressure switch (Left reverse) J-1
A7 X 2 Travel oil pressure switch (Right reverse) J-1
A8 X 2 Travel oil pressure switch (Left forward) K-1
A9 X 2 Travel oil pressure switch (Right forward) J-1
D1 SWP 2 Diode C-3
D2 SWP 2 Diode B-3
D3 SWP 2 Diode J-1
F1 VCH 6 Blade/Variable gauge selector switch L-7
F2 DT 2 Left PPC lock switch L-8
F3 DT 2 Intermediate connector (Spare) J-9
F4 DT 2 Rotary lamp J-9
F5 DT 2 Horn switch I-9
F6 DT 2 Right PPC lock switch H-8
F7 KES 2 Machine monitor (Service meter) H-9
F8 SWP 14 Machine monitor (Gauge/Lamp) H-9
F9 VCH 6 Lamp switch J-9
F10 VCH 6 Travel speed shifting switch I-9
F11 YAZAKI 4 Engine coolant temperature monitor timer relay A-5
F12 YAZAKI 6 Preheater monitor timer A-6
F13 YAZAKI 4 Engine stop solenoid timer A-5
FB1 – – Fuse box A-6
M1 YAZAKI 2 Horn G-1
M2 – 2 Fusible link (35 A) L-7
M3 YAZAKI 1 Starting motor (Terminal ST) L-7
M4 DT 3 Engine stop solenoid K-9
M5 X 2 Fuel pump G-8
M6 YAZAKI 1 Engine coolant temperature switch K-9
M7 SUMITOMO 3 Alternator (Terminal L, terminal TG, terminal P) K-9
M8 YAZAKI 2 Intermediate connector L-5
PC18MR-2 20-215
(1)
Address in
Connector No. Type No. of pins Name of device stereogram
M9 DT 2 PPC lock solenoid valve G-8
M10 DT 2 2nd travel speed selection solenoid valve G-8
M11 DT 2 Variable gauge selector solenoid valve I-1
M12 X 4 Intermediate connector (Spare) H-1
M13 YAZAKI 2 Fuel level sensor L-5
R1 Relay 5 Engine start circuit relay C-6
R2 Relay 5 PPC lock solenoid circuit relay B-5
R3 Relay 5 2nd travel speed selection solenoid circuit relay A-5
R4 YAZAKI 4 Engine safety relay C-5
R5 YAZAKI 4 Engine stop solenoid relay B-4
T-F1 Terminal 1 Starting switch (Terminal B) B-8
T-F2 Terminal 1 Starting switch (Terminal BR) B-7
T-F3 Terminal 1 Starting switch (Terminal ACC) A-8
T-F4 Terminal 1 Starting switch (Terminal C) A-8
T-F5 Terminal 2 Starting switch (Terminal R1) C-8
T-F6 Terminal 1 Starting switch (Terminal R2) B-7
T-M1 Terminal 2 Battery L-6
T-M2 Terminal 2 Starting motor (Terminal B) L-7
T-M3 Terminal 1 Engine oil pressure switch K-9
T-M4 Terminal 1 Alternator (Terminal B) H-8
T-M5 Terminal 1 Glow plug L-8
T-M6 Terminal 1 Revolving frame ground G-1
W1 DT 2 Intermediate connector I-1
W2 DT 3 Working lamp D-6
W3 DT 3 Additional working lamp G-1
20-216 PC18MR-2
(1)
Connectors arrangement stereogram
20-218 PC18MR-2
(1)
PC18MR-2 20-219
(1)
Troubleshooting Connection table for connector pin numbers
Connection table for connector pin numbers

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-220 PC18MR-2
(1)
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC18MR-2 20-221
(1)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-222 PC18MR-2
(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC18MR-2 20-223
(1)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-224 PC18MR-2
(1)
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC18MR-2 20-225
(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-226 PC18MR-2
(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
PC18MR-2 20-227
(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-228 PC18MR-2
(1)
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
PC18MR-2 20-229
(1)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-230 PC18MR-2
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
PC18MR-2 20-231
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-232 PC18MR-2
(1)
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
PC18MR-2 20-233
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-234 PC18MR-2
(1)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC18MR-2 20-235
(1)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-236 PC18MR-2
(1)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC18MR-2 20-237
(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-238 PC18MR-2
(1)
DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC18MR-2 20-239
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820T (normal type) Part No.: 08192-1810T (normal type)
08192-2820T (fine wire type) 08192-2810T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920T (normal type) Part No.: 08192-1910T (normal type)
08192-2920T (fine wire type) 08192-2910T (fine wire type)
20-240 PC18MR-2
(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC18MR-2 20-241
(1)
DRC26 Series connector

No.of
pins T-adapter Part
No.
24 799-601-9360
— Part No. : 7821-93-3110
40
799-601-9350
(A)
— Part No. : 7821-93-3120
40
799-601-9350
(B)
— Part No. : 7821-93-3130
20-242 PC18MR-2
(1)
Troubleshooting T-adapter - boxes and T-adapter table
T-adapter - boxes and T-adapter table

The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
KIT Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Part No. Type of connector No. of pins
799-601-2600 Box for measurement Econo-21P Q Q Q Q Q Q

799-601-3100 Box for measurement MS-37P Q
799-601-3200 Box for measurement MS-37P Q
799-601-3300 Box for measurement Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
PC18MR-2 20-243
(1)
KIT Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7320 SWP 16P Q

799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
20-244 PC18MR-2
(1)
KIT Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9240 HD30 18-21 Q Q

799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Box for measurement For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
pressure
799-601-9430 PVC socket 2P Q
PC18MR-2 20-245
(1)
Troubleshooting of electrical system
(E mode)
Before carrying out troubleshooting for electrical system (E mode)............................................................ 20-302
Information contained in troubleshooting table ........................................................................................... 20-304
E-1 Engine does not start ......................................................................................................................... 20-305
E-2 Engine does not stop ......................................................................................................................... 20-312
E-3 Engine oil pressure monitor does not indicate normally .................................................................... 20-314
E-4 Charge level monitor does not indicate normally ............................................................................... 20-317
E-5 Fuel level gauge does not indicate normally...................................................................................... 20-320
E-6 Service meter does not operate normally .......................................................................................... 20-323
E-7 Preheating system does not operate normally .................................................................................. 20-325
E-8 Travel speed shifting system does not operate normally ................................................................... 20-328
E-9 Engine coolant temperature monitor does not indicate normally ....................................................... 20-332
E-10 Lock lever does not operate normally ................................................................................................ 20-336
E-11 Blade/Variable gauge selector system does not operate normally .................................................... 20-339
E-12 Night lamp of machine monitor and working lamp do not light up ..................................................... 20-342
E-13 Travel alarm does not sound or does not stop sounding ................................................................... 20-345
PC18MR-2 20-301
(1)
Troubleshooting Before carrying out troubleshooting for electrical system (E mode)
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 Destination of power

capacity
Constant power supply
M2 45A Starting switch (Terminal B)
(Battery)
Fuse box 1 (FB1)
Type of power supply Fuse No. Fuse Destination of power

capacity
1
— (Between terminals — Unused
1 and 11)
Switch power supply 2 Lamp circuit
(Starting switch (Between terminals 20A
terminal BR) 2 and 12) Fuel pump circuit
3 Engine stop solenoid circuit

(Between terminals 30A
3 and 13) Safety relay circuit
PPC lock solenoid valve circuit

4
(Between terminals 20A 2nd travel speed selection solenoid valve circuit
4 and 14)
Switch power supply Engine coolant temperature monitor timer relay
(Starting switch
terminal ACC) Horn circuit
5
(Between terminals 10A Rotary lamp circuit (if equipped)
5 and 15)
Travel alarm (if equipped)
6
(Between terminals 20A Power supply for options
6 and 16)
20-302 PC18MR-2
(1)
Troubleshooting Before carrying out troubleshooting for electrical system (E mode)
Location of fuse and fuse numbers
PC18MR-2 20-303
(1)
Troubleshooting Information contained in troubleshooting table
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
Phenomena occurring on machine
information
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause 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.
• Short circuit
Cause that presumably trig-
Presumed cause Independent wiring harnesses are in contact with each other abnor-
gered failure in question
and standard mally.
value in normalcy (The assigned No. is for fil-
ing purpose only. It does not <Precaution for Troubleshooting>
stand for any priority) 1)Connector No. display method and handling of T-adapter
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-adepter 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
20-304 PC18MR-2
(1)
Troubleshooting E-1
E-1 Engine does not start
Failure
(1) When the starting switch is set in START, the starting motor does not revolve.
information
Relative • Since the engine starting circuit has the neutral safety function, the engine does not start unless the lock
information lever is in the LOCK position.

Low charge level of battery Battery voltage Electrolyte specific gravity
1 or low electrolyte specific
gravity Min. 12 V Min. 1.26
If the fusible link is broken, the circuit probably has a grounding fault.
2 Defective fusible link M2
(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 of switch Resistance
Defective starting switch
4 Between T-F1 (B) and OFF Min. 1 Mz
(Internal disconnection)
T-F3 (ACC) ON Max. 1 z
Between T-F1 (B) and OFF Min. 1 Mz
T-F4 (C) START Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting with-
Defective left PPC lock out turning starting switch.
5 switch (Internal disconnec- F2 (male) Left lock lever Resistance
tion) LOCK Min. 1 Mz
Between (1) and (2)
FREE Max. 1 z
Presumed cause aPrepare with starting switch OFF, then carry out troubleshooting with-
and standard Defective right PPC lock out turning starting switch.
value in normalcy 6 switch (Internal disconnec- F5 (male) Right lock lever Resistance
Between (1) and (2)
FREE Max. 1 z
out turning starting switch.
R1 (male) Resistance
Defective relay for engine
Between (1) and (2) 82 – 88 z
7 start circuit (Internal discon-
nection) Between (3) and (5) Min. 1 Mz
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
Defective safety relay (Inter- chassis ground
8
nal defect) Between (1) and (3) Charge input Max. 1 V
Between (2) and
Start output 10 – 15 V
chassis ground
If the start input, charge input, and power input are normal the safety
relay is defective.
PC18MR-2 20-305
(1)
Troubleshooting E-1

aPrepare with starting switch OFF, then hold starting switch in START
and carry out troubleshooting.
Starting motor 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
Defective alternator (Inter- carry out troubleshooting.
10
nal short circuit) M7 Voltage
Between (2) and chassis ground Max. 1 V
Wiring harness between battery (–) and chassis
Resistance Max. 1 z
ground
Wiring harness between T-M1 (+) and M2
Resistance Max. 1 z
Presumed cause (female) (2)
and standard Wiring harness between M2 (female) (1) and T-
value in normalcy Resistance Max. 1 z
F1 (B)
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 har- Wiring harness between F2 (female) (1) and F6
ness (Disconnection or Resistance Max. 1 z
11 (female) (2)
defective contact of connec-
Wiring harness between F6 (female) (1) and R1
tor) 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
Resistance Max. 1 z
M3 (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
20-306 PC18MR-2
(1)
Troubleshooting E-1

Between T-M1(+) – M2 (female) (2) wiring har-
Resistance Min. 1 z
ness and chassis ground
Between M2 (female) (1) – T-F1 (B) wiring har-
Resistance Min. 1 z
Between T-F3 (ACC) – FB1 (3), (4) wiring har-
Resistance Min. 1 z
Between FB1 (10) – F2 (female) (2) or other
related circuit wiring harness and chassis Resistance Min. 1 z
ground
Presumed cause Between F2 (female) (1) – F6 (female) (2) wir-
and standard Grounding fault in wiring Resistance Min. 1 z
ing harness and chassis ground
12 harness (Contact with
value in normalcy Between R4 (female) (2) – M3 (female) (ST)
ground circuit) Resistance Min. 1 z
wiring 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 T-
Resistance Min. 1 z
M2 (2) wiring harness and chassis ground
PC18MR-2 20-307
(1)
Troubleshooting E-1
Failure
(2) When the starting switch is set in START, the starting motor revolves.
information
Relative
• If the engine stop solenoid does not operate, the fuel injection pump does not injecting fuel.
information

If the fuse is broken, the circuit probably has a grounding fault (See
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
2
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 sole- Between (A) and (C) Holding voltage 10 – 15 V
3 noid (Internal disconnection
or short circuit) For 1 sec: 10 – 15 V
Between (B) and (C) Pulling voltage
After 1 sec: Max. 1 V
If the folding voltage and pulling voltage and normal but the solenoid rod
does not operate, the solenoid is defective.
turn it ON and carry out troubleshooting in each case.
F13 Voltage
Defective engine stop sole- Between (4) and (3) Input voltage 10 – 15 V
4
noid timer (Internal defect) For 1 sec: 10 – 15 V
Between (1) and (2) Output voltage
If the input voltage is normal but the output voltage is not normal, the
timer is defective.
Presumed cause
and standard aPrepare with starting switch OFF, then keep starting switch OFF and
value in normalcy turn it ON and carry out troubleshooting in each case.
R5 Voltage
Defective engine stop sole-
5 noid relay (Internal discon- For 1 sec: 10 – 15 V
Between (e) and (g) Coil voltage
nection or short circuit) After 1 sec: Max. 1 V
For 1 sec: Max. 1 V
Between (B) and (G) Contact voltage
After 1 sec: 10 – 15 V
Defective diode (Internal out turning starting switch.
6
short circuit) D2 (male) Resistance/Continuity
Between (1) and (2) Min. 1 Mz (No continuity)
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) –
Disconnection in wiring har- Resistance Max. 1 z
ness (Disconnection or
7 Wiring harness between F13 (female) (1) – R5
defective contact of connec- Resistance Max. 1 z
tor) (female) (e)
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
20-308 PC18MR-2
(1)
Troubleshooting E-1

Between T-F3 (ACC) – FB1 (3) wiring harness
Resistance Min. 1 Mz
and chassis ground
Between FB1 (9) – M4 (female) (A) or R5
Presumed cause
Grounding fault in wiring (female) (B) or F13 (female) (4) or circuit branch Resistance Min. 1 Mz
and standard
8 harness (Contact with end and chassis ground
value in normalcy
ground circuit) Between F13 (female) (1) – R5 (female) (e) wir-
Between F13 (female) (2) – R5 (female) (g) wir-
Between R5 (female) (G) – M4 (female) (B) wir-
PC18MR-2 20-309
(1)
Troubleshooting E-1
Circuit diagram related to engine preheating, start, charge, and stop
20-310 PC18MR-2
(1)
Troubleshooting E-2
E-2 Engine does not stop
Failure
Engine dose not stop.
information
Relative
• If the engine stop solenoid does not stop, the fuel injection pump does not stop injecting fuel.
information

aPrepare with starting switch OFF, then carry out troubleshooting with
starting switch OFF and ON.
1 Starting switch Position of switch Resistance
(Internal short circuit)
aCarry out troubleshooting with starting switch OFF.
Presumed cause Defective engine stop sole- When the connector (Right No.) of the engine stop solenoid
and standard 2
noid (Internal defect) is disconnected, if the engine does not stop, the solenoid M4
value in normalcy may be seized or stuck.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Short circuit with power Between T-F3 (ACC) – FB1 (3) wiring harness
Voltage Max. 1V
3 source (Contact with 12V and chassis ground
circuit) in wiring harness Between FB1 (9) – M4 (female) (A) or D2
(female) (1) or R5 (female) (B) or F13 (female) Voltage Max. 1V
(4) or circuit branch end and chassis ground
20-312 PC18MR-2
(1)
Troubleshooting E-2
Circuit diagram related to engine preheating, start, charge, and stop
PC18MR-2 20-313
(1)
Troubleshooting E-3
E-3 Engine oil pressure monitor does not indicate normally
Failure (1) When starting switch is turned ON (before engine is started), engine oil pressure monitor does not light
information up.
Relative • The engine oil pressure monitor should keep lighting up (before the engine is started) while the starting
information switch is in the ON position.

Cause 5).
2 Broken bulb The engine oil pressure monitor bulb may be broken. Check it directly.
Defective engine oil pres- start engine and carry out troubleshooting in each case.
3 sure switch (Internal discon- T-M3 (Switch side) Engine Resistance
nection) Between terminal and Stopped Max. 1 z
chassis ground Running Min. 1 Mz
Disconnection in wiring har- Wiring harness between T-F3 (ACC) – FB1 (3) Resistance Max. 1 z
4 ness (Disconnection or
Presumed cause Wiring harness between FB1 (10) – F8 (female)
defective contact) Resistance Max. 1 z
and standard (1)
value in normalcy Wiring harness between F8 (female) (2) – T-M3 Resistance Max. 1 z
Grounding fault in wiring
5 harness (Contact with Resistance Min. 1 Mz
and chassis ground
ground circuit)
Between FB1 (10) – F8 (female) (1) or circuit
branch end and chassis ground
start engine and carry out troubleshooting in each case.
F8 Engine Voltage
6 Defective machine monitor
Stopped (Starting
10 – 15 V
Between (1) and (2) switch is ON)
Running Max. 1 V
20-314 PC18MR-2
(1)
Troubleshooting E-3
Failure
(2) While engine is running, engine oil pressure monitor lights up.
information
Relative • The engine oil pressure monitor is kept OFF while the engine is running, but it lights up when low engine
information oil pressure is detected.

1 Low engine oil pressure Check the engine oil pressure. If it is low, repair it.
Defective engine oil pres- start engine and carry out troubleshooting in each case.
2 sure switch (Internal short T-M3 (Switch side) Engine Resistance
circuit) Between terminal and Stopped Max. 1 z
chassis ground Running Min. 1 Mz
and standard Grounding fault in wiring
value in normalcy 3 harness (Contact with Between F8 (female) (2) – T-M3 wiring harness
ground circuit) Resistance Min. 1 Mz
and chassis ground
F8 Engine Voltage
Stopped (Starting
10 – 15 V
Running Max. 1 V
PC18MR-2 20-315
(1)
Troubleshooting E-3
Circuit diagram related to engine oil pressure monitor and service meter
20-316 PC18MR-2
(1)
Troubleshooting E-4
E-4 Charge level monitor does not indicate normally
Failure
(1) When starting switch is turned ON (before engine is started), charge level monitor does not light up.
information
Relative • The charge level monitor should keep lighting up (before the engine is started) while the starting switch
information is in the ON position.

Cause 5).
2 Broken bulb The charge level monitor bulb may be broken. Check it directly.
Defective alternator M7 Engine Voltage
3
(Internal defect) Stopped (Starting
Between (1) and Max. 1 V
switch is ON)
chassis ground
Running 10 – 15 V
Disconnection in wiring har- Wiring harness between T-F3 (ACC) – FB1 (4) Resistance Max. 1 z
Presumed cause 4 ness (Disconnection or Wiring harness between FB1 (10) – F8 (female)
Resistance Max. 1 z
and standard defective contact) (1)
value in normalcy Wiring harness between F8 (female) (3) – M7
Resistance Max. 1 z
(female) (1)
and chassis ground
ground circuit)
F8 Engine Voltage
Stopped (Starting
10 – 15 V
Running Max. 1 V
PC18MR-2 20-317
(1)
Troubleshooting E-4
Failure
(2) While engine is running, charge level monitor lights up.
information
Relative • The charge level monitor is kept OFF while the engine is running, but it lights up when low charge volt-
information age is detected.

M7 Engine Resistance
Stopped (Starting
Defective alternator Between (1) and Max. 1 V
1 switch is ON)
(Defective generation) chassis ground
Running 10 – 15 V
Stopped (Starting
Between (2) and Max. 1 V
switch is ON)
Presumed cause chassis ground
Running 10 – 15 V
and standard
value in normalcy aPrepare with starting switch OFF, then carry out troubleshooting with-
Grounding fault in wiring out turning starting switch.
ground circuit) Between F8 (female) (3) – M7 (female) (1) wir-
F8 Engine Voltage
Stopped (Starting
10 – 15 V
Running Max. 1 V
20-318 PC18MR-2
(1)
Troubleshooting E-4
Circuit diagram related to preheating, starting, charging, and stopping of engine
PC18MR-2 20-319
(1)
Troubleshooting E-5
E-5 Fuel level gauge does not indicate normally
Failure
(1) While fuel level is high enough, gauge does not rise above level E.
information
Relative • The fuel level gauge may not indicate the fuel level normally for a while after the starting switch is turned
information ON. This is not a trouble, however.

Cause 4).
Resistance
M13 (male) Position of sensor float
(Reference value)
Defective fuel level sensor FULL 10 ± 0.5 z
2
3/4 (19 z)
Between (1) and (2) 1/2 32 ± 1.0 z
1/4 (49.5 z)
EMPTY 87 ± 1.5 z
Disconnection in wiring har- Wiring harness between FB1 (10) – F8 (female)
Resistance Max. 1 z
3 ness (Disconnection or (1)
defective contact) Wiring harness between F8 (female) (9) – M13
Resistance Max. 1 z
(female) (1)
Presumed cause
Wiring harness between M13 (female) (2) –
and standard Resistance Max. 1 z
value in normalcy chassis ground (T-M6)
and chassis ground
ground circuit)
Short circuit with power
5 source (Contact with 24V
circuit) in wiring harness Between F8 (female) (9) – M13 (female) (1) wir-
Voltage Max. 1 V
Resistance
F8 (female) Position of sensor float
(Reference value)
6 Defective machine monitor FULL 10 ± 0.5 z
3/4 (19 z)
Between (9) and
1/2 32 ± 1.0 z
chassis ground
1/4 (49.5 z)
EMPTY 87 ± 1.5 z
20-320 PC18MR-2
(1)
Troubleshooting E-5
Failure
(2) While fuel level is low, gauge does not lower below level F.
information

Resistance
(Reference value)
1
3/4 (19 z)
Between (1) and (2) 1/2 32 ± 1.0 z
1/4 (49.5 z)
EMPTY 87 ± 1.5 z
and standard out turning starting switch.
value in normalcy Between F8 (female) (9) – M13 (female) (1) wir-
Resistance
(Reference value)
3/4 (19 z)
Between (9) and
1/2 32 ± 1.0 z
chassis ground
1/4 (49.5 z)
EMPTY 87 ± 1.5 z
Failure
(3) Indicated fuel level is very different from actual fuel level.
information

Resistance
(Reference value)
1
3/4 (19 z)
Between (1) and (2) 1/2 32 ± 1.0 z
Presumed cause 1/4 (49.5 z)
and standard EMPTY 87 ± 1.5 z
Resistance
(Reference value)
3/4 (19 z)
Between (9) and
1/2 32 ± 1.0 z
chassis ground
1/4 (49.5 z)
EMPTY 87 ± 1.5 z
PC18MR-2 20-321
(1)
Troubleshooting E-5
Circuit diagram related to fuel level gauge
20-322 PC18MR-2
(1)
Troubleshooting E-6
E-6 Service meter does not operate normally
Failure
(1) When starting switch is turned ON (before engine started), service meter operates.
information
Relative
• The service meter is stopped and started by the signal of the engine oil pressure switch.
information

When the starting switch is turned ON (before the engine is started), if
Defective engine oil pres- the engine oil pressure monitor does not light up either, carry out trou-
1
sure monitor system bleshooting for trouble (1) in "E-3 Engine oil pressure monitor does not
indicate normally".
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting with-
Presumed cause 2 ness (Disconnection or out turning starting switch.
and standard defective contact of connec- Wiring harness between F7 (female) (1) – chas-
Resistance Max. 1 z
value in normalcy tor) sis ground (T-M6)
F7 Engine Voltage
Stopped (Starting
Max. 1 V
Running 10 – 15 V
Failure
(2) While engine is running, service meter does not operate.
information
Relative
• The service meter is stopped and started by the signal of the engine oil pressure switch.
information

While the starting switch is turned ON (before the engine is started), if
Defective engine oil pres- the engine oil pressure monitor lights up, carry out troubleshooting for
1
sure monitor system trouble (2) in "E-3 Engine oil pressure monitor does not indicate nor-
Presumed cause mally".
and standard aPrepare with starting switch OFF, then turn starting switch ON and
value in normalcy start engine and carry out troubleshooting in each case.
F7 Engine Voltage
Stopped (Starting
Max. 1 V
Running 10 – 15 V
PC18MR-2 20-323
(1)
Troubleshooting E-6
Circuit diagram related to service meter and engine oil pressure monitor
20-324 PC18MR-2
(1)
Troubleshooting E-7
E-7 Preheating system does not operate normally
Failure
(1) When starting switch is turned to HEAT position, preheater monitor does not light up.
information
• After the starting switch is turned to the HEAT position, the preheater monitor should light up for 10 sec-
Relative onds and then go off.
information • Before carrying out troubleshooting, check that the starting motor revolves normally. (If the starting mo-
tor does not revolve, carry out troubleshooting for trouble (1) in "E-1 Engine does not start".

1 Broken bulb The preheater monitor bulb may be broken. Check it directly.
If the preheater does not work (If the glow plug is not heated), carry out
2 Defective starting switch
troubleshooting for trouble (2).
aPrepare with starting switch OFF, then turn starting switch to HEAT
position and carry out troubleshooting.
F12 Voltage
Between (6) and (1) Preheating signal 10 – 15 V
Defective preheater monitor
3 Between (5) and (1) Start signal Max. 1 V
timer (Internal defect)
For 10 sec: Max. 1 V
Between (4) and (1) Lamp signal
After 10 sec: 10 – 15 V
If the preheating signal and start signal are normal but the lamp signal
is not normal, the preheater monitor timer is defective.
Disconnection in wiring har- out turning starting switch.
and standard
value in normalcy 4 ness (Disconnection or Wiring harness between T-F5 (R1) – F8
Resistance Max. 1 z
defective contact of connec- (female) (6) or F12 (female) (6)
tor) Wiring harness between F8 (female) (4) – F12
Resistance Max. 1 z
(female) (4)
5 harness (Contact with Between T-F5 (R1) – F8 (female) (5) or F12
ground circuit) (female) (6) or circuit branch end and chassis Resistance Min. 1 Mz
ground
aPrepare with starting switch OFF, then set starting switch in OFF posi-
tion and HEAT position and carry out troubleshooting in each case.
F8 Starting switch Voltage
OFF Max. 1 V
Between (5) and (4) For 10 sec: 10 – 15 V
HEAT
PC18MR-2 20-325
(1)
Troubleshooting E-7
Failure
(2) When starting switch is turned to HEAT position, preheater is not heated.
information
Relative • Before carrying out troubleshooting, check that the starting motor revolves normally. (If the starting mo-
information tor does not revolve, carry out troubleshooting for trouble (1) in "E-1 Engine does not start".

aPrepare with starting switch OFF, then set starting switch in OFF posi-
tion and HEAT position and carry out troubleshooting in each case.
1 Starting switch Starting switch Resistance
Between T-F1 (B) OFF Min. 1 Mz
and T-F5 (R1) HEAT Max. 1 z
Defective glow plug out turning starting switch.
Presumed cause 2
and standard (Internal disconnection) Glow plug (1 piece) Resistance
value in normalcy Between terminal and chassis Approx. 0.9 z
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting with-
ness (Disconnection or out turning starting switch.
3
tor) Wiring harness between T-F5 (R1) – T-M5 Resistance Max. 1 z
ground circuit) Between T-F5 (R1) – T-M5 or circuit branch end
and chassis ground
20-326 PC18MR-2
(1)
Troubleshooting E-7
Circuit diagram related to preheating, starting, charging, and stopping of engine
PC18MR-2 20-327
(1)
Troubleshooting E-8
E-8 Travel speed shifting system does not operate normally
(1) When travel speed shifting switch is set in low travel speed, 2nd travel speed selection monitor does
Failure
not go off.
information
(2) When travel speed shifting switch is set in low travel speed, travel speed does not lower.
Relative • If the travel speed shifting switch is set in the low travel speed position, the 2nd travel speed selection
information monitor should go off and the travel speed should lower.

Travel speed shifting
1 Defective machine monitor F8 Voltage
switch
Low travel speed Max. 1 V
Between (7) and (10)
High travel speed 10 – 15V
F10 (male) Position of switch Resistance
Defective travel speed shift- Hare (Hold) Max. 1 z
2 ing switch (Internal short cir- Between (1) and (2) Center (Auto return) Min. 1 Mz
cuit) Tortoise (Hold) Min. 1 Mz
Hare (Hold) Max. 1 z
Between (4) and (5) Center (Auto return) Max. 1 z
Tortoise (Hold) Min. 1 Mz
Presumed cause Between (1) and (2) 82 – 88 z
Defective 2nd travel speed
and standard
3 selection solenoid circuit Between (3) and (5) Min. 1 Mz
value in normalcy
relay (Internal short circuit) Between (3) and (6) Max. 1 z
Replace the 2nd travel speed selection solenoid circuit relay (R3) with
another relay. If the condition becomes normal at this time, the relay is
defective.
Defective 2nd travel speed M10 (male) Resistance
selection solenoid valve Between (1) and (2) 10.5 – 12 z
4
(Internal disconnection or Between (1) and chassis ground Min. 1 Mz
short circuit) Disconnect the 2nd travel speed selection solenoid valve (M10). If the
condition does not become normal at this time, the valve may be seized
or stuck.
Between F10 (female) (1) – R3 (female) (1) –
D1 – F10 (female) (4) wiring harness and chas- Voltage Max. 1 V
sis ground
circuit) in wiring harness
Between F8 (female) (7) – F10 (female) (5) –
R3 (female) (5) – M10 (female) (1) wiring har- Voltage Max. 1 V
20-328 PC18MR-2
(1)
Troubleshooting E-8
(3) When travel speed shifting switch is set in high travel speed, 2nd travel speed selection monitor does
Failure
not light up.
information
(4) When travel speed shifting switch is set in high travel speed, travel speed does not rise.
• If the travel speed shifting switch is set in the low travel speed position, the 2nd travel speed selection
monitor should light up and the travel speed should rise.
Relative
• The travel motor has an automatic gear shifting mechanism. If the travel load increases during high-
information
speed travel, the travel speed is automatically set low. (If the travel load decreases, the travel speed
rises again.)

Cause 7).
Travel speed shifting
2 Defective machine monitor F8 Voltage
switch
Low travel speed Max. 1 V
High travel speed 10 – 15V
F10 (male) Position of switch Resistance
Defective travel speed shift- Hare (Hold) Max. 1 z
3 ing switch (Internal short cir- Between (1) and (2) Center (Auto return) Min. 1 Mz
cuit) Tortoise (Hold) Min. 1 Mz
Hare (Hold) Max. 1 z
Between (4) and (5) Center (Auto return) Max. 1 z
Tortoise (Hold) Min. 1 Mz
Presumed cause
and standard Defective 2nd travel speed Between (1) and (2) 82 – 88 z
value in normalcy 4 selection solenoid circuit Between (3) and (5) Min. 1 Mz
relay (Internal short circuit) Between (3) and (6) Max. 1 z
Replace the 2nd travel speed selection solenoid circuit relay (R3) with
another relay. If the condition becomes normal at this time, the relay is
defective.
Defective 2nd travel speed out turning starting switch.
selection solenoid valve M10 (male) Resistance
5
(Internal disconnection or
short circuit) Between (1) and (2) 10.5 – 12 z
Between (1) and chassis ground Min. 1 Mz
Wiring harness between FB1 (10) – F10
Resistance Max. 1 z
Disconnection in wiring har- (female) (2) or R3 (female) (3)
ness (Disconnection or Wiring harness between F10 (female) (1) – R3
6 Resistance Max. 1 z
defective contact of connec- (female) (1) – D1 (1), (2) – F10 (female) (4)
tor) Wiring harness between R3 (female) (2) –
Resistance Max. 1 z
Wiring harness between F8 (female) (7) – F10
(female) (5) – R3 (female) (5) – M10 (female) Resistance Max. 1 z
(1)
PC18MR-2 20-329
(1)
Troubleshooting E-8

Disconnection in wiring har- Wiring harness between F8 (female) (10) –
Resistance Max. 1 z
ness (Disconnection or chassis ground (T-M6)
6
defective contact of connec- Wiring harness between M10 (female) (2) –
Presumed cause Resistance Min. 1 Mz
and standard and chassis ground
value in normalcy Between FB1 (10) – F10 (female) (2) or R3
Grounding fault in wiring (female) (3) or circuit branch end and chassis Resistance Min. 1 Mz
7 harness (Contact with ground
ground circuit) Between F10 (female) (1) – R3 (female) (1) –
D1 (1), (2) – F10 (female) (4) wiring harness Resistance Min. 1 Mz
and chassis ground
Between F8 (female) (7) – F10 (female) (5) –
R3 (female) (5) – M10 (female) (1) wiring har- Resistance Min. 1 Mz
20-330 PC18MR-2
(1)
Troubleshooting E-8
Circuit diagram related to travel speed shifting switch and 2nd travel speed selection monitor
PC18MR-2 20-331
(1)
Troubleshooting E-9
E-9 Engine coolant temperature monitor does not indicate normally
Failure (1) When starting switch is turned ON (before engine is started), engine coolant temperature monitor does
information not light up for 3 seconds.
Relative • When starting switch is turned ON, the engine coolant temperature monitor should keep lighting up (be-
information fore the engine is started) for 3 seconds and then go off.

Cause 5).
The engine coolant temperature monitor bulb may be broken. Check it
2 Broken bulb
directly.
aPrepare with starting switch OFF, then turn starting switch from OFF
to ON and carry out troubleshooting (Do not turn starting switch to
START).
Defective engine coolant F11 Voltage
3 temperature monitor timer Between (4) and (3) Power supply input 10 – 15 V
relay (Internal defect)
Between (2) and (3) Start signal input Max. 1 V
For 3 sec: Max. 1 V
Between (1) and (3) Lamp output
After 3 sec: 10 – 15 V
Disconnection in wiring har- Wiring harness between FB1 (10) – F11
Resistance Max. 1 z
4 ness (Disconnection or (female) (4)
defective contact) Wiring harness between F11 (female) (3) –
Resistance Max. 1 z
Presumed cause
and standard Resistance Max. 1 z
value in normalcy (female) (6)
Grounding fault in wiring and chassis ground
5 harness (Contact with Between FB1 (10) – F11 (female) (4) or F8
ground
Between FB11 (female) (1) – F8 (female) (6) or
M6 (female) (1) and chassis ground
Short circuit with power carry out troubleshooting.
circuit) in wiring harness Between FB11 (female) (1) – F8 (female) (6) or
Resistance Max. 1 V
M6 (female) (1) and chassis ground
aPrepare with starting switch OFF, then hold starting switch OFF and
ON and carry out troubleshooting in each case (Do not turn starting
switch to START).
7 Defective machine monitor F8 Starting switch Voltage
OFF Max. 1 V
OFF o ON
20-332 PC18MR-2
(1)
Troubleshooting E-9
Failure (2) When starting switch is turned ON (before engine is started), engine coolant temperature monitor lights
information up but it does not go off after 3 seconds.
Relative • When starting switch is turned ON, the engine coolant temperature monitor should keep lighting up (be-
information fore the engine is started) for 3 seconds and then go off.

Defective engine coolant
Engine coolant
1 temperature switch (Internal M6 (male) Resistance
temperature
short circuit)
Between (1) and Max. 108°C Min. 1 Mz
chassis Min. 115 ± 3°C Max. 1 z
aPrepare with starting switch OFF, then turn starting switch from OFF
to ON and carry out troubleshooting (Do not turn starting switch to
START).
F11 Voltage
Defective engine coolant Between (4) and (3) Power supply input 10 – 15 V
2 temperature monitor timer Between (2) and (3) Start signal input Max. 1 V
Presumed cause relay (Internal defect) For 3 sec: Max. 1 V
Between (1) and (3) Lamp output
and standard After 3 sec: 10 – 15 V
value in normalcy Disconnect the engine coolant temperature monitor timer relay (F11). If
the engine coolant temperature monitor goes off at this time, the timer
relay is defective.
3 harness (Contact with Between F8 (female) (6) – F11 (female) (1) –
ground circuit) M6 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
ON and carry out troubleshooting in each case.
F8 Starting switch Voltage
OFF Max. 1 V
OFF o ON
PC18MR-2 20-333
(1)
Troubleshooting E-9
Failure
(3) While engine is running, engine coolant temperature monitor lights up.
information
Relative • The engine coolant temperature monitor should be kept turned off while the engine is running, but it
information should go off when rising of engine coolant temperature is detected.

If the monitor goes off when the engine speed is set to low idle, the
1 Overheating of engine
engine may be overheating. Find out the cause and repair.
aPrepare with starting switch OFF, then keep starting switch OFF or
start engine and carry out troubleshooting.
Defective engine coolant
Engine coolant
2 temperature switch (Internal M6 (male) Resistance
temperature
short circuit)
Between (1) and Max. 108°C Min. 1 Mz
chassis Min. 115 ± 3°C Max. 1 z
Presumed cause
and standard
value in normalcy Grounding fault in wiring out turning starting switch.
3 harness (Contact with Between F8 (female) (6) – F11 (female) (1) –
ground circuit) M6 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
aPrepare with starting switch OFF, then keep starting switch OFF or
start engine and carry out troubleshooting.
Engine coolant
4 Defective machine monitor F8 Resistance
temperature
Max. 108°C Min. 1 Mz
Between (1) and (2)
Min. 115 ± 3°C Max. 1 z
20-334 PC18MR-2
(1)
Troubleshooting E-9
Circuit diagram related to engine coolant temperature monitor
PC18MR-2 20-335
(1)
Troubleshooting E-10
E-10 Lock lever does not operate normally
Failure (1) When lock lever is in FREE position, work equipment, swing system, travel system, and blade do not
information move.
Relative
information

Cause 7).
Defective left PPC lock out turning starting switch.
2 switch (Internal disconnec- F2 (male) Left lock lever Resistance
Between (1) and (2)
FREE Max. 1 z
Defective right PPC lock out turning starting switch.
3 switch (Internal disconnec- F6 (male) Right lock lever Resistance
Between (1) and (2)
FREE Max. 1 z
Defective PPC lock sole-
Between (1) and (2) 86 – 106 z
4 noid relay (Internal discon-
nection) Between (3) and (4) Max. 1 z
Between (3) and (5) Min. 1 Mz
Replace the PPC lock solenoid relay (R2) with another relay. If the con-
dition becomes normal at this time, the relay is defective.
Defective PPC lock sole- out turning starting switch.
Presumed cause 5 noid valve (Internal discon- M9 (male) Resistance
and standard nection or short circuit) Between (1) and (2) 10.5 – 12 z
value in normalcy Between (1) and chassis ground Min. 1 Mz
Wiring harness between FB1 (10) – F2 (female)
Resistance Max. 1 z
(2) or R2 (female) (3)
Disconnection in wiring har- Resistance Max. 1 z
(female) (2)
ness (Disconnection or
6 Wiring harness between F6 (female) (1) – R2
defective contact of connec- Resistance Max. 1 z
tor) (female) (1)
Wiring harness between R2 (female) (2) –
Resistance Max. 1 z
Wiring harness between R2 (female) (5) – M9
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
7 harness (Contact with Between FB1 (10) – F2 (female) (2) or R2
ground
Between F2 (female) (1) – F6 (female) (2) wir-
20-336 PC18MR-2
(1)

Presumed cause Between F6 (female) (1) – R2 (female) (1) wir-
Grounding fault in wiring Resistance Min. 1 Mz
and standard ing harness and chassis ground
value in normalcy 7 harness (Contact with
Between R2 (female) (5) – M9 (female) (1) wir-
Failure
(2) When lock lever is in LOCK position, work equipment, swing system, travel system, and blade move.
information
Relative
information

Defective left PPC lock
1 F2 (male) Left lock lever Resistance
switch (Internal short circuit)
LOCK Min. 1 Mz
Between (1) and (2)
FREE Max. 1 z
Defective right PPC lock
2 F6 (male) Right lock lever Resistance
switch (Internal short circuit)
LOCK Min. 1 Mz
Between (1) and (2)
FREE Max. 1 z
Defective PPC lock sole- Between (1) and (2) 86 – 106 z
Presumed cause 3 noid relay (Internal short cir-
and standard cuit) Between (3) and (4) Max. 1 z
value in normalcy Between (3) and (5) Min. 1 Mz
Replace the PPC lock solenoid relay (R2) with another relay. If the con-
dition becomes normal at this time, the relay is defective.
Defective PPC lock sole- M9 (male) Resistance
4 noid valve (Internal discon- Between (1) and (2) 10.5 – 12 z
nection or short circuit) Between (1) and chassis ground Min. 1 Mz
Disconnect the PPC lock solenoid valve (M9). If the condition does not
become normal at this time, the valve may be seized or stuck.
Between F6 (female) (1) – R2 (female) (1) wir-
5 source (Contact with 12V Voltage Max. 1 V
circuit) in wiring harness
Between R2 (female) (5) – M9 (female) (1) wir-
Voltage Max. 1 V
PC18MR-2 20-337
(1)
Circuit diagram related to PPC lock switch
20-338 PC18MR-2
(1)
E-11 Blade/Variable gauge selector system does not operate normally
Failure
(1) When blade/variable gauge selector switch is set in BLADE position, variable gauge moves.
information
Relative • The blade and variable gauge are selected by changing the blade control valve circuit with the variable
information gauge selector solenoid valve.

Defective blade/variable Blade/Variable gauge
1 gauge selector switch F1 (male) Resistance
selector switch
(Internal short circuit)
Blade Min. 1 Mz
Between (2) and (3)
Variable gauge Max. 1 z
Presumed cause
and standard Defective variable gauge
value in normalcy M11 (male) Resistance
selector solenoid valve
2 Between (1) and (2) 5.5 ± 0.4 z
short circuit) 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.
circuit) in wiring harness Between F1 (female) (2) – M11 (male) (1) or D3
Voltage Max. 1 V
(female) (1) wiring harness and chassis ground
PC18MR-2 20-339
(1)
Failure
(2) When blade/variable gauge selector switch is set in VARIABLE GAUGE position, blade moves.
information
Relative • The blade and variable gauge are selected by changing the blade control valve circuit with the variable
information gauge selector solenoid valve.

Cause 6).
Defective blade/variable
Blade/Variable gauge
2 gauge selector switch F1 (male) Resistance
selector switch
Blade Min. 1 Mz
Between (2) and (3)
Variable gauge Max. 1 z
Defective variable gauge out turning starting switch.
selector solenoid valve M11 (male) Resistance
3
short circuit) Between (1) and (2) 5.5 ± 0.4 z
Between (1) and chassis ground Min. 1 Mz
Defective diode (Internal out turning starting switch.
4
short circuit) D3 (male) Resistance/Continuity
Presumed cause
and standard Between (1) and (2) Min. 1 Mz (No continuity)
Disconnection in wiring har-
ness (Disconnection or Resistance Max. 1 z
5 (3)
Wiring harness between F1 (female) (2) – M11
(female) (1)
Resistance Max. 1 z
6 harness (Contact with Between FB1 (10) – F1 (female) (3) or circuit
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
20-340 PC18MR-2
(1)
Circuit diagram related to blade/variable gauge selector switch
PC18MR-2 20-341
(1)
E-12 Night lamp of machine monitor and working lamp do not light up
Failure
(1) When lamp switch is turned ON, night lamp of machine monitor does not light up.
information
Relative
• If the working lamp does not light up either, carry out troubleshooting for trouble (2).
information

1 Broken bulb The night lamp bulb may be broken. Check it directly.
Disconnection in wiring har- out turning starting switch.
ness (Disconnection or Wiring harness between F8 (female) (8) – cir-
2 Resistance Max. 1 z
Presumed cause defective contact of connec- cuit branch point (E)
and standard tor) Wiring harness between F8 (female) (10) –
Resistance Max. 1 z
value in normalcy chassis ground (T-M6)
3 Defective machine monitor F8 Lamp switch Voltage
OFF Max. 1 V
ON 10 – 15 V
20-342 PC18MR-2
(1)
Failure
(2) When lamp switch is turned ON, working lamp does not light up.
information
Relative
—
information

Defective working lamp
1 The working lamp bulb may be broken. Check it directly.
(Broken bulb)
Cause 6).
ON and carry out troubleshooting in each case.
3 Starting switch Starting switch Resistance
T-F2 (BR) ON Max. 1 z
Defective lamp switch
4 F9 (male) Lamp switch Resistance
OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Wiring harness between T-F2 (BR) – FB1 (2) Resistance Max. 1 z
Resistance Max. 1 z
(3)
Presumed cause
Wiring harness between F9 (female) (2) – W2
and standard Disconnection in wiring har- Resistance Max. 1 z
(female) (A)
value in normalcy ness (Disconnection or
5
defective contact of connec- Wiring harness between F9 (female) (2) – W2
tor) (female) (A) or W3 (female) (A) [When addi- Resistance Max. 1 z
tional working lamp is installed]
Wiring harness between W2 (female) (B) –
Resistance Max. 1 z
Wiring harness between W2 (female) (B) or W3
(female) (B) – chassis ground (T-M6) [When Resistance Max. 1 z
additional working lamp is installed]
Between T-F2 (BR) – FB1 (2) wiring harness
and chassis ground
Grounding fault in wiring branch end wiring harness and chassis ground
6 harness (Contact with Between F9 (female) (2) – W2 (female) (A) or
ground circuit) F8 (female) (8) wiring harness and chassis Resistance Min. 1 Mz
ground
Between F9 (female) (2) – W2 (female) (A) or
W3 (female) (A) or F8 (female) (8) wiring har-
ness and chassis ground [When additional
working lamp is installed]
PC18MR-2 20-343
(1)
Circuit diagram related to lamp switch
20-344 PC18MR-2
(1)
E-13 Travel alarm does not sound or does not stop sounding
Failure
(1) When machine travels, travel alarm does not sound.
information
Relative
—
information

Cause 8).
aPrepare with starting switch OFF, then start engine and carry out trou-
bleshooting in each case.
A5 (female) Travel lever Voltage/Resistance
Between (1) and Operated (Right, left,
Defective travel alarm 10 – 15 V
2 chassis ground forward, reverse)
(Internal defect)
Between (2) and
Neutral Max. 1 z
chassis ground
If the voltage and resistance are normal but the alarm does not sound,
the travel alarm is defective.
Defective left reverse PPC bleshooting in each case.
3 oil pressure switch (Internal A6 (male) Left travel lever Resistance
disconnection) Neutral Min. 1 Mz
Between (1) and (2)
Reverse Max. 1 z
Defective right reverse PPC bleshooting in each case.
Between (1) and (2)
Reverse Max. 1 z
Defective left forward PPC bleshooting in each case.
Presumed cause
and standard 5 oil pressure switch (Internal A8 (male) Right travel lever Resistance
value in normalcy disconnection) Neutral Min. 1 Mz
Between (1) and (2)
Forward Max. 1 z
Defective right forward PPC bleshooting in each case.
6 oil pressure switch (Internal A9 (male) Right travel lever Resistance
Between (1) and (2)
Forward Max. 1 z
Wiring harness between FB1 (11) – A6 (female)
Disconnection in wiring har- (1) or A7 (female) (1) or A8 (female) (1) or A9 Resistance Max. 1 z
ness (Disconnection or (female) (1)
7
defective contact of connec- Wiring harness between A6 (female) (2) or A7
tor) (female) (2) or A8 (female) (2) or A9 (female) Resistance Max. 1 z
(2) – A5 (female) (1)
Wiring harness between A5 (female) (2) – chas-
Resistance Max. 1 z
sis ground (T-M6)
Between FB1 (11) – A6 (female) (1) or A7
(female) (1) or A8 (female) (1) or A9 (female) Resistance Min. 1 Mz
(1) wiring harness and chassis ground
ground circuit)
Between A6 (female) (2) or A7 (female) (2) or
A8 (female) (2) or A9 (female) (2) – A5 (female) Resistance Min. 1 Mz
PC18MR-2 20-345
(1)
Failure
(2) When machine stops traveling, travel alarm does not stop sounding.
information
Relative
—
information

Defective left reverse PPC bleshooting in each case.
short circuit) Neutral Min. 1 Mz
Between (1) and (2)
Reverse Max. 1 z
Defective right reverse PPC bleshooting in each case.
Between (1) and (2)
Reverse Max. 1 z
Presumed cause
Defective left forward PPC bleshooting in each case.
and standard
value in normalcy 3 oil pressure switch (Internal A8 (male) Right travel lever Resistance
Between (1) and (2)
Forward Max. 1 z
Defective right forward PPC bleshooting in each case.
4 oil pressure switch (Internal A9 (male) Right travel lever Resistance
Between (1) and (2)
Forward Max. 1 z
Short circuit with power carry out troubleshooting.
5 source (Contact with 12V Between A6 (female) (2) or A7 (female) (2) or
circuit) in wiring harness A8 (female) (2) or A9 (female) (2) – A5 (female) Voltage Max. 1 V
20-346 PC18MR-2
(1)
Circuit diagram related to travel alarm
PC18MR-2 20-347
(1)
Troubleshooting of hydraulic and
mechanical system (H mode)
Information contained in troubleshooting table ........................................................................................... 20-402
H-1 Speed or power of whole work equipment, travel, swing, and blade is low ....................................... 20-403
H-2 Engine speed lowers extremely or engine stalls................................................................................ 20-404
H-3 Whole work equipment, travel system, swing system, and blade do not move ................................. 20-405
H-4 Abnormal sound comes out from around hydraulic pump ................................................................. 20-406
H-5 Fine control performance or response is low ..................................................................................... 20-406
H-6 Speed or power of boom is low.......................................................................................................... 20-407
H-7 Speed or power of arm is low ............................................................................................................ 20-408
H-8 Speed or power of bucket is low ........................................................................................................ 20-409
H-9 Speed or power of boom swing is low ............................................................................................... 20-410
H-10 Work equipment does not move singly .............................................................................................. 20-410
H-11 Work equipment hydraulic drift is large.............................................................................................. 20- 411
H-12 Time lag of work equipment is large .................................................................................................. 20-412
H-13 In compound operation of work equipment, speed of part loaded more is low.................................. 20-412
H-14 Machine deviates during travel .......................................................................................................... 20-413
H-15 Travel speed or travel power is low ................................................................................................... 20-415
H-16 Machine is not steered well or steering power is low......................................................................... 20-415
H-17 Travel speed does not change........................................................................................................... 20-416
H-18 Travel motor does not work (one side only)....................................................................................... 20-416
H-19 Speed or power of swing is low ......................................................................................................... 20-417
H-20 Machine does not swing .................................................................................................................... 20-419
H-21 Swing acceleration performance is low.............................................................................................. 20-421
H-22 Machine overruns when it stops swinging ......................................................................................... 20-422
H-23 Large shock is made when machine stops swinging ......................................................................... 20-423
H-24 When upper structure stops swinging, it makes large sound............................................................. 20-423
H-25 Hydraulic drift of swing is large .......................................................................................................... 20-424
H-26 Speed or power of blade is low.......................................................................................................... 20-425
H-27 Blade does not move ......................................................................................................................... 20-426
H-28 Hydraulic drift of blade is large........................................................................................................... 20-426
H-29 Variable gauge does not move .......................................................................................................... 20-427
H-30 Troubleshooting for hydraulic breaker ............................................................................................... 20-428
PC18MR-2 20-401
(4)
Troubleshooting Information contained in troubleshooting table
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
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
2
Cause for presumed failure
Presumed cause <Contents>
and standard (The attached No. for filing
• The standard values in normalcy by which to judge "good" or "no
3 and reference purpose only.
value in normalcy good" about presumed causes.
It does not stand for any pri-
• References for making judgement of "good" or "no good"
ority)
4
20-402 PC18MR-2
(1)
Troubleshooting H-1
H-1 Speed or power of whole work equipment, travel, swing, and blade is low
Failure
• Speed or power of whole work equipment, travel, swing, and blade is low
information
Relative • Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.
information • Check the oil pressure while the hydraulic oil temperature is 45 – 55 °C.

1 Clogged suction strainer The suction filter of the hydraulic tank may be clogged. Check it directly.
Low performance or internal The gear pump performance may be lowered or the gear pump may
2
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
+0.39
Malfunction of relief valve in 3.72 –0.10 MPa
3 All levers in neutral
2-spool solenoid valve {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.
PPC lock solenoid valve output
Lock lever
pressure
Malfunction of PPC lock
4 0 MPa
solenoid valve LOCK
{0 kg/cm²}
+0.2
3.14 –0 MPa
FREE
{32 +20 kg/cm²}
Low performance or internal The piston pump performance may be lowered or the piston pump may
5
defect of piston pump have a defect in it. Check the piston pump directly.
Presumed cause
and standard aPrepare with engine stopped, then run engine at high idle and carry
value in normalcy out troubleshooting.
Control lever LS differential pressure
+0.98
2.5 0 MPa
All levers in neutral
Malfunction or defective {25 +10
6 0 kg/cm²}
adjustment of LS valve
1.57 ± 0.1 MPa
Arm-in operation (Half stroke)
{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.
Control lever Main relief pressure
Malfunction or defective +0.98
7 adjustment of main relief 23.0 –0.49 MPa
Arm-in relief
valve {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.
8 Malfunction of unload valve Control lever Unload pressure
+0.98
2.5 0 MPa
{235 +10
0 kg/cm²}
PC18MR-2 20-403
(1)
Troubleshooting H-2
H-2 Engine speed lowers extremely or engine stalls
Failure
• Engine speed lowers extremely or engine stalls
information

Control lever LS differential pressure
+0.98
2.5 0 MPa
1 0 kg/cm²}
1.57 ± 0.1 MPa
Arm-in operation (Half stroke)
{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
Presumed cause valve directly.
and standard The LS circuit orifices (on the pump side and control valve side) may be
2 Clogged LS circuit orifice
value in normalcy clogged. Check them directly.
Arm-in relief
valve {235 +10
–5 kg/cm²}
If none of causes 1 – 4 is the cause of the trouble, the engine output may
4 Low engine output
be lowered. Carry out troubleshooting for the engine unit (S mode).
20-404 PC18MR-2
(1)
Troubleshooting H-3
H-3 Whole work equipment, travel system, swing system, and blade do not move
Failure
• Whole work equipment, travel system, swing system, and blade do not move
information

1 Clogged suction strainer The suction filter of the hydraulic tank may be clogged. Check it directly.
Defective coupling or gear The coupling (between the piston pump and gear pump) or the gear
2
pump shaft pump shaft may be defective. Check the directly.
Low performance or internal The gear pump performance may be lowered or the gear pump may
3
defect of gear pump have a defect in it. Check the gear pump directly.
Control lever Control circuit basic pressure
+0.39
Malfunction of relief valve in 3.72 –0.10 MPa
2-spool solenoid valve {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.
PPC lock solenoid valve output
Lock lever
pressure
Malfunction of PPC lock
5 0 MPa
solenoid valve LOCK
Presumed cause {0 kg/cm²}
and standard
+0.2
value in normalcy 3.14 0 MPa
FREE
{32 +20 kg/cm²}
Defective damper or piston The damper (between the engine and piston pump) or the piston pump
6
pump shaft shaft may be defective. Check the directly.
Low performance or internal The piston pump performance may be lowered or the piston pump may
7
defect of piston pump have a defect in it. Check the piston pump directly.
Arm-in relief
valve {235 +10
–5 kg/cm²}
9 Malfunction of unload valve Control lever Unload pressure
+0.98
2.5 0 MPa
{25 +10
0 kg/cm²}
PC18MR-2 20-405
(1)
Troubleshooting H-4, H-5
H-4 Abnormal sound comes out from around hydraulic pump
Failure
• Abnormal sound comes out from around hydraulic pump
information
Relative
• Before carrying out troubleshooting, check that the oil level in the hydraulic tank is normal.
information

1 Low hydraulic oil level The hydraulic oil level may be low. Check it directly.
2 Hydraulic oil of low quality
The hydraulic oil may contain air. Check it directly.
Clogging of hydraulic tankThe hydraulic tank cap may be clogged and negative pressure may be
Presumed cause 3
cap applied to the tank. Check the cap directly.
and standard
value in normalcy 4 Clogging of hydraulic tankThe hydraulic tank strainer may be clogged and negative pressure may
strainer be supplied to the suction circuit. Check the strainer directly.
5 Defective piston pump 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
• Fine control performance or response is low
information

aPrepare with engine stopped, then run engine at high idling and carry
Control levers LS differential pressure
+0.98
2.5 0 MPa
1 0 kg/cm²}
1.57 ± 0.1 MPa
Arm IN (Half stroke)
{16 ± 1 kg/cm²}
Presumed cause
If normal oil pressure is not obtained by adjustment, the LS valve may
and standard
value in normalcy 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
2 Clogging of LS circuit orifice
clogged. Check them directly.
3 Malfunction of unload valve Control levers Unload pressure
+0.98
2.5 0 MPa
All levers in neutral +10
{25 0 kg/cm²}
20-406 PC18MR-2
(1)
Troubleshooting H-6
H-6 Speed or power of boom is low
Failure
• Speed or power of boom is low
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
Relative
of whole work equipment, travel, swing, and blade speed is low".)
information
• Check the oil pressure and leakage from the cylinder while the hydraulic oil temperature is 45 – 55 °C.

Right work equipment control lever PPC valve output pressure
Malfunction of right PPC 0 MPa
1 Set in neutral
valve (boom circuit) {0 kg/cm²}
+0.2
Operate to raise boom 3.14 0 MPa
Operate to lower boom {32 +20 kg/cm²}
Malfunction of boom control
2 The boom control valve spool may have a malfunction. Check it directly.
valve (spool)
Presumed cause
Malfunction of boom control
and standard The pressure compensation valve of the boom control valve may be
3 valve (pressure compensa-
value in normalcy malfunction. Check it directly.
tion valve)
Malfunction or defective
The suction valve of the boom control valve may have a malfunction or
4 seal of boom control valve
defective seal. Check it directly.
(suction valve)
Malfunction or defective The centralized safety valve may be malfunctioning or its seal may be
5 seal of centralized safety- defective. Check the centralized safety valve directly. (A trouble in the
suction valves centralized safety valve has effects on the arm and bucket.)
Defective seal of boom cyl- out troubleshooting.
6
inder Boom cylinder Leakage from cylinder
Relieve by raising boom 10 cc/min
PC18MR-2 20-407
(1)
Troubleshooting H-7
H-7 Speed or power of arm is low
Failure
• Speed or power of arm is low
information
Relative
information

Left work equipment control lever PPC valve output pressure
Malfunction of left PPC 0 MPa
1 Set in neutral
valve (arm circuit) {0 kg/cm²}
+0.2
Operated to move arm IN 3.14 0 MPa
Operated to move arm OUT {32 +20 kg/cm²}
Malfunction of arm control
2 The arm control valve spool may have a malfunction. Check it directly.
valve (spool)
Presumed cause Malfunction of arm control
The pressure compensation valve of the arm control valve may be mal-
and standard 3 valve (pressure compensa-
function. Check it directly.
value in normalcy tion valve)
Since the suction valves of the arm control valve may have a malfunc-
4 seal of arm control valve
tion, check them directly.
(suction valve)
The centralized safety valve may be malfunctioning or its seal may be
defective. Check the centralized safety valve directly. (A trouble in the
5 seal of centralized safety-
centralized safety valve has effects on the arm, bucket, boom swing,
suction valves
and blade, too.)
Defective seal of arm cylin- out troubleshooting.
6
der Arm cylinder Leakage from cylinder
Relieved in move-IN operation 10 cc/min
20-408 PC18MR-2
(1)
Troubleshooting H-8
H-8 Speed or power of bucket is low
Failure
• Speed or power of bucket is low
information
Relative
information

Right work equipment control lever PPC valve output pressure
Malfunction of right PPC 0 MPa
1 Set in neutral
valve (bucket circuit) {0 kg/cm²}
+0.2
Operated to move CURL bucket 3.14 0 MPa
Operated to move bucket DUMP {32 +20 kg/cm²}
Malfunction of bucket con- The bucket control valve spool may have a malfunction. Check it
2
trol valve (spool) directly.
Presumed cause Malfunction of bucket con-
The pressure compensation valve of the bucket control valve may be
and standard 3 trol valve (pressure com-
malfunction. Check it directly.
value in normalcy pensation valve)
Since the suction valves of the bucket control valve may have a malfunc-
4 seal of bucket control valve
tion, check them directly.
(suction valve)
defective. Check the centralized safety valve directly. (A trouble in the
5 seal of centralized safety-
centralized safety valve has effects on the arm, bucket, boom swing,
suction valves
and blade, too.)
Defective seal of bucket cyl- out troubleshooting.
6
inder Bucket cylinder Leakage from cylinder
Relieved in move-CURL operation 10 cc/min
PC18MR-2 20-409
(1)
H-9 Speed or power of boom swing is low
Failure
• Speed or power of boom swing is low
information
Relative
information

Boom swing control pedal PPC valve output pressure
Malfunction of boom swing 0 MPa
1 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 +2
swing {32 0 kg/cm²}
Malfunction of boom swing The boom swing control valve spool may have a malfunction. Check it
2
control valve (spool) directly.
Presumed cause Malfunction of boom swing
and standard The pressure compensation valve of the boom swing control valve may
3 control valve (pressure
value in normalcy have a malfunction. Check it directly.
compensation valve)
The suction valve of the boom swing control valve may have a malfunc-
4 seal of boom swing control
tion. Check it directly.
valve (suction valve)
Malfunction or defective defective. Check the centralized safety valve directly. (A trouble in the
5
seal of suction valves centralized safety valve has effects on the arm, bucket, boom swing,
and blade, too.)
Defective seal of boom out troubleshooting.
6
swing cylinder Boom swing cylinder Leakage from cylinder
Relieve at left swing 10 cc/min
H-10 Work equipment does not move singly
(1) Boom does not move singly.

Failure (2) Arm does not move singly.
information (3) Bucket does not move singly.
(4) Boom swing system does not move singly.
Relative • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information • When starting troubleshooting, warm up the hydraulic oil to 45 – 55 °C.

Work equipment control lever
PPC valve output pressure
and pedal
Presumed cause
1 Malfunction of PPC valve 0 MPa
and standard Set lever in neutral
value in normalcy {0 kg/cm²}
+0.2
3.14 0 MPa
Operate lever
{32 +20 kg/cm²}
Malfunction of control valve
2 The control valve spool may have a malfunction. Check it directly.
(spool)
20-410 PC18MR-2
(1)
Troubleshooting H-11
H-11 Work equipment hydraulic drift is large
(1) Hydraulic drift of boom is large

Failure (2) Hydraulic drift of arm is large
information (3) Hydraulic drift of bucket is large
(4) Hydraulic drift of boom swing is large
information • Check the leakage from the cylinder while the hydraulic oil temperature is 45 – 55 °C.

Work equipment cylinder Leakage from cylinder
Defective seal of hydraulic
1 Relieved by boom RAISE
Presumed cause cylinder
and standard Relieved by arm IN
10 cc/min
Relieved by bucket CURL
value in normalcy
Relieved by boom SWING LEFT
Malfunction of control valve
2 The control valve spool may be malfunctioning. Check it directly.
(spool)
Malfunction of control valve The suction valve of the control valve may be malfunctioning. Check it
3
(suction valve) directly.
PC18MR-2 20-411
(1)
H-12 Time lag of work equipment is large
(1) Time lag of boom is large

Failure
(2) Time lag of arm in large
information
(3) Time lag of bucket in large
Relative
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
Presumed cause Cause Standard value in normalcy and references for troubleshooting
and standard Malfunction of control valve The suction valve of the control valve may have a malfunction. Check it
value in normalcy 1 (suction valve) directly.
H-13 In compound operation of work equipment, speed of part loaded more is low
Failure
• In compound operation of work equipment, speed of part loaded more is low
information
Relative
information

The pressure compensation valve of the control valve on less load side
may have a malfunction. Check it directly.
More load Less load
Presumed cause Combination of operations
Malfunction of pressure side side
and standard RAISE boom + Move arm IN Boom Arm
value in normalcy 1 compensation valve on less
load side 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
20-412 PC18MR-2
(1)
H-14 Machine deviates during travel
Failure
(1) Machine deviates during ordinary travel
information

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, de-
formation, and damage.
Travel lever PPC valve output pressure
0 MPa
Malfunction of travel PPC Neutral
2 {0 kg/cm²}
valve +0.2
Operated to right, left, forward, 3.14 0 MPa
or reverse {32 +20 kg/cm²}
Output difference of above Max. 0.4 MPa
between right and left {Max. 4 kg/cm²}
Presumed cause
and standard Malfunction of travel control
3 The travel control valve spool may be malfunctioning. Check it directly.
value in normalcy valve (spool)
Malfunction of travel controlThe pressure compensation valve (with right and left junction mecha-
4 valve (pressure compensa- nism) of the travel control valve may be malfunctioning. Check it
tion valve) directly.
The seal of the center swivel joint may be defective. Check it directly.
Defective seal of center • Replace right and left hoses between the center swivel joint and travel
5
swivel joint 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.
6 mance of travel motor • Replace right and left hoses between the center swivel joint and travel
(motor unit) motor with each other. If the turning direction does not change, 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.)
PC18MR-2 20-413
(1)
Failure
(2) Machine deviates when it starts (It does not deviate during ordinary travel)
information

0 MPa
Malfunction of travel PPC Set in neutral
1 {0 kg/cm²}
Presumed cause valve +0.2
and standard Operate to drive left-right, 3.14 0 MPa
forward-reverse {32 +20 kg/cm²}
value in normalcy
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.
20-414 PC18MR-2
(1)
H-15 Travel speed or travel power is low
Failure
• Travel speed or travel power is low
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
Relative
equipment, travel, swing, and blade speed is low".)
information
• Check the oil pressure while the hydraulic oil temperature is 45 – 55 °C.

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, de-
formation, and damage.
Presumed cause
Malfunction of travel PPC 0 MPa
and standard 2 Neutral
valve {0 kg/cm²}
value in normalcy
+0.2
Operated to right, left, forward, 3.14 0 MPa
Malfunction of travel control
valve (spool)
The pressure compensation valve of the travel control valve may be
malfunctioning. Check it directly.
tion valve)
H-16 Machine is not steered well or steering power is low
Failure
• Machine is not steered well or steering power is low
information

1 Neutral
valve {0 kg/cm²}
+0.2
Presumed cause Operated to right, left, forward, 3.14 0 MPa
and standard or reverse {32 +20 kg/cm²}
value in normalcy
valve (spool)
The pressure compensation valve of the travel control valve may be
malfunctioning. Check it directly.
tion valve)
Defective seal of center
4 The seal of the center swivel joint may be defective. Check it directly.
swivel joint
PC18MR-2 20-415
(1)
H-17 Travel speed does not change
Failure
• Travel speed does not change
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
Relative
decreases, the travel speed is set high again.)
information

2nd travel speed
Travel speed shifting 2nd travel speed
selection solenoid
Malfunction of 2nd travel switch selection monitor
Presumed cause valve output pressure
1 speed selection solenoid
and standard 0 MPa
valve Low speed mode OFF
+0.2
3.14 0 MPa
High speed mode ON
{32 +20 kg/cm²}
Malfunction of travel motor The speed change section (selector valve and servo valve) of the travel
2
(speed change section) motor may be malfunctioning. Check it directly.
H-18 Travel motor does not work (one side only)
Failure
• Travel motor does not work (one side only)
information

1 Neutral
valve {0 kg/cm²}
Presumed cause +0.2
and standard Operated to right, left, forward, 3.14 0 MPa
value in normalcy
valve (spool)
Malfunction of travel motor The counterbalance valve of the travel motor may be malfunctioning.
3
(with counterbalance valve) Check it directly.
Malfunction of travel motor The motor unit of the travel motor may be malfunctioning. Check it
4
(motor unit) directly.
20-416 PC18MR-2
(1)
H-19 Speed or power of swing is low
Failure
(1) Speed or power of swing is low in both directions
information
• Before carrying out troubleshooting, check that work equipment, travel system, and blade system are
Relative
information

Swing holding brake
Work equipment control levers
Malfunction of shuttle valve release signal pressure
1 for swing holding brake 0 MPa
Presumed cause All levers in neutral
(inside control valve) {0 kg/cm²}
and standard
value in normalcy Operated to swing LEFT +0.2
3.14 0 MPa
Operated to swing RIGHT
Operated to arm IN {32 +20 kg/cm²}
Malfunction of swing control
2 The swing control valve spool may be malfunctioning. Check it directly.
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-2 20-417
(1)
Failure
(2) Speed or power of swing is low in only 1 direction
information

Work equipment control levers PPC valve output pressure
Malfunction of swing PPC 0 MPa
valve {0 kg/cm²}
+0.2
Operated to swing LEFT 3.14 0 MPa
Operated to swing RIGHT {32 +20 kg/cm²}
Swing holding brake
Presumed cause release signal pressure
Malfunction of shuttle valve
and standard 2 0 MPa
for swing holding brake All levers in neutral
Operated to swing LEFT +0.2
3.14 0 MPa
valve (spool)
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 suction valve of the swing motor may be malfunctioning. Check it
5
20-418 PC18MR-2
(1)
H-20 Machine does not swing
Failure
(1) Machine does not swing in either direction
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 sys-
Relative
tem, swing system, and blade system do not work".)
information

Swing holding brake
Presumed cause
and standard 3.14 0 MPa
value in normalcy Operated to swing RIGHT
valve (spool)
3
Malfunction of swing motor The motor unit of the travel motor may be malfunctioning. Check it
4
PC18MR-2 20-419
(1)
Failure
(2) Machine does not swing in only 1 direction
information

valve {0 kg/cm²}
+0.2
Swing holding brake
Presumed cause All levers in neutral
and standard
value in normalcy 3.14 0 MPa
valve (spool)
The load check valve in the spool of the swing control valve may be mal-
4 valve (load check valve in
functioning. Check it directly.
spool)
(safety valve)
19.1 ± 0.98 MPa
{195 ± 10 kg/cm²}
6
20-420 PC18MR-2
(1)
H-21 Swing acceleration performance is low
Failure
(1) Swing acceleration performance is low in both directions
information
Relative
information

Presumed cause valve (spool)
and standard Malfunction of swing motor The parking brake section (timer valve and parking brake) of the swing
2
value in normalcy (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
3
Failure
(2) Swing acceleration performance is low in only 1 direction
information

valve {0 kg/cm²}
+0.2
Presumed cause 2 Malfunction of swing control The swing control valve spool may be malfunctioning. Check it directly.
and standard valve (spool)
value in normalcy Malfunction of swing control
The load check valve in the spool of the swing control valve may be mal-
3 valve (load check valve in
functioning. Check it directly.
spool)
(safety valve)
19.1 ± 0.9 MPa
{195 ± 10 kg/cm²}
5
PC18MR-2 20-421
(1)
H-22 Machine overruns when it stops swinging
Failure
(1) Machine overruns when it stops swinging in both directions
information
Relative
information

Presumed cause Malfunction of swing control
and standard valve (spool)
value in normalcy Malfunction of swing motor The motor unit of the travel motor may be malfunctioning. Check it
2
Failure
(2) Machine overruns when it stops swinging in only 1 direction
information

valve {0 kg/cm²}
+0.2
Presumed cause Operated to swing RIGHT {32 +20 kg/cm²}
and standard
value in normalcy 2 The swing control valve spool may be malfunctioning. Check it directly.
valve (spool)
(safety valve)
19.1 ± 0.9 MPa
{195 ± 10 kg/cm²}
4
20-422 PC18MR-2
(1)
H-23 Large shock is made when machine stops swinging
Failure
• Large shock is made when machine stops swinging
information
information • When starting troubleshooting, set the hydraulic oil temperature to 45 – 55 °C.

Work equipment control lever PPC valve output pressure
1 Set all in neutral
valve {0 kg/cm²}
+0.2
Presumed cause Malfunction of shuttle valve
The shuttle valve for the swing holding brake may be malfunctioning.
and standard 2 for swing holding brake
Check it directly.
value in normalcy (inside control valve)
Since the swing control valve spool may have a malfunction, check it
3
valve (spool) directly.
(safety valve)
19.1 ± 0.98 MPa
{195 ± 10 kg/cm²}
5
H-24 When upper structure stops swinging, it makes large sound
Failure
• When upper structure stops swinging, it makes large sound
information
Relative
information

Malfunction of back pres- The back pressure check valve may have a malfunction. Check it
1
sure check valve directly.
Presumed cause The swing motor safety valves may have a malfunction. Check the
and standard 2 valves directly. (They may be checked by exchanging with each other
value in normalcy (safety valve)
and checking change of the phenomenon.)
The swing motor suction valves may have a malfunction. Check the
3 valves directly. (They may be checked by exchanging with each other
(suction valves)
and checking change of the phenomenon.)
PC18MR-2 20-423
(1)
H-25 Hydraulic drift of swing is large
Failure
(1) While swing holding brake is applied
information

Swing holding brake
Lock lever
release pressure
0 MPa
LOCK
{0 kg/cm²}
+0.2
3.14 0 MPa
FREE
Presumed cause {32 +20 kg/cm²}
and standard Malfunction or defective
1 seal of swing motor (parking Swing holding brake
value in normalcy Work equipment control lever
brake section) release signal pressure
0 MPa
{0 kg/cm²}
3.14 0 MPa
Operated to swing RIGHT +2
Operated to arm IN {32 0 kg/cm²}
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
(2) While swing holding brake is released
information
Relative
• Release the swing holding brake by swinging and moving the arm IN.
information

Defective seal of swing con- The seal of the swing control valve spool may be defective. Check it
1
trol valve (spool) directly.
Presumed cause The seal of the safety valve of the swing motor may be defective. Check
Defective seal of swing
2 it directly. (The sealing condition can be judged by replacing the right
and standard motor (safety valve)
value in normalcy and left safety valves and checking the change of the phenomenon.)
The seal of the suction valve of the swing motor may be defective.
Defective seal of swing Check it directly. (The sealing condition can be judged by replacing the
3
motor (suction valve) right and left suction valves and checking the change of the phenome-
non.)
20-424 PC18MR-2
(1)
H-26 Speed or power of blade is low
Failure
• Speed or power of blade is low
information
• Before carrying out troubleshooting, check that work equipment, travel system, and swing system are
Relative
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55 °C.

Blade control lever PPC valve output pressure
Malfunction of blade PPC 0 MPa
1 Set in neutral
valve {0 kg/cm²}
+0.2
Operated to blade RAISE 3.14 0 MPa
Presumed cause Operated to blade LOWER {32 +20 kg/cm²}
and standard
Malfunction of blade control
value in normalcy 2 The blade control valve spool may have a malfunction. Check it directly.
valve (spool)
Malfunction of variable The variable gauge solenoid valve may be malfunctioning. Check it
3 gauge selector solenoid directly. (If the solenoid valve is not changed normally, the variable
valve gauge probably moves when the blade is operated.)
Defective seal of blade cyl- out troubleshooting.
4
inder Blade cylinder Leakage from cylinder
Relieve by lowering blade 10 cc/min
PC18MR-2 20-425
(1)
H-27 Blade does not move
Failure
• Blade does not move
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 sys-
tem, swing system, and blade system do not work".)
Relative
• The blade circuit pressure is also used for the variable gauge. Accordingly, the blade does not move
information
while the blade/variable gauge selector switch is set in the variable gauge position.
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55 °C.

Blade control lever PPC valve output pressure
Malfunction of blade PPC 0 MPa
1 Set in neutral
valve {0 kg/cm²}
+0.2
Operated to blade RAISE 3.14 0 MPa
Operated to blade LOWER {32 +20 kg/cm²}
Presumed cause Malfunction of blade control
and standard 2 The blade control valve spool may have a malfunction. Check it directly.
valve (spool)
value in normalcy
3 gauge selector solenoid directly. (If the solenoid valve is not changed normally, the variable
valve gauge probably moves when the blade is operated.)
Defective seal of blade cyl- out troubleshooting.
4
Deformation of blade cylin-
5 The blade cylinder or blade is deformed. Check them directly.
der or blade
H-28 Hydraulic drift of blade is large
Failure
• Hydraulic drift of blade is large
information

Defective seal of blade con-
1 The seal of blade control valve spool may be defective. Check it directly.
Presumed cause trol valve (spool)
and standard aPrepare with engine stopped, then run engine at high idling and carry
value in normalcy Defective seal of blade cyl- out troubleshooting.
2
20-426 PC18MR-2
(1)
H-29 Variable gauge does not move
Failure
• Variable gauge does not move
information
• Since the blade circuit pressure is also used for the variable gauge, check that the blade moves normal-
Relative
ly before carrying out troubleshooting. (If the blade does not move normally, carry out troubleshooting
information
for "H-27 Blade does not move".)

1 gauge selector solenoid directly. (If the solenoid valve is not changed normally, the blade prob-
Presumed cause valve ably moves when the variable gauge is operated.)
and standard
value in normalcy 2 Defective variable gauge
The variable gauge cylinder seal may be defective. Check it directly.
cylinder
Deformed track frame The variable gauge section of the track frame may be deformed.
3
(variable gauge section) Check it directly.
PC18MR-2 20-427
(1)
H-30 Troubleshooting for hydraulic breaker
Failure
(1) Breaker does not strike
information
Relative
• Before carrying out troubleshooting, check that hydraulic tank oil level is normal.
information

1 Malfunction of control valve Disassemble and check that valve body and control valve slide normally.
Presumed cause 2 Breakage of control valve Replace.
and standard 3 Low hydraulic oil level Add.
value in normalcy Loosened mounting nuts of
4 valve body assembly and Retighten.
front end assembly
Failure
(2) Blow impact and blow frequency are low
information
Relative
information

Presumed cause 1 Low engine speed Increase engine speed.
and standard 2 Malfunction of control valve Disassemble and check that valve body and control valve slide normally.
value in normalcy 3 Seized chisel Remove chisel and repair seized part (apply grease).
4 Improper setting of chisel Press chisel straight.
Failure
(3) Blow frequency is normal but blow impact is low
information
Relative
information

Add nitrogen gas.
Presumed cause Low accumulator gas pres-
1 5.4 MPa
and standard sure Gas pressure
Broken accumulator dia-
2 Replace.
phragm
Failure
(4) Much oil or little black oil leaks through chisel socket
information
Relative
—
information

Presumed cause
1 Worn U-packing Replace.
and standard
2 Damaged U-packing Remove flaws of hammer piston and replace packing.
value in normalcy
3 Grease leakage This is not abnormal phenomenon.
20-428 PC18MR-2
(4)
Failure
(5) High-pressure hose swings abnormally
information
Relative
information

Adjust nitrogen gas pressure.
High accumulator gas pres-
1 5.4 MPa
sure Gas pressure
Presumed cause {55 kg/cm²}
and standard Add nitrogen gas.
value in normalcy 2 Low accumulator gas pres- 5.4 MPa
sure Gas pressure
{55 kg/cm²}
Broken accumulator dia-
3 Replace.
phragm
Failure
(6) Oil leakage through mating faces of valve body, cylinder and accumulator
information
Relative
—
information
Presumed cause Cause Standard value in normalcy and references for troubleshooting
and standard 1 Worn or hardened O-ring Replace.
value in normalcy 2 Loosened bolt and nut Retighten.
PC18MR-2 20-429
(4)
Troubleshooting of engine
(S mode)
Troubleshooting chart ................................................................................................................................. 20-502
PC18MR-2 20-501
(1)
Troubleshooting Troubleshooting chart
Troubleshooting chart
a This troubleshooting chart is transferred from the Shop Manual for 3D76E-1 Engine.
Trouble Cause Remedy

Engine does not Engine unit
start
• Air leakage to outside (Insufficient compression • Replace head gasket
pressure) • Tighten head bolts, injection nozzles,
and glow plugs
• Internal air leakage (Insufficient compression pres- • Check cylinders and piston rings for
sure) wear and replace them
• Defective valve timing (Insufficient compression • Check timing gear
pressure)
• Defective contact of valve (Insufficient compres- • Replace valve spring and repair valve
sion pressure) seat contact
• Seized crankshaft, camshaft, piston, or bearing • Repair or replace
metal
• Increased volume of combustion chamber (Insuffi- • Correct sinking distance of valves
cient compression pressure)
Fuel system
• Fuel tank is empty • Add fuel
• Use of viscous fuel • Use specified fuel
• Use of fuel of low cetane number • Use specified fuel
• Water in fuel • Use specified fuel
• Gasoline in fuel • Use specified fuel
• Clogged fuel filter • Replace fuel filter element
• Fuel leakage through injection pipe nut • Tighten nut
• Clogged fuel pipe • Clean and repair
• Defective injection pump • Repair or replace
• Defective fuel feed pump • Replace
• Defective fuel injection timing • Adjust
• Removed or broken start spring or governor spring • Repair or replace
Electrical system
• Insufficient battery capacity or dead battery • Use battery of specified capacity
• Over-discharged battery • Charge or replace
• Defective starting motor • Repair or replace
• Wrong or defective wiring • Check and repair
• Defective starting switch • Repair or replace
• Broken fuse • Remove cause and replace
• Malfunctioning or defective engine stop solenoid • Check and repair or replace
20-502 PC18MR-2
(1)

Engine does not Fuel system
stop
• Removed control rack and fork lever • Repair
• Sticking control rack of injection pump • Repair or replace injection pump
Electrical system
• Defective engine stop solenoid • Replace
Engine hunts Air intake and exhaust systems
• Clogged air cleaner • Clean or replace air cleaner element
Fuel system
• Clogged fuel filter • Replace filter element
• Fuel leakage through injection pipe nut • Tighten nut
• Defective injection nozzle • Repair or replace
• Clogged fuel overflow pipe • Repair bent part or clean
• Defective governor spring, start spring, or idle limit • Replace spring
spring
• Malfunction of governor weight • Repair
Exhaust gas is Engine unit
white or blue
• Worn piston ring, piston, and cylinder • Replace piston ring and piston and
repair cylinder
• Increased volume of combustion chamber (Insuffi- • Correct sinking distance of valves
cient compression pressure)
Lubrication system
• Too much oil • Reduce oil level to specified level
Fuel system
Exhaust gas is Engine unit
black or dark gray
and output is • Overload • Reduce load
insufficient • Air leakage to outside of cylinder • Tighten head bolts, injection nozzles,
and glow plugs
• Slight seizure of moving parts of engine • Repair or replace
Fuel system
• Use of low-grade fuel • Use specified fuel
• Clogged fuel filter • Replace filter element
• Defective spraying of fuel • Repair or replace injection nozzle
• Uneven fuel injection rate • Repair or replace injection pump
Air intake and exhaust systems
• Clogged air cleaner • Clean or replace element
PC18MR-2 20-503
(1)

Much oil is Engine unit
consumed
• Leakage through tightened parts and plugs • Tighten to specified torque
• Defective crankshaft oil seals, O-rings, gaskets, • Replace
etc.
• Defective valve stem seals • Replace seals
• Abutment joints of piston rings are in same direc- • Set abutment joints in opposite direc-
tion tions
• Worn or sticking O-rings • Replace
• Worn piston ring grooves • Replace pistons and piston rings
Fuel is in oil Fuel system
• Defective injection pump • Replace pump element or pump assem-
bly
• Defective fuel feed pump • Replace
Water is in oil Engine unit
• Broken head gasket • Replace
• Cracked crankcase or cylinder head • Replace
• Broken O-ring or packing in water passage • Replace
between gear case and crankcase
Oil pressure is low Lubrication system
• Low oil level • Add oil to specified level
• Low quality of oil • Use specified oil
• Defective relief valve • Repair or replace
• Too large oil clearance of each bearing metals • Check and replace bearing metals,
bushings, shaft, etc.
• Clogged oil passage • Check and clean
• Defective oil pump • Check and replace
• Defective oil hole or plug or omission of fitting of • Check and repair
plug
Oil pressure is Lubrication system
high
• Low oil temperature • Run engine until oil temperature rises
• Use of low-quality oil • Use specified oil
• Defective relief valve • Repair or replace
20-504 PC18MR-2
(1)

Engine overheats Cooling system
• Loosened or broken fan belt • Adjust or replace
• Low coolant level • Add coolant to specified level
• Clogged radiator net or radiator fins • Clean
• Dirty coolant • Replace coolant
• Defective radiator or radiator cap • Check and replace
• Clogged coolant passage • Clean
• Defective route of cooling air • Secure route of cooling air
• Defective thermostat • Replace
• Defective water pump seal • Replace
Engine overheats Engine unit
• Continuous overload operation • Reduce load
• Broken head gasket (Reduced coolant) • Replace
• Insufficient tightening of head bolts • Tighten to specified torque
Lubrication system
• Low oil level • Add oil to specified level
Fuel system
• Use of low-grade fuel • Use specified fuel
Battery is Electrical system
discharged
abnormally • Loosened fan belt • Adjust or replace
(Battery is dead) • Deteriorated battery • Replace
• Low electrolyte level • Add distilled water and charge
• Defective alternator, AC dynamo, or regulator • Repair or replace
Glow lamp does Electrical system
not light up
• Broken glow lamp • Replace
• Defective switch • Replace
• Defective glow lamp timer • Replace
Charge lamp does Electrical system
not light up
• Defective alternator or regulator • Repair or replace
• Broken bulb • Replace
• Broken fuse • Replace
Charge lamp does Electrical system
not go off
• Loosened or broken fan belt • Adjust or replace
• Defective alternator, AC dynamo, or regulator • Repair or replace
PC18MR-2 20-505
(1)
30 Disassembly and assembly
How to read this manual ................................ 30- 2

Precautions when performing operation ........ 30- 4
Special tool list ............................................... 30- 6
Sketch of special tools .................................. 30-7-1
Removal and installation of fuel injection pump
assembly................................................... 30- 8
Removal and installation of radiator
assembly................................................... 30- 9
Removal and installation of hydraulic oil cooler
assembly....................................................30-11
Removal and installation of engine and
hydraulic pump assembly ......................... 30-12
Removal and installation of track shoe
assembly .................................................. 30-16
Disassembly and assembly of idler
assembly................................................... 30-17
Disassembly and assembly of recoil spring ... 30-18
Disassembly and assembly of track roller
assembly .................................................. 30-20
Assembly of travel motor assembly ............... 30-21
Removal and installation of floor frame
assembly................................................... 30-30
Removal and installation of revolving frame .. 30-35
Removal and installation of swing circle
assembly................................................... 30-38
Disassembly and assembly of hydraulic pump
assembly................................................... 30-39
Disassembly and assembly of control valve
assembly................................................... 30-48
Removal and installation of hydraulic system
and center swivel joint assembly .............. 30-52
Disassembly and assembly of center swivel
joint assembly ........................................... 30-54
Removal and installation of swing motor
assembly................................................... 30-56
Disassembly and assembly of swing motor
assembly................................................... 30-57
Removal and installation of work equipment
assembly................................................... 30-64
Disassembly and assembly of hydraulic cylinder
assembly................................................... 30-66
Disassembly and assembly of hydraulic breaker
assembly................................................... 30-70
PC18MR-2 30-1
(4)
Disassembly and assembly How to read this manual
How to read this manual

Removal and installation of assemblies
Special tools Installation of parts
• Special tools that are deemed necessary for re- • Except where otherwise instructed, install parts is
moval or installation of parts are listed. the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing part are
kind of information shown with [*1] mark in the Installation section,
1) Necessity identifying which step the instructions are intend-
t: Special tools which cannot be substi- ed for.
• Marks shown in the Installation section stand for
tuted, should always be used.
the following.
q: Speciall tools which are very useful if
available, can be substituted with com- k This mark indicates safety-related pre-
mercially available tools. cautions, which must be followed when
doing the work.
2) Distinction of new and existing special tools. a This marks gives guidance or precau-
N: Tools with new part numbers, newly tions when doing the procedure.
2 This mark stands for a specific coating

developed for this model.
R: Tools with upgraded part numbers,
remodeled from already available tools agent to be used.
3 This mark indicates the specified torque.

for other models.
Blank: Tools already available for other models,
5
used without any modification.
3) Circle mark (Q) in sketch column. This mark indicates an amount of oil or
A circle mark means that a sketch of the water to be added.
special tool is presented in the section of
Sketches for Special Tools. Sketches of special tools
a Part No. of special tools starting with 79*T means
that they are locally made parts and as such not • Various special tools are illustrated for the conve-
interchangeable with those made by Komatsu in nience of local manufacture.
Japan e.g. 79*T---×××---××××.
Removal of parts
• The Removal section contains procedures, pre-

cautions and the amount of oil or water to be
drained.
• Various symbols used in the Removal section are
explained and listed below.
k This mark indicates safety-related pre-
cautions, which must be followed when
doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water be drained.
4 This mark shows the weight of a part or a

device.
30-2 PC18MR-2
(2)
Disassembly and assembly How to read this manual
Disassembly and assembly of assemblies
Special tools
• Special tools which are deemed necessary for Assembly

disassembly and assembly are listed in this sec-
tion. • Section titled Assembly contain procedures, pre-
• List of the special tools contains the following cautions and the know-how for the work, as well
kind of information. as the amount of oil or water to be added.
1) Necessity • Various symbols used in the Assembly section
t: Special tools which cannot be substi- are explained and listed below.
tuted, should always be used. k This mark indicates safety-related pre-
q: Speciall tools which are very useful if cautions, which must be followed when
available, can be substituted with com- doing the work.
mercially available tools. a This marks gives guidance or precau-
tions when doing the procedure.
2 This mark stands for a specific coating
2) Distinction of new and existing special tools.
N: Tools with new part numbers, newly
agent to be used.
3 This mark indicates the specified torque.
developed for this model.
R: Tools with upgraded part numbers,
5
remodeled from already available tools
for other models. This mark indicates an amount of oil or
Blank: Tools already available for other models, water to be added.
used without any modification.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the Sketches of special tools
special tool is presented in the section of
Sketches for Special Tools. 1) Vartious special tools are illustrated for the
4) Part No. of special tools starting with 79*T convenience of local manufacture.
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T---×××--
-××××.
Disassembly
• The Disassembly section contains procedures,

precautions and the amount of oil or water to be
drained.
• Various symbols used in the Disassembly sec-
tion are explained and listed below.
k This mark indicates safety-related precau-
tions which must be followed when doing
the work.
a This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or water to be

drained.
PC18MR-2 30-3
(2)
Disassembly and assembly Precautions when performing operation
Precautions when performing operation

Be sure to follow the general precautions given below when performing removal or installation (disassmbly or
assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or install blind 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 avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the
wiring, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify and show their installation position and help to prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 PC18MR-2
(2)
Disassembly and assembly Precautions when performing operation
2. 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.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with tow or three 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 installing snap rings, check that the snap ring is installed 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.
a 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 it at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the
cylinder 100 mm from the end of their 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.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations

• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the spec-
ified level. Run the engine to circulate the coolant water through the system. Then check the coolant
water level again.
• 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.
• If the piping or hydraulic equipment have been removed for repair, Bleed the air from the system after
reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
PC18MR-2 30-5
(2)
Disassembly and assembly Special tool list
Special tool list

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
models.
: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 (See sketches of
special tools).
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
790-101-5001 Push tool KIT q 1
790-201-5131 • Plate 1
1 Press fitting of bushing
Disassembly, assembly of 790-101-5021 • Grip 1
idler assembly
01010-50816 • Bolt 1
2 790-201-2720 Spacer q 1 Installation of floating seal

L
790-101-5081 • Plate 1
3 Press fitting of bushing
Disassembly, assembly of
track roller assembly 790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 790-201-2710 Spacer q 1 Installation of floating seal

recoil spring assembly M 792-371-1400 Sleeve t 1 Disassembly, assembly of
recoil spring assembly
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1 Separation of rotor and swivel

joint
Disassembly, assembly
of center swivel joint T 790-101-2540 • Washer 1
assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
Separation of rotor and swivel
joint
790-101-2660 • Adapter 2
790-502-1003 Cylinder repair stand t 1

1 hydraulic cylinder assembly
790-101-1102 Hydraulic pump t 1
of hydraulic cylinder
2 790-330-1100 Wrench assembly t 1 Removal, installation of cylin-
der head
U
assembly Commercially
available Socket t 1 Width across
flats: 32 mm
Removal,
3 Commercially
available Socket t 1 installation of Width across
flats: 36 mm
piston nut
Commercially
available Socket t 1 Width across
flats: 41 mm
30-6 PC18MR-2
(2)
Disassembly and assembly Special tool list
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
790-201-1702 Push tool KIT t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1 Press fitting

4 of bushing
For arm, swing,
790-201-1721 • Push tool 1 variable gauge
790-201-1731 • Push tool 1 For arm, blade
790-101-5021 • Grip 1
01010-50816 • Bolt 1 Press fitting

Disassembly, assembly 5 of dust seal
of hydraulic cylinder U For bucket,
assembly 790-201-1530 • Plate 1 swing, variable
gauge
For boom,
790-201-1540 • Plate 1 arm, blade
6 790-720-1000 Expander q 1 Installation of piston ring
796-720-1740 Piston ring ø65 q 1

For blade
07281-00709 Clamp q 1
7 796-720-1630 Piston ring ø65 • 55 q 1 For boom, arm, swing
796-720-1620 Piston ring ø50 q 1 For bucket, variable gauge

Piston clamp ø50 – For boom. arm, swing, bucket,
07281-00609
60 q 1
variable gauge
1 796T-170-2420 Stand t 1 N Q Installation of breaker
2 796T-170-2430 Shaft t 1 N Q Pulling out of bushing
3 796T-170-2440 Shaft t 1 N Q Press fitting of bushing

of hydraulic breaker V 4 796T-170-2450 Shaft t 1 N Q Press fitting of bushing
assembly
5 796T-170-2460 Shaft t 1 N Q Press fitting of dust seal
Removal and installation of
6 796-170-2160 Handle t 1
cover
7 796-170-2170 Valve assembly t 1 Charging with nitrogen gas
PC18MR-2 30-7
(4)
Disassembly and assembly Sketch of special tools
Sketch of special tools

Note) Komatsu cannot accept any responsibility for special tools
manufactured according to these drawings.
V1 Stand
V2 Shaft
30-7-1 PC18MR-2
(4)
V3 Shaft
V4 Shaft
PC18MR-2 30-7-2
(4)
V5 Shaft
30-7-3 PC18MR-2
(4)
Disassembly and assembly Removal and installation of fuel injection pump assembly
Removal and installation of 7. Remove 4 mounting bolts (10) and fuel injection
pump (9).
fuel injection pump assembly a While turning lever R, remove the fuel injec-
tion pump.
Removal
1. Tilt up the floor frame. For details, see Removal
and installation of radiator assembly.
2. Disconnect air hoses (1) and (2) and remove air

cleaner (3). [*1]
Installation
• Carry out installation in the reverse order to re-
moval.
[*1]
3 Air hose (1) clamp:
3. Close fuel valve A.

4. Remove fuel injection tubes (4) together. 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}
5. Disconnect fuel return hose (5) and fuel supply 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
hose (6).
6. Remove pin (7) and disconnect fuel control

cable (8).
a Check the position of the pin hole.
30-8 PC18MR-2
(2)
Disassembly and assembly Removal and installation of radiator assembly
Removal and installation of 3) Remove bolts (4). [*1]
radiator assembly
Removal
k Lower the boom to bring the work equipment in
contact with the ground.
1. 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).
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. See the next page.)
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).)
a Angle between bar B and boom (1) when k When opening and closing the floor, do
floor frame is tilted up not put any part of body under the floor.
PC18MR-2 30-9
(2)
Disassembly and assembly Removal and installation of radiator assembly
5) Take lock pin (6) (red) out of part H of 6. Disconnect radiator upper hose (11). [*2]
bracket E (red) and insert it in the position
shown below. 7. Remove radiator assembly (12).
k Check that lock pin (6) is fixing pin P.
a When removing the radiator assembly, take
care not to damage its core.
2. Drain the coolant.

6 Coolant: 1.0 l Installation
3. Disconnect reservoir tank hose (7). • Carry out installation in the reverse order to re-
moval.
4. Disconnect clip (8) and remove cover (9).
[*1]
3 Floor frame mounting bolt:
151.9 – 191.1 Nm {15.5 – 19.5 kgm}
[*2]
3 Radiator hose clamp:

4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
5. disconnect radiator lower hose (10). [*2]
30-10 PC18MR-2
(2)
Disassembly and assembly Removal and installation of hydraulic oil cooler assembly
Removal and installation of Installation

hydraulic oil cooler assembly • Carry out installation in the reverse order to re-
moval.
Removal
k Loosen the oil filler cap of the hydraulic tank
[*1]
a When the floor frame tilted up is lowered,
gradually to release the internal pressure of the hose (5) touches it easily. To prevent this, be
hydraulic tank. sure to connect hose (5) so that it will go un-
der flange F. (Part A)
and installation of radiator assembly. • Refilling with oil (Hydraulic tank)
a Add oil through the oil filler to the specified level.
2. Drain the hydraulic oil. Run the engine to circulate the oil through the
6 Hydraulic oil: 15.2 l system. Then, check the oil level again.
5 Hydraulic oil: 15.2 l

3. Open cover (1).
• Bleeding air
4. Disconnect reservoir tank hose (2).
a Bleed air. For details, see Testing and adjusting,
Bleeding air from each part.
5. Disconnect clip (3).
6. Remove sponge (4).
7. Disconnect hoses (5) and (6) from the hydraulic

oil cooler. [*1}
8. Remove the 4 mounting bolts and hydraulic oil

cooler assembly (7).
a When removing the hydraulic oil cooler as-
sembly, take care not to damage its core.
PC18MR-2 30-11
(2)
Disassembly and assembly Removal and installation of engine and hydraulic pump assembly
Removal and installation of 7. Disconnect fuel hose (5).
engine and hydraulic pump 8. Remove water drain valve bracket (6) and dis-
assembly connect the fuel hose from back side.
Removal
k Loosen the oil filler cap of the hydraulic tank
gradually to release the internal pressure of the
hydraulic tank.

2. Lift off canopy (1). [*1]

4 Canopy: 65 kg
9. Disconnect fuel return hose (7).
3. Drain the fuel.

6 Fuel: 19 l (When full)
10. Remove cover (8).
4. Drain the coolant.
6 Coolant: 1.0 l 11. Remove battery (9).
5. Drain the hydraulic oil.

6. Disconnect air hoses (2) and (3) and remove air

cleaner (4). [*2]
30-12 PC18MR-2
(2)
12. Disconnect hydraulic hose (10). 18. Remove pin (16).
13. Disconnect clips (11) and (12). 19. Remove bracket (17).
a Fuel control cable (18) and fuel filter F come
14. Disconnect connector (13). off, too.
15. Remove bracket (14). 20. Remove radiator assembly (19). For details, see
Removal and installation of radiator assembly.
16. Sling counterweight and fuel tank assembly (15)

temporarily. 21. Remove fan (20) and fan guard (21). [*4]
17. Lift off counterweight and fuel tank assembly 22. Disconnect connector (22) and (23) and heater
(15). [*3] terminal (24).
4 Counterweight and fuel tank assembly
23. Disconnect clip (25).
(15): 180 kg
PC18MR-2 30-13
(3)
24. Disconnect connector (26) and terminal (27) 29. Disconnect suction hose (34).
from the alternator.
25. Disconnect connector (28) and terminal (29)

from the starting motor.
26. Disconnect terminal (30).
30. Sling engine and hydraulic pump assembly (35)

temporarily.
31. Remove 4 mounting bolts (36). [*5]
27. Disconnect engine ground cable (31) from under

the starting motor.
32. Lift off engine and hydraulic pump assembly

(35).
a Check that all the wires and pipes are discon-
nected.
28. Disconnect gear pump outlet hose (32) and pis- a When lifting off the assembly, take care that
ton pump outlet hose (33). it will not interfere with other parts.
4 Engine and hydraulic pump assem-
bly: 130 kg
30-14 PC18MR-2
(3)
Installation [*5]
• Carry out installation in the reverse order to re- 2 Engine mounting bolt: Adhesive (LT-2)
moval. 3 Engine mounting bolt:
59 – 74 Nm {6 – 7.6 kgm}
[*1]
3 Canopy mounting bolt: • Refilling with coolant
98 – 122.5 Nm {10 – 12.5 kgm} a Add coolant through the coolant filler to the spec-
ified level. Run the engine to circulate the cool-
[*2] ant through the system. Then, check the coolant

level again.
8.8 ± 0.49 Nm {0.9 ± 0.05 kgm} 5 Coolant: 1.0 l

Air hose (3) clamp:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm} • Refilling with oil (Hydraulic tank)
[*3] Run the engine to circulate the oil through the
3 Counterweight mounting bolt

system. Then, check the oil level again.
Right side: 152 – 191 Nm {15.5 – 19.5 kgm} 5 Hydraulic oil: 15.2 l
Left side: 456 – 568 Nm {46.5 – 58 kgm}
a Fuel hose (5) may be flattened between the • Bleeding air
counterweight and frame F. To prevent this, a Bleed air. For details, see Testing and adjusting,
check that the route of hose (5) is on the in- Bleeding air from each part.
k Run the engine and check that air comes (is

side of F.
pushed) out from the radiator. If air does not

come (is not 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 (20) so that it will be as shown in the figure
at left when seen from above.
a If fan (20) is installed in the correct direction, its
shaft is seen clearly.
PC18MR-2 30-15
(3)
Disassembly and assembly Removal and installation of track shoe assembly
Removal and installation of 4. Lower the floated track frame a little and remove
track shoe assembly (2) from idler J side first,
track shoe assembly then from sprocket S side.
Removal
1. Swing the upper structure by 90° and raise the
machine by using the work equipment.
5. Pull out track shoe assembly (2) to this side and

lift it off.
4 Rubber shoe: 55 kg
Steel shoe: 85 kg
2. Loosen valve (1) to discharge the grease and
loosen track shoe tension. [*1] Installation
k Since valve (1) may jump out because of • Carry out installation in the reverse order to re-
the internal high-pressure grease, do not moval.
loosen it more than 1 turn.
[*1]
a Adjust the track shoe tension. For details,
see Testing and adjusting, Testing and ad-
justing track shoe tension.
3. Loosen the track shoe assembly (2).
30-16 PC18MR-2
(2)
Disassembly and assembly Disassembly and assembly of idler assembly
Disassembly and assembly of 3. Using tool L2, install 2 oil seals (3) to the idler.
idler assembly 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, sup-
Special tools
ply grease into the idler.
2 Inside of idler:
New/Remodel
Symbol
Necessity
Part No. Part name Grease (G2-LI), Approx. 36 cc
Sketch
Q'ty
790-101-5131 • Plate 1
1
L 790-101-5021 • Grip 1
01010-50816 • Bolt 1
2 791-201-2720 Spacer q 1
a Only the assembly procedure is described in this

section.
Assembly
1. Using tool L1, press fit 2 bearings (6) to idler (7).
2 Inside of bearing: Grease (G2-LI)
4. Install support (2) to shaft (5) of the idler.
2 Mounting bolt: Adhesive (LT-2)
5. Install plate (1).

6. Install idler cushion assembly. (Steel shoe spec-

ification)
2. Install shaft (5) and fix it with snap ring (4).
PC18MR-2 30-17
(2)
Disassembly and assembly Disassembly and assembly of recoil spring
Disassembly and assembly of 3) Apply hydraulic pressure gradually to com-

press the spring and remove nut (6).
recoil spring a Compress the spring until you can loosen
the nut.
a The recoil spring is used for only the steel shoe a Installed load of spring: 6,860 N {700 kg}
specification.
4) Release the hydraulic pressure gradually to
Special tools release spring (8), and then remove stopper
(7) and spring (8) from cylinder (9).
New/Remodel
a Free length of spring: 200 mm
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
M 792-371-1400 Sleeve t 1
Disassembly
1. Piston
1) Remove grease fitting (1) and valve (2) from
rod (3).
2) Remove rod (3) from cylinder assembly (4).
2. Recoil spring
a Only steel shoe specification
1) Remove cotter pin (5) from nut (6).
3. Cylinder
1) Remove dust seal (10) from cylinder (9).
2) Remove backup ring (11).
3) Remove O-ring (12).
2) 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 se-
curely.
30-18 PC18MR-2
(2)
Disassembly and assembly Disassembly and assembly of recoil spring
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).
2. Recoil spring
a Only steel shoe specification
1) Assemble cylinder assembly (4), spring (8),
and stopper (7).
4) Fix nut (6) with cotter pin (5).
3. 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 fit-
ting, return them about 2 turns.
3) Install rod (3) and push it into cylinder
assembly (4), and then press the grease out
2) Using tool M, set the recoil spring to the
of valve (2) and bleed air from cylinder (9).
press.
k Since the installed load of the spring is
4) Tighten valve (2).
3 Valve (2): 59 – 74 Nm {6 – 7.5 kgm}
large and dangerous, set the spring se-
5) Tighten grease fitting (1).
curely.
a Direct grease fitting (1) toward outside
3) Apply hydraulic pressure gradually to com-
(the side panel) of the machine.
press 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}
PC18MR-2 30-19
(2)
Disassembly and assembly Disassembly and assembly of track roller assembly
Disassembly and assembly of 1. Using tool L3, press fit bearing (5) to track roller
(6).
2 Inside of bearing: Grease (G2-LI)
track roller assembly
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5081 • Plate 1
3
L 790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 790-201-2710 Spacer q 1
a Only the assembly procedure is described in this

section. 2. Install shaft (4) and fix it with snap ring (3).
Assembly 3. Using tool L4, install oil seals (2) to the track
roller (6).
2 Oil seal lip: Grease (G2-LI)
• Assembly parts
a Take care that dirt will not stick to the oil

seals.
a After installing the oil seal to either side, sup-
ply grease into track roller (6).
2 Inside of track roller (6):
Grease (G2-LI), Approx. 44 cc
a Precautions for installing to machine

3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
30-20 PC18MR-2
(2)
Disassembly and assembly Assembly of travel motor assembly
Assembly of travel motor

assembly
Only the assembly procedure is described in this
section.
G eneral precautions fo r d isassembly 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-2 30-21
(2)
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.
1) Insert spool assembly (2), rings (3) (both

sides), and springs (4) (both sides) in body 1
(1) in order.
2) Fit O-rings (5) to plugs (6) (both sides) and
tighten the plugs.
a O-ring (5): See sectional structure draw-
ing.
a Plug (6): See photo in 4).
a Spool assembly (2) cannot be disassem- 3) Install spool (8), spool (9), and spring (10) to
bled. 2nd gear spool (7).
3 Tightening torque for plug (both

sides): 127 – 167 Nm {13 – 17 kgm}
(Width across flats of hexagon
socket head: 27 mm)
4) 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.)
30-22 PC18MR-2
(2)
5) 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}
socket head: 8 mm)
7) Press fit bearing (17) and spring pin (16) to

body 1 (1).
6) 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}
socket head: 5 mm)
8) Install O-rings (18) and (19) to body 1.
PC18MR-2 30-23
(2)
• Body 2 (20) 12) Install control piston (25) to body 2 (20).

9) Press fit oil seal (21) to body 2 (20).
2 Space between lips of oil seal (21):
Grease (G2-LI)
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.
30-24 PC18MR-2
(2)
15) Install rocker cam (28) to body 2 (20). 18) Set steel plate (32) in body 2 (20), matching
2 Sliding surface of rocker cam (28):
it to the groove.
Hydraulic oil
2 Back side of rocker cam (28):
Grease (G2-LI) (If rocker cam (28)
comes off)
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.
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.
17) Set disc plate (31) in body 2 (20), matching it

to the groove.
PC18MR-2 30-25
(2)
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.
2. Reduction gear unit

1) Install floating seal (42) and O-ring (43) to
hydraulic motor (41).
5 Inside of body 2 (20): a Install floating seal (42) with the sealing
Hydraulic oil (approx.100 cm3) surface up.
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 fig-
ure.
30-26 PC18MR-2
(2)
2) Install bearing inner race (44) and steel balls 4) Install body (47) to hydraulic motor (41).
(45) having the retainer to hydraulic motor a Clamp the reduction gear unit flange and
(41) in order. (1 set) hydraulic motor flange with a C-clamp, a
a Take care of the directions of the bearing hydraulic press, etc.
inner race and retainer. (See the section-
al structure drawing.)
a The steel balls may come off the retainer.
Take care not to lose them.
5) 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 section-
al structure drawing.)
a The steel balls may come off the retainer.
Take care not to lose them.
3) Set the O-ring to seal ring (46) and install

them to body (47).
a Insert seal ring (46) with the sealing sur-
face up.
PC18MR-2 30-27
(2)
6) Fix the bearing with snap ring (50).

a Adjust the preload on the bearing by the
thickness of the snap ring.
10) Install O-ring (59) to body (47).

2 O-ring (59): Grease (G2-LI)
7) 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.
8) 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. 11) Insert slide ring (61) in cover (60).
2 Slide ring: Grease (G2-LI)
(For fitting the slide ring to the cover)
9) Install sun gear and carrier 2 assembly (58)

to body (47).
a Sun gear: (57) --- See the sectional struc-
ture drawing.
a Sun gear and carrier 2 assembly (58) is
supplied only as an assembly. (Including
sun gear (57).)
30-28 PC18MR-2
(2)
12) Supply hydraulic oil and install cover (60). 14) Tighten socket head plugs (63) (G3/8).
5 Hydraulic oil (330 cc)

a Tighten the plug on the side of the letters
of DRAIN first. (Lock the cover with the
a Take care not to damage the O-ring. flange of the plug.)
3 Socket head plug (63):
a Match the letters of "DRAIN" on the cover
to the cut of the body. (A)
46 – 51 Nm {4.7 – 5.2 kgm}
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-2 30-29
(2)
Disassembly and assembly Removal and installation of floor frame assembly
Removal and installation of 4. Disconnect connector (3).
floor frame assembly 5. Disconnect clips (4) – (6).
Removal
2. Lift off canopy (1). [*1]

4 Canopy: 65 kg
6. Disconnect connectors (7) and (8).
3. Remove battery (2).
7. Remove cover (9).
30-30 PC18MR-2
(2)
8. Disconnect horn assembly (10) from inside of 15. Remove clip (21).
cover (9).
16. Disconnect connectors (22) and (23).
9. Remove clip (11). a Since the connectors do not have No. labels,
record their destinations.
17. Remove bracket (24).
18. Disconnect connector (25) from under bracket

(24).
10. Disconnect connectors (12) and (13) and heater

terminal (14).
11. Remove clip (15).
19. Disconnect clip (26) and ground wire (27).
20. Disconnect 8 work equipment PPC hoses (28)

and (29). [*2]
a Hose band colors
• Hoses (28) on this side (Order from
above): White, green, brown, and or-
ange
• Hoses (29) on deeper side (Order from
above): Blue, yellow, red, and black

from the alternator.

from the starting motor.
14. Disconnect terminal (20).
PC18MR-2 30-31
(2)
21. Disconnect PPC hoses (30) and (31).

a Hose band colors
• (30): Red and green
• (31): No band
a Prepare plugs before disconnecting the hos-

es.
a Prepare tags to record the destinations of the
hoses.
25. Disconnection of fuel control cable (39)

1) Remove pin (37).
a Record the position of the pin hole.
2) Loosen locknut (38). [*6]
a Before loosening the locknut, record the
installed dimension.
3) Pull out fuel control cable (39) toward the
floor frame.
22. Disconnect 4 travel PPC hoses (32). [*3] a Check the route of the cable.
a Hose band colors:
Right front: Black and yellow,
Right rear: Yellow and green,
Left front: Yellow and brown,
Left rear: Yellow and orange
23. Disconnect 2 swing PPC hoses (33) and (34).

[*4]
a Hose band colors:
Left side: Red and white,
Right side: Blue and white
26. Sling floor frame assembly (40) temporarily.
24. Disconnect PPC hoses (35) and (36) from the

control valve. [*5]
a Hose band colors
• (35) on front side of chassis:
Yellow and blue
• (36) on rear side of chassis:
Red and yellow
30-32 PC18MR-2
(2)
27. Remove 2 upper mounting bolts (41) of damper 31. Lift off floor frame assembly (40).
4 Floor frame assembly: 130 kg
(42).
k Since damper (42) is pressed strongly, it a Before lifting off the assembly, check that all
may jump out to the right or left. the wires and pipes are disconnected.
Take care. After removing the upper mount-
ing bolts, do not stand near the damper.
28. Pull out lock pin (43) and remove pin (44).
29. Sling up floor frame assembly (40) a little to

expand damper (42) fully. (Damper (42) jumps
out.)
30. Remove right and left pins (45).
PC18MR-2 30-33
(2)
Installation 6. Install damper (42).
1. Remove damper (42) and spring (49) according

to the following procedure.
1) Remove damper (42).
2) Remove plates (46) and (48) and bracket
(47).
7. Install bracket (47).
3) Remove plate (50) and spring (49).
• Carry out the rest of installation in the reverse

order to removal.
3 Canopy mounting bolt:

[*1]
98 – 122.5 Nm {10 – 12.5 kgm}

2. Sling and install floor frame assembly (40).
[*2] [*3] [*4] [*5]
a When connecting the hoses, check their
band colors.
[*6]
a Adjust the cable tension. For details, see
Testing and adjusting, Adjusting fuel control
lever.
• Refilling with oil (Hydraulic tank)

Run the engine to circulate the oil through the
3. Install right and left pins (45). 5 Hydraulic oil:
4. Sling up the floor frame assembly higher than • Bleeding air

the length of the damper around pins (45). a Bleed air. For details, see Testing and adjusting,
5. Install spring (49), right and left plates (46), and
plate (50).
30-34 PC18MR-2
(2)
Disassembly and assembly Removal and installation of revolving frame
Removal and installation of 4. Drain the hydraulic oil.
revolving frame 6 Hydraulic oil: 15.2 l
Removal 5. Remove the floor frame assembly. For details,

see Removal and installation of floor frame
1. Stop the machine with the work equipment assembly.
extended.
a When draining the hydraulic oil, swing the up- 6. Remove the work equipment assembly. For
per structure 30° to the left. (Do not swing details, see Removal and installation of work
90°.) equipment assembly.
7. Remove plate (2).
8. Pull out pin (3) and remove boom cylinder

assembly (4). [*1]
a Hose H was disconnected from the control
valve in the section of the work equipment
assembly.
4 Boom cylinder: 25 kg
2. Remove engine undercover (1).
9. Remove hose (5).
3. Check that the upper structure is so swung that

you can remove revolving frame mounting bolts
(17).
a A: Oil pan
PC18MR-2 30-35
(2)
10. Remove rubber cover (6) and 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.
15. Disconnect hoses (10) – (16) from the control

valve to remove revolving frame mounting bolts
(17).
a Before disconnecting the hoses, prepare
plugs.
11. Disconnect hoses A, B, C, and D from the con- hoses.
trol valve assembly. a Hose band colors
a The hoses have labels on them. • (10): White
a A – H of the hose labels are the name of the • (11): No band
• (12): Brown and yellow
connecting ports of the center swivel joint.
• (13): Black and yellow
• (14): Black
12. Disconnect host T from the hydraulic tank. • (15): Red
a J: Center swivel joint • (16): White and blue
13. Disconnect hose H and nipple (7) from center 16. Sling revolving frame assembly (18) temporarily.
swivel joint assembly (9). a Wind the sling onto the rear part.
14. Remove lever (8) from center swivel joint

assembly (9). [*2]
30-36 PC18MR-2
(2)
17. Remove 16 revolving frame mounting bolts (17). Installation

[*3]
a A: Oil pan • Carry out installation in the reverse order to re-
moval.
k When aligning the pin holes, never insert

[*1]
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 Lever mounting bolt: Adhesive (LT-2)

[*2]
18. Lift off revolving frame assembly (18). 3 Lever mounting bolt:
a Check that all the pipes are disconnected 157 – 196 Nm {16 – 20 kgm}
and take care not to damage the center swiv-
2 Revolving frame assembly mounting

el joint. [*3]
4 Revolving frame assembly: 750 kg bolt: Adhesive (LT-2)
3 Revolving frame assembly mounting
bolt: 59 – 74 Nm {6 – 7.5 kgm}
(Target: 65.7 Nm {6.7 kgm})

• Bleeding air
PC18MR-2 30-37
(2)
Disassembly and assembly Removal and installation of swing circle assembly
Removal and installation of swing circle assembly
Removal Installation
1. Remove the revolving frame assembly. For • Carry out installation in the reverse order to re-
details, see Removal and installation of revolv- moval.
ing frame assembly.

[*1]
2. Disconnect grease hoses (1) and (2).
3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
3. Remove 18 mounting bolts (3). [*1]
(Target: 65.7 Nm {6.7 kgm})
4. Install hanging bolts and lift off swing circle
[*2]
assembly (4). [*2]
4 Swing circle assembly: 25 kg
a 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 fig-
ure.
2 Inner race tooth surface: Grease (G2-LI)
30-38 PC18MR-2
(2)
Disassembly and assembly Disassembly and assembly of hydraulic pump assembly
Disassembly and assembly of hydraulic pump assembly

a Packing (14), oil seal (37), seal washer (9), and Special tool
O-rings must be replaced when the pump assem-
bly is assembled again. Accordingly, be sure to • Oil seal driving jig: Tool S
prepare new ones before disassembling. (Sup-
plied 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.
PC18MR-2 30-39
(2)
Disassembly
k Never adjust or remove the set screw (ADJ).
o If it is adjusted or removed, the engine may
stall.
1. Removal of gear pump assembly (1)

1) Remove hexagon head bolts (2) M8 x 20 (2
pieces).
2) Remove gear pump assembly (1), collar (3),

coupling (4), and O-rings (5) and (6).
2. Removal of adjustment unit (ADJ)

a If it is obliged to disassemble adjustment unit
(ADJ), record projection K of the screw in ad-
vance.
Loosen hexagon nut (7) fully and remove set
screw (8) and seal washer (9).
30-40 PC18MR-2
(2)
3. Removal of LS valve
Remove LS valve (11) from body H (10).
a The spool may fall from the LS valve. Take
care.
5. Disassembly of body H (10)

1) Remove packing (14) from body H (10).
4. 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 in-
ternal spring.
3) Loosen the 2 temporary mounting bolts and
separate the bodies.
2) Remove spring guide (15) and valve plate

(16) from body H (10).
a Record the direction (each side) of valve
plate (16).
a Hit the spring insertion part of body H (10)

lightly with a plastic hammer, and the
bodies are separated easily.
PC18MR-2 30-41
(2)
3) Pull control piston (18) out of sleeve (17). 6. Disassembly of body S (12) assembly
4) Remove sleeve (17). 1) Remove spring T1 (30) from body S (12).
a An O-ring is fitted. 2) Remove spring holder (31).
5) Remove plug (20), O-ring (21), and choke 3) Remove cylinder barrel assembly (32).
6) Remove plug (23), O-ring (24), and choke
4) Remove rocker cam (33) and rocker pin

(34).
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.
30-42 PC18MR-2
(2)
5) Remove snap ring (35) on the shaft drive 7. Cylinder barrel assembly (32)
shaft side from body S (12). a Only cylinder barrel assembly (32) or assem-
6) Hit shaft (36) lightly with a plastic hammer to bly of piston (40) and shoe (41) is supplied.
pull oil seal (37) and the assembly of shaft 1) Remove shoe holder (42) from cylinder bar-
(36) and bearing (38) out of body S (12). rel (39). (Piston (40) and shoe (41) are
removed together.)
2) Remove barrel holder (43) and retainer (44).

3) Remove needle (45).
• Inspection and measurement

a Check of wear of oil seal mounting part
Wear Z 0.025 mm
PC18MR-2 30-43
(2)
• Inspection and measurement of piston Assembly

k If foreign matter enters the pump, the pump will
assembly and cylinder barrel
a Check visually that piston assembly and
cylinder barrel are free from a flaw, scuff be broken. Take care.
mark, abnormal wear, etc. (Check the
sliding parts in particular.) • Carry out installation in the reverse order to re-
a Check clearance between outside diam- moval.
eter d of piston (40) and inside diameter
D of cylinder barrel (39). 1. Cylinder barrel assembly (32)
D – d Z 0.050 mm 1) Install retainer (47), spring C (48), retainer
(47), and snap ring (46) in order.
a See the figure left below.
2) Install needle (45), retainer (44), and barrel
holder (43) to cylinder barrel (39).
a Take care of installing position of retainer
(44).
a Axial moving distance of piston (40) and

shoe (41)
E Z 0.2 mm
3) Install shoe holder (42), in which piston (40)

and shoe (41) assembly is inserted, to cylin-
der barrel (39).
4) Remove snap ring (46) from inside of cylin-

der barrel (39), and then remove retainer
(47), spring C (48), and retainer (47) in
order.
30-44 PC18MR-2
(2)
2. 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.
4) 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)
5) Install cylinder barrel assembly (32).
6) Install spring holder (31) to spring T1 (30)
2) Drive oil seal (37) with oil seal driving jig and set spherical part B of the spring holder
TOOL S. Hit the jig lightly with a hammer. in the hole of rocker cam (33).
a Place body S (12) on body H (10) tempo-
rarily for the ease of work.
3. Body H
1) Install choke (22), O-ring (21), and plug (20)
3) Install snap ring (35) to body S (12) on the to body H (10).
shaft drive shaft side. 2) Install choke (25), O-ring (24), and plug (23)
to body H (10).
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.)
PC18MR-2 30-45
(2)
3) Install filter (29) to body H (10).

3 Tightening torque for filter (29):
0.60 – 0.78 Nm {0.061 – 0.079 kgm}
4) 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}
8) 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 bar-
rel. Take care not to mistake the direc-
tion of the valve plate.
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}
9) Install 2 pins (50) to body H (10).
6) Install control piston (18) to sleeve (17).

7) Install spring guide (15).
30-46 PC18MR-2
(2)
10) Install packing (14) to face to be mated with

body S (12).
a Be sure to replace packing (14) with new
one.
6. Installation of adjustment unit

1) Fix set screw (8) and seal washer (9) with
hexagon nut (7) to projection K measured
4. Installation of body S (12) and body H (10) before disassembling.
3 Hexagon nut (7):

1) Install 2 temporary mounting bolts M10 x 80 a Replace seal washer (9) with new one.
to 2 holes on the upper side and tighten
them gradually. 19.6 – 20.6 Nm {2 – 2.1 kgm}
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}
7. 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.
5. 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}
PC18MR-2 30-47
(2)
Disassembly and assembly 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
a Work in a clean indoor place where there is no 2 Mating face of block:

dirt and dust. Apply Sealend 242 or equivalent.
3 PA1 – PA8, PB1 – PB8 (M14 x 1.5):
a Clean the parts in clear solvent, and then dry
them with compressed air.
29.4 – 39.2 Nm {3 – 4.0 kgm}
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 af-
ter tightening them.
30-48 PC18MR-2
(2)
• Section B-B • Section C-C

2 15-2L: Apply a drop (about 0.02 g) of
a Take care of the installed direction of each spool.
a For 8 places of 07-1L on the right side and left
LOCTITE (No. 638) to threads.
3 15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
side, apply the following.
a When tightening and loosening the bolts of 07-
1L, be sure to keep the spool in the valve cham-
a After orifice (1) is installed, its head must not
ber.
project from the mating face of the block.
3 07-1L: 6.9 – 9.8 Nm {0.7 – 1.0 kgm}
PC18MR-2 30-49
(2)
• Sections K-K, L-L, M-M, and AA-AA

a Section AA-AA is under the top cover in the section of the 9-spool valve (attachment valve). (See the sec-
tional structure drawing.)
a All sections (07-1L): See the explanation of section B-B.
2 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}
30-50 PC18MR-2
(2)
• Sections F-F, G-G, and J-J

a All sections (07-1L): See the explanation of sec-
tion B-B.
3 15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
PC18MR-2 30-51
(2)
Removal and installation of hydraulic system and
Disassembly and assembly center swivel joint assembly

hydraulic system and center
swivel joint assembly
Removal
1. Place blocks [1] under the blade and raise the
chassis with the blade and work equipment.
2. Place blocks [2] under the tracks and place the

chassis on those blocks.
3. Remove undercover (1).

7. Remove rubber cover (4) and disconnect hoses

E, F, G, and H.
a The hoses other than hose H have labels on
them.
4. Drain the hydraulic oil.
5. Disconnect hoses (2) and (3) from the center

swivel joint.
• Hoses (2) are labeled A, C, E, G, and I from
the bottom.
• Hoses (3) are labeled B, D, F, H, and J from
the bottom.
a A – J: Hoses are labeled.
plugs.
hoses.
30-52 PC18MR-2
(2)
Removal and installation of hydraulic system and
Disassembly and assembly center swivel joint assembly
8. Disconnect hoses A, B, C, and D from the con- Installation

trol valve assembly.
a The hoses have labels on them. • Carry out installation in the reverse order to re-
a A – H of the hose labels are the name of the moval.
connecting ports of the center swivel joint.
2 Lever mounting bolt: Adhesive (LT-2)

[*1]
3 Lever mounting bolt:

9. Disconnect host T from the hydraulic tank.
a J: Center swivel joint
59 – 74 Nm {6 – 7.6 kgm}

• Bleeding air
10. Disconnect hose (5).
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-2 30-53
(2)
Disassembly and assembly Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of 4. Remove dust seal (6) and 5 plugs (7) from
swivel shaft (5).
center swivel joint assembly
5. Remove 4 plugs (8) from swivel shaft (5).
Special tools a There are 2 types of the plugs.
New/Remodel
6. Remove ring (10), O-ring (11), backup ring (12),
Symbol
Necessity
Part No. Part name and 10 slipper seal (13).
Sketch
Q'ty
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
Disassembly
1. Remove bolts (1) and plate (2).
2. Remove O-ring (3) and snap ring (4).
3. Using tool T, pull rotor (9) out of swivel shaft (5).
30-54 PC18MR-2
(2)
Disassembly and assembly Disassembly and assembly of center swivel joint assembly
Assembly
1. Install O-ring (11), backup ring (12), and 10 slip-
per seals (13) to rotor (9).
2. Install dust seal (6) to swivel shaft (5).

2 Dust seal lip: Grease (G2-LI).
3. 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.
3 Plug (7): 4.90 – 6.86 Nm {0.5 – 0.7 kgm}
3 Plug (8): 16.7 ± 2.9 Nm {1.7 ± 0.3 kgm}
4. 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 slip-
per seals and O-ring.
2 Contact faces of rotor and swivel shaft:
Grease (G2-LI)
5. Install ring (10), snap ring (4), and O-ring (3).

3 Mounting bolt (1):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
PC18MR-2 30-55
(2)
Disassembly and assembly Removal and installation of swing motor assembly
Removal and installation of Installation

swing motor assembly • Carry out installation in the reverse order to re-
moval.
Removal
1. Tilt up the floor frame. For details, see Removal a Add oil through the oil filler to the specified level.
and installation of radiator assembly. Run the engine to circulate the oil through the

2. Disconnect hoses (1) – (5).
plugs.
a Prepare tags to record the destinations of the • Bleeding air
hoses. a Bleed air. For details, see Testing and adjusting,
3. Remove 4 mounting bolts (6).

a Push hose H with the hand to set it apart from
the swing motor assembly.
4. Lift off swing motor assembly (7).

3 Swing motor assembly: 25 kg
30-56 PC18MR-2
(2)
Disassembly and assembly Disassembly and assembly of swing motor assembly
Disassembly and assembly of swing motor assembly

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 neces-
sary.
PC18MR-2 30-57
(2)
• Motor 9. Remove drive (10).
2. Grip the flange with the pinion gear down.
3. 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).
5. Remove spring (3), pin (4), balancing plate (5),

and valve (6).
12. Remove springs (13) from flange mounting (12).
13. Remove snap ring (ø 47), (14), bearing (15), and

shaft face seal (16) from flange mounting (12).
a Assemble only when necessary.
6. Remove valve plate (7).
7. Remove valve drive (8).
8. Remove geroler (9).
30-58 PC18MR-2
(2)
14. Remove piston (17). 19. Remove snap ring (o/ 45) (24), collar (25), bear-
ing (26) from pinion gear assembly (23).
15. Remove ring (18). 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 (ø 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-2 30-59
(2)
Assembly
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.
• Assembly of brake assembly

1. Install bearing (26), collar (25), and snap ring (ø
45) (24) to pinion gear (23).
a Install bearing (26) with the shield side to-
ward the pinion.
a Install collar (25) with the chamfered side to-
ward the snap ring.
3. Install pinion gear assembly (23) to bearing
housing (21).
a Press the pinion side with a press or a plastic
hammer.
4. Install plate (19) to the bearing housing.
2. Install X-ring (27) to bearing housing (21).
30-60 PC18MR-2
(2)
5. Install discs (20) to the bearing housing. 12. Coat spring (13) with grease and stick it to
a Install plates (19) and discs (20) alternately flange mounting (12).
2 Spring (13): Grease (G2-LI)
so that last plate (19) will be on the top.
13. Install the O-ring to flange mounting (12).
6. Install the 2 O-rings (inside and outside) to ring

(18).
14. Install flange mounting (12) to bearing housing
7. Install ring (18) to bearing housing (21).
(21).
a Take care that the spring will not fall.
a When assembling, set the drain hole as
shown in the following illustration.
8. Install the O-ring to piston (17).
9. Install piston (17) to bearing housing (21).
10. Install shaft face seal (16) to flange mounting

(12).
11. Install bearing (15) and fix it with snap ring (14).
PC18MR-2 30-61
(2)
15. Tighten bolts (11) evenly in the diagonal order.

a Degrease bolts (11) in advance.
LOCTITE #242
34.3 Nm {3.5 kgm}
22. Install valve (6), taking care of the following.

a 1) Match the spline teeth of valve (6) (equiva-
lent 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.
• Assembly of motor section
2) Turn valve (6) to the left by 15° from the
state of 1) above to engage it.
16. Install the O-rings (2 types) to the grooves of
k When valve (6) is installed, if it is turned to
flange mounting (12).
the right by 15° from the position where it is
17. Install drive (10).
matched to the teeth of valve drive (8), the
motor will revolve in reverse, and that will be
18. Install geroler (9).
very dangerous.
a Match drain hole D to the flange mounting.
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).
30-62 PC18MR-2
(2)
23. Install spring (3) and pin (4) to hose H of valve

housing (2) in order.
24. Install the O-rings (2 types) to valve housing (2).
28. Install the timer valve to the motor body.

3 Hexagon socket head bolt:
15 Nm {1.5 kgm}
25. Install inner face seal (28) and outer face seal
(29) to balancing plate (5).
26. Install balancing plate (5) to valve housing

assembly (2), matching its cut part to pin (4).
27. Install valve housing assembly (2).

a While inserting thin rod (3) such as a screw-
driver in port B of the valve housing (See il-
lustration 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.
LOCTITE #242
53 Nm {5.4 kgm}
a Tighten the bolts evenly in the diagonal or-
der.
PC18MR-2 30-63
(2)
Disassembly and assembly Removal and installation of work equipment assembly

work equipment assembly
k Release the residual hydraulic pressure from
the hydraulic circuit. For details, see Releasing
k Extract the boom cylinder and bucket cylinder to

residual pressure from hydraulic circuit.
the stroke end and lower the work equipment to
k Set the lock lever in the lock position.

the ground.
Removal
2. Disconnect 6 hoses (1) – (6).

a (3) and (5) are for the boom cylinder.
a The hoses are labeled.
6. Sling boom cylinder (12) temporarily and remove

plate (13) and pin (14). [*1]
a Lower boom cylinder onto stand [1].
3. Disconnect connector (7).
4. Remove cover (8) and disconnect horn assem-

bly (9) from cover (8).
5. Remove clip (10) from wiring harness (11).
30-64 PC18MR-2
(2)
Disassembly and assembly Removal and installation of work equipment assembly
7. Sling work equipment assembly (15) temporarily. Installation

• Carry out installation in the reverse order to re-
moval.

[*1]

2 Pin and sliding surface on boom side:
Molybdenum disulfide lubricant (LM-P)


[*2]
8. Remove plate (16) and boom foot pin (17). [*2]
2 Pin and sliding surface on swing bracket
side: Molybdenum disulfide lubricant
(LM-P)


9. Lift off work equipment assembly (15).
4 Work equipment assembly: 150 kg
• Bleeding air
PC18MR-2 30-65
(2)
Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of a In this section, only the assembly procedure is

explained.
hydraulic cylinder assembly
Assembly
Special tools
a The following steps are common to all the cylin-
New/Remodel
ders, unless otherwise specified.
a Take care not to damage the packings, dust
Symbol
Necessity
Part No. Part name
Sketch
seals, O-rings, etc.
a Clean all the parts. After assembling, cover the
Q'ty
piping ports and pin holes to prevent dirt from en-
790-502-1003 Cylinder repair stand t 1
1 tering them.
790-101-1102 Hydraulic pump t 1
a Do not insert each backup ring forcibly, but warm
2 790-330-1100 Wrench assembly t 1 it in water at 50 – 60°C and then insert it.
Commercially
available
Socket (Width across
flats: 32 mm) t 1
1. Cylinder
3 Commercially
available
Socket (Width across
flats: 36 mm) t 1 1) Press fit bushing (24).
Commercially Socket (Width across 2) Press fit 2 dust seals (23).
available flats: 41 mm) t 1

790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 • Push tool (For
bucket, boom
790-201-1721 1
swing, and vari-
able gauge)
790-201-1731 • Push tool (For arm 1

and blade)
U
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 • Plate (For bucket,
790-201-1530 boom swing, and 1
variable gauge)
2. Piston rod
• Plate (For boom,
790-201-1540
arm, and blade)
1 1) Press fit bushing (22) to piston rod (6).
2) Press fit 2 dust seals (21).
6 790-720-1000 Expander q 1
796-720-1740 Ring piston ø 65 (For

blade) q 1
07281-00709 Clamp (For blade) q 1

Ring piston ø 60, 55
796-720-1630 (For boom, arm, and q 1
boom swing)
7
Ring piston ø 50 (For
796-720-1620 bucket and variable q 1
gauge)
Clamp piston ø 50 -
07281-00609
60 (For boom, arm,
boom swing, bucket, q 1
and variable gauge)
30-66 PC18MR-2
(2)
3. Cylinder head assembly

1) Using tool U4, press fit bushing (20) to cylin-
der head 14.
a Do not perform this step for boom cylin-
der.
a Boom cylinder.
2) Using tool U5, press fit dust seal (18).
8) Install cylinder head assembly (11) to piston

rod (6).
3) Install snap ring (17).

4) Install rod packing (19).
5) Install O-ring (15) and backup ring (16).
6) Install O-ring (30).
7) Install O-ring (12) and 2 backup rings (13).
a Perform this step for only the boom cylin-
der.
PC18MR-2 30-67
(2)
4. Piston assembly 6) Install piston assembly (5) to piston rod (6).

1) Install cushion plunger (10) to piston rod (6).
a Perform this step for only the boom cylin-
der.
7) Set piston rod assembly (2) to tool U1.

8) Using tool U3, install piston nut (4).
• Width across flats of piston nut
2) Set piston ring (9) to tool U6 and give 8 – 10 Boom cylinder: 36 mm
turns to the handle to expand the piston ring. 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}
3) Install piston ring (9) to piston (8). Boom swing cylinder:
4) Using tool U7, contract piston ring (9). 343 ± 34.0 Nm {35 ± 3.5 kgm}
5) Install wear ring (7). Blade cylinder:
412 ± 41.0 Nm {42 ± 4.2 kgm}
Variable gauge cylinder:
324 ± 32.5 Nm {33 ± 3.3 kgm}
30-68 PC18MR-2
(2)
5. Piston rod assembly

1) Install piston rod assembly (2) to cylinder (3).
2) Set cylinder assembly (1) to tool U1.

3) 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-2 30-69
(2)
Disassembly and assembly Disassembly and assembly of hydraulic breaker assembly
Disassembly and assembly of hydraulic breaker assembly
30-70 PC18MR-2
(4)
Breaker arm parts list

No. Part name Q'ty
1 Cap 1
2 Bolt, cap 1
3 Washer, seal 1
4 Cover 1
5 Diaphragm 1
6 Shell 1
7 Ring, valve 1
8 O-ring 1
9 Bolt 4
10 Body, valve 1
11 Plug 2
12 Bolt 4
13 Valve, control 1
14 Plug 3
15 Spring 1
16 Ball, steel 1
17 Tube, inner 1
18 Piston 1
19 O-ring 1
20 Pin 1
21 Cylinder 1
22 Plug 3
23 Packing 1
24 Seal, dust 1
25 Front end 1
26 Washer 4
27 Nut 4
28 Fitting, grease 1
29 Pin, lock 1
30 Pin, ring 1
31 Bushing, chisel 1
32 Bushing, chisel 1
33 Chisel 1
34 Plug 1
35 O-ring 1
36 Seal 4
37 Bushing 4
PC18MR-2 30-71
(4)
Special tools Disassembly of valve body assembly

1. Pull out control valve (13) from valve body (10).
New/Remodel
Symbol
2. Remove draw bolt (12).
Necessity
Part No. Part name
a Heat the draw bolt stud with a burner and
Sketch
Q'ty
burn out the screw lock to remove.
1 796T-170-2420 Stand t 1 N Q
Disassembly of cylinder assembly
2 796T-170-2430 Shaft t 1 N Q 1. Pull out inner tube (17) and piston (18) from the
3 796T-170-2440 Shaft t 1 N Q cylinder assembly.
V 4 796T-170-2450 Shaft t 1 N Q a Do not remove plug (14), spring (15) and
5 796T-170-2460 Shaft t 1 N Q steel ball (16) from inner tube (17).
6 796-170-2160 Handle t 1
2. Remove O-ring (19) from the cylinder assembly.
7 796-170-2170 Valve assembly t 1
3. Remove dust seal (24) and packing (23) from

Disassembly cylinder assembly (21).
a Stick a thin screwdriver or a needle into the
a Work in a clean place free from dirt and dust.
packing to remove.
a Erect the hydraulic breaker assembly on a stand
when disassembling it.
a For each part, see the drawing on the previous
page.
Disassembly of breaker unit

1. Remove 4 mounting bolts (9) and accumulator
assembly (6).
2. Remove nuts (27) and washers (26) to discon-

nect 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.
3. Using tool V6, remove cover (4) from shell (6).
4. Remove diaphragm (5), cap bolt (2) and seal

washer (3) from cover (4).
5. Remove O-ring (8) and backup ring (9) from

shell (6).
30-72 PC18MR-2
(4)
Disassembly of front end assembly Assembly

1. Chisel bushing
1) Set front end assembly (25) to tools V1 and a For each part, see the drawing on the previous
V2 and pull out bushings (31) and (32) page.
simultaneously, using the hydraulic press.
a Hydraulic press capacity: Assembly of front end assembly
Min. 294 kN {30 ton} 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}
2. 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 chis-
el bushing (31) and inside of front end as-
2. Dust seal and bushing sembly (25) and press fit slowly.
Push out dust seal (36) and bushing (37) with a a Press fitting force: Min. 98 kN {10 ton}
round bar 36 – 39 mm in diameter. 2) Using tool V3 and the hydraulic press, press
fit chisel bushing (32).
a Apply lubricating oil to the outside of chis-
el bushing (32) and inside of front end as-
sembly (25) and press fit slowly.
2 Lubricating oil: Engine oil (EO10-CD)
a Press fitting force: Min. 78 kN {8 ton}
PC18MR-2 30-73
(4)
Assembly of cylinder assembly Assembly of accumulator

1. Install packing (23) and dust seal (24) to cylinder 1. Grip shell (6) in vise [1].
assembly (21).
a Clean the packing and dust seal grooves. 2. Fit diaphragm (5) to cover (4).
2 Packing and dust seal grooves, packing
a Press around the diaphragm until its lip is fit-
ted perfectly to the groove of the cover.
2 Inside of shell (6) and outside of dia-
and dust seal: Engine oil (EO10-CD)
a Using a screwdriver, the corners of which are
phragm (5): Engine oil (EO10-CD)
2 Threaded part of shell: Red lead
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. 3. Using tool V6, tighten cover (4).
a Use a new packing and a new dust seal. a Taking care of the threaded parts of the shell
and cover, tighten the cover slowly until it be-
2. If plug (22) was removed, tighten it to the follow- comes almost flush with the shell.
3 Cover: 206 ± 9.8 Nm {21.0 ± 1.0 kgm}
ing torque.
3 Plug: 58.8 Nm {6 kgm}
3. Install O-ring (19) to the groove of cylinder (21).
4. Tighten washer (3) and cap bolt (2) temporarily.

a Tighten these parts permanently after charg-
ing the accumulator with gas.
4. Insert piston (18) in cylinder assembly (21).
2 Outside of piston: Engine oil (EO10-CD)
5. Install backup ring (7) and O-ring (8) to accumu-
lator assembly (6).
5. Insert inner tube (17) in cylinder assembly (21).
6. Install cap (1) fitted with O-ring (35).
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}
3. If plug (11) was removed, tighten it to the follow-

ing torque.
3 Plug: 30 Nm {3 kgm}
30-74 PC18MR-2
(4)
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 fol-
lowing figure.
2. 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)
3. 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}
4. 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 fin-
ger.
a Stroke of control valve: 10 mm
5. 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 as-
sembly to the valve body assembly.
2 O-ring (8): Engine oil (EO10-CD)
3 Mounting bolt: 98.1 Nm {10 kgm}
PC18MR-2 30-75
(4)
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 accu-
mulator 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 han-
dle 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 counter-
clockwise 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 atmo-
sphere.
9) After pressure gauge D indication lowers,
remove tool V7.
10) Install the accumulator protection nut.
30-76 PC18MR-2
(4)
90 Others
Hydraulic circuit diagram................................90- 3

Electrical circuit diagram ................................90- 5
PC18MR-2 90-1
Hydraulic circuit diagram
PC18MR-2 90-3
Electrical circuit diagram
PC18MR-2 90-5

PC18MR2

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SEBM038404

Machine model Serial number

PC18MR-2 15001 and up

• PC18MR-2 mount the 3D67E-1A engine.

10 Structure, function and maintenance standard ........................... 10-1

20 Testing and adjusting ........................................................................................ 20-1

30 Disassembly and assembly .......................................................................... 30-1

90 Others ............................................................................................................................. 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

List of revised pages

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Important safety notice

16. When removing components, be careful not to

17. When removing piping, stop the fuel or oil from

18. As a general rule, do not use gasoline to wash

Structure and function

Testing and adjusting

Disassembly and assembly

How to read the shop manual Revised edition mark

3. Additional pages: Additional pages are indi-

• If a part cannot be smoothly removed from the

Method of disassembling, connecting push-pull type coupler

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

Standard tightening torque

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flats Tightening torque (Nm {kgm})

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flats Tightening torque (Nm {kgm})

Tightening torque for 102 and 114 engine series

(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —

(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —

Electric wire code

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Classification by color and code

Millimeters to inches (B)

Liter to U.S. Gallon

Liter to U.K. Gallon

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0