PC18MR3

SEN04306-02
HYDRAULIC
PC18MR-3
EXCAVATOR
SERIAL NUMBERS 20001 and up
SEN04308-02
HYDRAULIC EXCAVATOR
PC18MR-3
Machine model Serial number

PC18MR-3 20001 and up
00 Index and foreword 00

100 Index
Composition of shop manual .......................................................................................................................... 2

Table of contents ............................................................................................................................................. 4
PC18MR-3 00-100 1
100 Index
SEN04308-02 Composition of shop manual
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title..................................................................................................................................... Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04306-02
00 Index and foreword .................................................................................................................... SEN04307-02

100 Index .................................................................................................................................. SEN04308-02 q
200 Foreword and general information ..................................................................................... SEN04309-00
01 Specification ............................................................................................................................... SEN04310-00

100 Specification and technical data......................................................................................... SEN04311-00
10 Structure, function and maintenance standard........................................................................... SEN04312-00

100 Engine and cooling system ................................................................................................ SEN04313-00
200 Power train......................................................................................................................... SEN04314-00
300 Undercarriage and frame ................................................................................................... SEN04315-00
410 Hydraulic system, Part 1 .................................................................................................... SEN04316-00
500 Work equipment................................................................................................................. SEN04319-00
600 Cab and its attachments .................................................................................................... SEN04320-00
700 Electrical system ................................................................................................................ SEN04321-00
20 Standard value table................................................................................................................... SEN04322-00

100 Standard service value table.............................................................................................. SEN04495-00
30 Testing and adjusting ................................................................................................................. SEN04323-00

100 Testing and adjusting ......................................................................................................... SEN04496-00
40 Troubleshooting.......................................................................................................................... SEN04324-00
100 General information on troubleshooting............................................................................. SEN04497-00
200 Troubleshooting of electrical system (E-mode).................................................................. SEN04498-00
300 Troubleshooting of hydraulic and mechanical system (H-mode) ....................................... SEN04499-00
400 Troubleshooting of engine (S-mode).................................................................................. SEN04500-00
50 Disassembly and assembly........................................................................................................ SEN04325-00

100 General information on disassembly and assembly .......................................................... SEN04620-00 Q
200 Engine and cooling system ................................................................................................ SEN04621-00 Q
300 Power train......................................................................................................................... SEN04622-00 Q
00-100 2 PC18MR-3
100 Index
Composition of shop manual SEN04308-02
400 Undercarriage and frame ...................................................................................................SEN04623-00 Q

500 Hydraulic system ................................................................................................................SEN04624-00 Q
600 Work equipment .................................................................................................................SEN04625-00 Q
700 Cab and its attachments.....................................................................................................SEN04626-00 Q
800 Electrical system ................................................................................................................SEN04627-00 Q
90 Diagrams and drawings..............................................................................................................SEN04326-01

100 Hydraulic diagrams and drawings ......................................................................................SEN04327-00
200 Electrical diagrams and drawings.......................................................................................SEN04328-01
PC18MR-3 00-100 3
100 Index
SEN04308-02 Table of contents
Table of contents 1
00 Index and foreword
100 Index SEN04308-02
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN04309-00

Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN04311-00
Specification dimension drawing ................................................................................................................... 2
Working range drawing ................................................................................................................................. 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 7
Table of fuel, coolant and lubricants.............................................................................................................. 9
10 Structure, function and maintenance standard

100 Engine and cooling system SEN04313-00
PTO............................................................................................................................................................... 2
Cooling system.............................................................................................................................................. 4
200 Power train SEN04314-00
Power train .................................................................................................................................................... 2
Swing circle ................................................................................................................................................... 3
300 Undercarriage and frame SEN04315-00
Track frame ................................................................................................................................................... 2
Idler cushion.................................................................................................................................................. 3
Idler ............................................................................................................................................................... 5
Track roller .................................................................................................................................................... 6
Sprocket ........................................................................................................................................................ 7
Track shoe..................................................................................................................................................... 8
410 Hydraulic system, Part 1 SEN04316-00
Hydraulic components layout drawing .......................................................................................................... 2
Hydraulic tank ............................................................................................................................................... 3
Center swivel joint ......................................................................................................................................... 4
Travel motor .................................................................................................................................................. 5
Hydraulic cylinder.......................................................................................................................................... 14
Solenoid valve............................................................................................................................................... 18
Variable gauge valve..................................................................................................................................... 21
Multi-control valve (If equipped) .................................................................................................................... 22
Hydraulic pump ............................................................................................................................................. 2
Control valve ................................................................................................................................................. 8
00-100 4 PC18MR-3
100 Index
Table of contents SEN04308-02

CLSS ............................................................................................................................................................. 2
Operation for each function and valve........................................................................................................... 6
Swing motor................................................................................................................................................... 20
PPC valve...................................................................................................................................................... 23
500 Work equipment SEN04319-00
Work equipment ............................................................................................................................................ 3
Dimensions of each part of work equipment ................................................................................................. 6
600 Cab and its attachments SEN04320-00
Floor .............................................................................................................................................................. 2
700 Electrical system SEN04321-00
Engine control system ................................................................................................................................... 2
Electric control system................................................................................................................................... 4
Component parts of system........................................................................................................................... 9
KOMTRAX system ........................................................................................................................................ 10
Monitor system .............................................................................................................................................. 13
Sensors ......................................................................................................................................................... 16
20 Standard value table

100 Standard service value table SEN04495-00
Standard value table for engine related parts ................................................................................................ 2
Standard value table for chassis related parts............................................................................................... 3
30 Testing and adjusting

100 Testing and adjusting SEN04496-00
List of testing, adjusting, and troubleshooting tools....................................................................................... 3
Measuring engine speed ............................................................................................................................... 5
Measurement of exhaust gas color ............................................................................................................... 6
Adjusting valve clearance.............................................................................................................................. 7
Testing compression pressure....................................................................................................................... 9
Testing engine oil pressure............................................................................................................................ 10
Testing and adjusting fuel injection timing ..................................................................................................... 11
Adjusting engine stop solenoid...................................................................................................................... 13
Bleeding air from fuel circuit .......................................................................................................................... 14
Testing and adjusting fan belt tension ........................................................................................................... 15
Adjusting fuel control lever linkage ................................................................................................................ 16
Measurement of clearance in swing circle bearings...................................................................................... 17
Testing and adjusting track shoe tension....................................................................................................... 18
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits ............................. 20
Testing and adjusting control circuit basic pressure ...................................................................................... 23
Testing and adjusting pump LS differential pressure..................................................................................... 25
Measuring solenoid valve output pressure .................................................................................................... 27
Measuring PPC valve output pressure .......................................................................................................... 29
Adjusting play of work equipment and swing PPC valves ............................................................................. 31
Measuring swing holding brake release pressure ......................................................................................... 31
Testing oil leakage from cylinder ................................................................................................................... 33
Releasing residual pressure from hydraulic circuit ........................................................................................ 35
Bleeding air from cylinder .............................................................................................................................. 35
Pressurizing hydraulic tank............................................................................................................................ 36
How to open and close (tilt) floor ................................................................................................................... 37
Inspection procedures for diode .................................................................................................................... 39
How to start operation of KOMTRAX terminal............................................................................................... 40
Lamp display of KOMTRAX terminal............................................................................................................. 44
Removal and installation of KOMTRAX terminal........................................................................................... 47
Preparation work for troubleshooting of electrical system ............................................................................. 48
PC18MR-3 00-100 5
100 Index
SEN04308-02 Table of contents
40 Troubleshooting
100 General information on troubleshooting SEN04497-00
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Checks before troubleshooting ..................................................................................................................... 4
Classification and procedures of troubleshooting ......................................................................................... 5
Connection table for connector pin numbers ................................................................................................ 8
T- branch box and T- branch adapter table ................................................................................................... 44
200 Troubleshooting of electrical system (E-mode) SEN04498-00
Before carrying out troubleshooting for electrical system (E-mode) ............................................................. 2
Information contained in troubleshooting table ............................................................................................. 4
E-1 Engine does not start.............................................................................................................................. 5
E-2 Engine does not stop.............................................................................................................................. 12
E-3 When starting switch is turned ON, any item does not operate.............................................................. 14
E-4 When starting switch is turned ON, some items do not operate............................................................. 16
E-5 Alarm buzzer is abnormal....................................................................................................................... 17
E-6 Engine oil pressure caution is turned ON............................................................................................... 19
E-7 Charge level caution is turned ON.......................................................................................................... 20
E-8 Preheating system does not operate or preheater does not become hot............................................... 22
E-9 Coolant temperature gauge is abnormal ................................................................................................ 24
E-10 Fuel level gauge is abnormal................................................................................................................ 28
E-11 Service meter does not operate while engine is running ...................................................................... 32
E-12 2nd travel speed is not selected ........................................................................................................... 35
E-13 Working lamp does not light up ............................................................................................................ 38
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK,
work equipment still moves..................................................................................................................... 40
E-15 Blade/Variable gauge selector system does not operate normally....................................................... 43
300 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04499-00
Information contained in troubleshooting table ............................................................................................. 3
H-1 Speed or power of whole work equipment, travel, swing, and blade is low............................................ 4
H-2 Engine speed lowers extremely or engine stalls .................................................................................... 5
H-3 Whole work equipment, travel system, swing system, and blade do not move ..................................... 6
H-4 Abnormal sound comes out from around hydraulic pump...................................................................... 7
H-5 Fine control performance or response is low ......................................................................................... 7
H-6 Speed or power of boom is low .............................................................................................................. 8
H-7 Speed or power of arm is low ................................................................................................................. 9
H-8 Speed or power of bucket is low............................................................................................................. 10
H-9 Speed or power of boom swing is low .................................................................................................... 11
H-10 Work equipment does not move singly ................................................................................................ 11
H-11 Work equipment hydraulic drift is large................................................................................................. 12
H-12 Time lag of work equipment is large..................................................................................................... 13
H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 13
H-14 Machine deviates during travel............................................................................................................. 14
H-15 Travel speed or travel power is low...................................................................................................... 16
H-16 Machine is not steered well or steering power is low ........................................................................... 16
H-17 Travel speed does not change ............................................................................................................. 17
H-18 Travel motor does not work (one side only) ......................................................................................... 17
H-19 Speed or power of swing is low ............................................................................................................ 18
H-20 Machine does not swing....................................................................................................................... 20
H-21 Swing acceleration performance is low ................................................................................................ 22
H-22 Machine overruns when it stops swinging............................................................................................ 23
H-23 Large shock is made when machine stops swinging ........................................................................... 24
H-24 When upper structure stops swinging, it makes large sound ............................................................... 24
H-25 Hydraulic drift of swing is large............................................................................................................. 25
H-26 Speed or power of blade is low ............................................................................................................ 26
H-27 Blade does not move............................................................................................................................ 27
H-28 Hydraulic drift of blade is large ............................................................................................................. 27
H-29 Variable gauge does not move............................................................................................................. 28
00-100 6 PC18MR-3
100 Index
Table of contents SEN04308-02
H-30 Troubleshooting for hydraulic breaker .................................................................................................. 29

400 Troubleshooting of engine (S-mode) SEN04500-00
Troubleshooting chart .................................................................................................................................... 2
50 Disassembly and assembly

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

100 Hydraulic diagrams and drawings SEN04327-00
Hydraulic circuit diagram ............................................................................................................................... 3
200 Electrical diagrams and drawings SEN04328-01
Electrical circuit diagram................................................................................................................................ 3
Connector list and stereogram ...................................................................................................................... 5
PC18MR-3 00-100 7
SEN04308-02
PC18MR-3 Hydraulic excavator

Form No. SEN04308-02
©2008 KOMATSU
All Rights Reserved
Printed in Japan 05-08 (01)
00-100 8
SEN04309-00
HYDRAULIC EXCAVATOR
PC18MR-3

00 Index and foreword 00
200 Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC18MR-3 00-200 1
SEN04309-00 Safety notice
Safety notice (Rev. 2008/02)1

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety plates stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety plates and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 PC18MR-3
Safety notice SEN04309-00
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
PC18MR-3 00-200 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00-200 4 PC18MR-3
Safety notice SEN04309-00
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC18MR-3 00-200 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00-200 6 PC18MR-3
How to read the shop manual SEN04309-00
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC18MR-3 00-200 7
SEN04309-00 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 PC18MR-3
Explanation of terms for maintenance standard SEN04309-00
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC18MR-3 00-200 9
SEN04309-00 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 PC18MR-3
Handling of electric equipment and hydraulic component SEN04309-00
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors 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,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC18MR-3 00-200 11
SEN04309-00 Handling of electric equipment and hydraulic component
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 sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-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 sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 PC18MR-3
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC18MR-3 00-200 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 PC18MR-3
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC18MR-3 00-200 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 PC18MR-3
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC18MR-3 00-200 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
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 check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked 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
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil 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.
00-200 18 PC18MR-3
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 contaminants 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 secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC18MR-3 00-200 19
SEN04309-00 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engine
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 PC18MR-3
Handling of connectors newly used for engines SEN04309-00
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC18MR-3 00-200 21
SEN04309-00 Handling of connectors newly used for engines
q 95, 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 PC18MR-3
How to read electric wire code SEN04309-00
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC18MR-3 00-200 23
SEN04309-00 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
00-200 24 PC18MR-3
How to read electric wire code SEN04309-00
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC18MR-3 00-200 25
SEN04309-00 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) 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
3) 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
00-200 26 PC18MR-3
Precautions when carrying out operation SEN04309-00
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q 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 at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC18MR-3 00-200 27
SEN04309-00 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
00-200 28 PC18MR-3
Method of disassembling and connecting push-pull type coupler SEN04309-00
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
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.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC18MR-3 00-200 29
SEN04309-00 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00-200 30 PC18MR-3
Method of disassembling and connecting push-pull type coupler SEN04309-00
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
PC18MR-3 00-200 31
SEN04309-00 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

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
a Fig. A a Fig. B
00-200 32 PC18MR-3
Standard tightening torque table SEN04309-00
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal 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 connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 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} 127.4 {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}
PC18MR-3 00-200 33
SEN04309-00 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(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 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
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
14 — —
00-200 34 PC18MR-3
Standard tightening torque table SEN04309-00
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

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
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

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
PC18MR-3 00-200 35
SEN04309-00 Conversion table
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (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)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
00-200 36 PC18MR-3
Conversion table SEN04309-00
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
Liters to U.S. Gallons

1 l = 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
PC18MR-3 00-200 37
Liters to U.K. Gallons

1 l = 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 7.699 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
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
00-200 38 PC18MR-3
kg/cm2 to lb/in2
1 kg/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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC18MR-3 00-200 39
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 (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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 81 177.8
–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 60 140.0 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
00-200 40 PC18MR-3
PC18MR-3 00-200 41
SEN04309-00

©2008 KOMATSU
All Rights Reserved
00-200 42
SEN04311-00
HYDRAULIC EXCAVATOR
PC18MR-3

01 Specification 1
100 Specification and technical data
Specification dimension drawing..................................................................................................................... 2
Working range drawing ................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 7
Table of fuel, coolant and lubricants................................................................................................................ 9
PC18MR-3 01-100 1
SEN04311-00 Specification dimension drawing
Specification dimension drawing1
Item Unit PC18MR-3
Operating weight Canopy specification kg 1,855 [1,900]

Bucket capacity m 3
0.044
Komatsu 3D67E-2
Engine model —
Diesel engine
Rated engine output kW{HP}/rpm 11.2 {15} / 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 715
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
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe
specification are shown.)
a Values in [ ] are for steel shoe specification.
a Operating weight of machine with full tank of fuel and a 75 kg operator (ISO 6016).
01-100 2 PC18MR-3
Working range drawing SEN04311-00
Working range drawing 1
Working range (mm) PC18MR-3
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-3 01-100 3
SEN04311-00 Specifications
Specifications 1
PC18MR-3
Machine model
Canopy specification
Serial number 20001 and up
Bucket capacity m3 0.044

1,855
Operating weight kg [1,900]
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
Ground pressure kPa {kg/cm2} 30.7 {0.31}
[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 counterweight 430 [430]
Min. ground clearance 170 [170]
Tail swing radius 715
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
specification are shown.)
a Values in [ ] are for steel shoe specification.
a Operating weight of machine with full tank of fuel and a 75 kg operator (ISO 6016).
01-100 4 PC18MR-3
Specifications SEN04311-00
PC18MR-3
Machine model
Model 3D67E-2
Type 4-cycle, water cooled, in-line direct injection type,
swirl chamber type
No. of cylinders – bore x stroke mm 3 – 67 × 73.6
Piston displacement l {cc} 0.778 {778}
Flywheel horsepower kW {HP}/rpm 11.2 {15} / 2,600
Performance
Maximum torque Nm {kgm}/rpm 45.6 {4.65} / 2,000

Engine
High idle speed rpm 2,780

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

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
Type x No. Variable displacement piston type x 1, gear type x 1

Hydraulic pump
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/cm } 2 19.1 {195}
Type x No. 9-spool type x 1

Hydraulic system
Boom, Bucket, Arm

Control
valve
Breaker, Swing, Hydraulic assist control

Control method Travel
Blade Direct control
Travel motor Variable-displacement piston motor (with counter-

Hydraulic
balance valve, parking brake) x 2

motor
Fixed-displacement Orbit-roll type motor (with

Swing motor brake 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-3 01-100 5
SEN04311-00 Specifications
PC18MR-3
Machine model
Cylinder type Double acting piston

Boom cylinder
Inside diameter of cylinder 60

Outside diameter of piston rod 35
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
01-100 6 PC18MR-3
Weight table SEN04311-00
Weight table 1
k This weight table is a guide for use when transporting or handing components.
Unit: kg
PC18MR-3
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) 11
Battery 12
Revolving frame 200
Floor frame 125
Canopy assembly 68
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) 362
• Track frame 198
• Idler assembly 20 × 2
• Recoil spring assembly 12 × 2
• Carrier roller assembly (shoe plate) 1×2
• Track roller assembly 3×6
• Travel motor (with reduction gear) 18 × 2
• Sprocket 5×2
• Swing circle 24
• Center swivel joint 10
PC18MR-3 01-100 7
SEN04311-00 Weight table
1
Unit: kg
PC18MR-3
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
01-100 8 PC18MR-3
Table of fuel, coolant and lubricants SEN04311-00
Table of fuel, coolant and lubricants 1

a For details of notes (Notes 1 and 2 ...) in the table, see "Operation and Maintenance Manual".
Unit: l
PC18MR-3
Reservoir
Specified capacity Refill capacity
Engine oil pan 3.6 3.3
Final drive case (each) 0.3 0.3
Idle (each) 0.036 0.036
Track roller (each) 0.044 0.044
Hydraulic system 23.8 15.2
Fuel tank 19 —
Cooling system 3.1 —
PC18MR-3 01-100 9
SEN04311-00

©2008 KOMATSU
All Rights Reserved
01-100 10
SEN04313-00
HYDRAULIC EXCAVATOR
PC18MR-3

10 Structure, function and

maintenance standard 1
100 Engine and cooling system
PTO................................................................................................................................................................. 2
Cooling system ............................................................................................................................................... 4
PC18MR-3 10-100 1
SEN04313-00 PTO
PTO 1
1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump
10-100 2 PC18MR-3
PTO SEN04313-00
PC18MR-3 10-100 3
SEN04313-00 Cooling system
Cooling system 1
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
10-100 4 PC18MR-3
Cooling system SEN04313-00
Specifications
Radiator Oil cooler
Core type AL louver type fin AL drawn-cup
Fin 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}
4.9
Vacuum valve cracking pressure kPa {kg/cm2} {0.05} —
PC18MR-3 10-100 5
SEN04313-00

©2008 KOMATSU
All Rights Reserved
10-100 6
SEN04314-00
HYDRAULIC EXCAVATOR
PC18MR-3


200 Power train
Power train...................................................................................................................................................... 2
Swing circle..................................................................................................................................................... 3
PC18MR-3 10-200 1
200 Power train
SEN04314-00 Power train
Power train 1
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)
10-200 2 PC18MR-3
200 Power train
Swing circle SEN04314-00
Swing circle 1
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-3 10-200 3
SEN04314-00

©2008 KOMATSU
All Rights Reserved
10-200 4
SEN04315-00
HYDRAULIC EXCAVATOR
PC18MR-3


300 Undercarriage and frame
Track frame ..................................................................................................................................................... 2

Idler cushion.................................................................................................................................................... 3
Idler ................................................................................................................................................................. 5
Track roller ...................................................................................................................................................... 6
Sprocket .......................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC18MR-3 10-300 1
SEN04315-00 Track frame
Track frame 1
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.)
10-300 2 PC18MR-3
Idler cushion SEN04315-00
Idler cushion 1
Steel shoe spec.
Unit: mm
Standard size Repair limit

Free Installed Installed Free Installed
1 Recoil spring length length load length 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-3 10-300 3
SEN04315-00 Idler cushion
1
Rubber shoe spec.
1. Cylinder Specifications
2. Rod Grease G2-LI
3. Lubricator
Amount of grease cc 70
10-300 4 PC18MR-3
Idler SEN04315-00
Idler 1
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 –0.025 +0.039
7 30 0 – 0.064 1.5 Replace
and support –0.025 +0.030
PC18MR-3 10-300 5
SEN04315-00 Track roller
Track roller 1
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
10-300 6 PC18MR-3
Sprocket SEN04315-00
Sprocket 1
Unit: mm
Standard size Tolerance Repair limit

1 Wear of root circle diameter +1.0
255 251
–2.0
2 Wear of tip circle diameter 290 ±1.5 278 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-3 10-300 7
SEN04315-00 Track shoe
Track shoe 1
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
10-300 8 PC18MR-3
Track shoe SEN04315-00
1
Steel shoe
Unit: mm
Standard size Repair limit Replace

bushing and
1 Link pitch
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
Tolerance Standard
Standard Interfer-
interfer-
Interference between link size Shaft Hole ence limit
5 ence
and regular pin Replace
+0.155 +0.050 0.100 –
14 —
+0.150 +0.150 0.105
Interference between link +0.154 +0.050 0.100 –
6 22 —
and 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-3 10-300 9
SEN04315-00

©2008 KOMATSU
All Rights Reserved
10-300 10
SEN04316-00
HYDRAULIC EXCAVATOR
PC18MR-3


410 Hydraulic system, Part 1
Hydraulic components layout drawing ............................................................................................................ 2
Hydraulic tank ................................................................................................................................................. 3
Center swivel joint........................................................................................................................................... 4
Travel motor .................................................................................................................................................... 5
Hydraulic cylinder.......................................................................................................................................... 14
Solenoid valve............................................................................................................................................... 18
Variable gauge valve..................................................................................................................................... 21
Multi-control valve (If equipped).................................................................................................................... 22
PC18MR-3 10-410 1
SEN04316-00 Hydraulic components layout drawing
Hydraulic components layout drawing 1
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
10-410 2 PC18MR-3
Hydraulic tank SEN04316-00
Hydraulic tank 1
1. Filler cap Specifications

2. Hydraulic tank
Item Unit Standard
3. Sight gauge
4. Drain plug Tank capacity l 18.5
5. Bypass valve Oil amount l 15.2
6. Filter
Bypass valve set 150 ± 30
7. Strainer kPa {kg/cm2}
pressure {1.53 ± 0.31}
Pressure valve 70 ± 15
kPa {kg/cm2}
cracking pressure {0.71 ± 0.15}
Vacuum valve 0–5
kPa {kg/cm2}
cracking pressure {0 – 0.05}
PC18MR-3 10-410 3
SEN04316-00 Center swivel joint
Center swivel joint 1
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 2nd travel speed selector valve
Unit: mm
Standard size Standard clearance Clearance limit

Clearance between rotor and
5 Replace
shaft 45 0.055 – 0.085 0.090
10-410 4 PC18MR-3
Travel motor SEN04316-00
Travel motor 1
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 2nd travel speed 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-3 10-410 5
SEN04316-00 Travel motor
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
10-410 6 PC18MR-3
Principle of operation
q The PHV Series travel motor consists of the fixed
part which consists of hydraulic motor (2) and
hydraulic valve and the rotary part which consists
of simple planetary reduction gear unit (1).
a (b1) consists of 4 planetary gears and (b2) 1. Simple planetary reduction gear unit
consists of 3 planetary gears. (Double reduction)
2. Hydraulic motor
3. Automatic 1st valve
4. Counterbalance valve
5. Carrier 2
PC18MR-3 10-410 7
1. Reduction gear unit q The reduction ratio of the 2 stages of the sim-
ple planetary gears is generally given by the
Function following expression.
q 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 q 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)
q In the following figure, gear (s2) is coupled with
the hydraulic motor output shaft by spline (or
by a shaft). The revolution of gear (s2) is
reduced through gears (s2), (b2), and (a2).
q The reduced revolution is further reduced
through gears (s1), (b1), and (a1) coupled with
carrier 2 (5) by spline.
q This revolution is transmitted through internal
gears (a1) and (a2) to the rotary part and used
for travel.
10-410 8 PC18MR-3
2. Hydraulic motor
Function
q This hydraulic motor is an axial piston motor
(rotary cylinder swash plate type). It converts
the hydraulic energy from the pump into rotary
movement.
Operation
q The hydraulic oil flowing in through the hydrau-
lic valve is supplied to valve plate (3).
q The hydraulic oil supplied to port (A) flows into
the cylinder port in cylinder barrel (2) corre-
sponding to port (A) and pushes piston (1).
q The pushing force of the above hydraulic oil is
converted through rocker cam (4) into rotary
force and output to shaft (5) coupled with cylin-
der barrel (2).
q The return oil in the cylinder port flows out
through port (B) of valve plate (3).
q When the motor revolves in reverse, the
hydraulic oil flows in through port (B) and the
return oil flows out through port (A).
PC18MR-3 10-410 9
Operation of 2nd motor q If the 2nd gear lever is set, hydraulic oil (P) is
q Rocker cam (4) has 2 faces of (A) and (B) on led through the 2nd spool into control chamber
the opposite side to the face on which shoe (6) (10).
slides. It is supported on 2 balls (7) fixed to q Control piston (11) moves until face (B) of
body (8). rocker cam (4) reaches body (8), and then
q Balls (7) are installed a little higher than the rocker cam (4) is fixed at swash plate angle
axis. Accordingly, in the 1st gear speed, face (b). At this time, the delivery of the motor is
(A) is pressed against body (8) by the hydraulic reduced.
force applied to piston (1) and the force of
spring (9), and swash plate angle is set to (a)
and the delivery of the motor is increased.
q While the engine is stopped, control chamber

(10) is connected through the 2nd spool to the
drain port.
q As a result, rocker cam (4) is returned to the
1st gear speed position by spring (9), thus the
1st gear speed is always selected when the
machine starts travel.
10-410 10 PC18MR-3
3. Hydraulic valve
1) Counterbalance valve
Operation q Even if the hydraulic oil from port (A) is

q If the hydraulic oil is supplied through port (A), stopped, the hydraulic motor continues revolu-
it pushes check valve (2) open and flows in tion by inertia.
port (A') on the inlet side of the hydraulic motor. q At this time, the return oil is controlled gradu-
q On the other hand, the hydraulic oil flows ally by the changing speed and shape of the
through choke (C) into chamber (D) and cut of spool (3) to stop the hydraulic motor
moves spool (3) to the right against spring (4). smoothly.
q As a result, the oil on the return side of the
hydraulic motor flows in through port (B') and
returns through body (1) and opening (E) of
spool (3) to port (B) to rotate the hydraulic
motor.
q If the hydraulic oil is supplied through port (B),
each part operates in the opposite direction
and the hydraulic motor revolves in reverse.
q If the hydraulic oil from port (A) is stopped,
spool (3) moved to the right is returned to the
left by the force of spring (4).
q At this time, the oil in chamber (D) controls the
speed of spool (3) returning to the left with
choke (C).
PC18MR-3 10-410 11
2) Automatic 1st valve
Operation q If the drive pressure is increased from the 2nd

q If the 2nd pilot switch is turned ON, the 2nd gear speed level to the set pressure of the 1st
pilot pressure is led through port (PP) into gear speed, the total of rightward forces (F1)
hydraulic pressure pilot (1) and force (F1) is and (F2) applied to automatic 1st valve (5)
generated. increases the total of leftward forces (F3) and
q Force (F1) moves automatic 1st valve (5) to (F4). As a result, automatic 1st valve (5)
the right against force (F4) and sets the system moves to the left and sets the system in the 1st
in the 2nd gear speed. gear speed.
q On the other hand, the drive pressure is led q If the drive pressure lowers from the 1st gear
into pilots (2) and (3) to generate forces (F2) speed level to the set pressure of the 2nd gear
and (F3). speed, the total of rightward forces (F1) and
q Since the pressure receiving area of hydraulic (F2) applied to automatic 1st valve (5)
pilot (3) is larger than that of (2), force (F3) is decreases the total of leftward forces (F3) and
larger than force (F2). As the drive pressure is (F4). As a result, automatic 1st valve (5)
increased, the difference between forces (F2) moves to the right and sets the system in the
and (F3) is increased. 2nd gear speed.
10-410 12 PC18MR-3
4. Parking brake
Function q If the hydraulic oil is supplied to port (A) or (B),
q When the travel motor is stopped, the parking hydraulic oil (P) is led into chamber (5).
brake fixes the hydraulic motor output shaft Hydraulic oil (P) moves brake piston (6) to the
mechanically. right against the force of spring (7).
q As a result, disc plate (3) and steel plate (4) is
Operation released and the friction force is lost and cylin-
q While the hydraulic oil is not supplied to port der barrel (1) can revolve.
(A) or (B), spring (7) presses brake piston (6)
to the left.
q At this time, disc plate (3) fixed by the semi
lunar groove of cylinder barrel (1) is fixed
between steel plate (4) which is also fixed to
body (2).
q As a result, cylinder barrel (1) cannot revolve
because of the friction force of disc plate (3)
and steel plate (4) and the hydraulic motor out-
put shaft is fixed.
PC18MR-3 10-410 13
SEN04316-00 Hydraulic cylinder
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
10-410 14 PC18MR-3
Hydraulic cylinder SEN04316-00
Boom swing cylinder
Blade cylinder
Variable gauge cylinder
PC18MR-3 10-410 15
SEN04316-00 Hydraulic cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance

name size Shaft Hole clearance limit
–0.025 +0.039 0.025 –

Boom 35 0.403
–0.064 +0.080 0.103
–0.025 +0.132 0.031 –
Arm 35 0.496
Clearance –0.064 +0.006 0.196
between piston –0.020 +0.133 0.013 – Replace
1
rod and bush- Bucket 30
–0.053 –0.007 0.186
0.486 bushing
ing
–0.020 +0.133 0.013 –
Boom swing 30 0.486
–0.053 –0.007 0.186
–0.025 +0.132 0.031–
Blade 35 0.496
–0.064 +0.006 0.196
Variable –0.020 +0.133 0.013 –
30 0.486
gauge –0.053 –0.007 0.186
–0.025 +0.134 0.097 –
Boom 35 1.0
–0.064 +0.072 0.198
–0.010 +0.111 0.046 –
Arm 30 1.0
–0.050 +0.036 0.161
Clearance –0.090 +0.099 0.130 –
between piston Bucket 30
–0.130 +0.040 0.229
1.0
2 rod supporting
shaft and bush- Boom swing –0.010 +0.111 0.046 –
30 1.0
ing –0.050 +0.036 0.161
–0.010 +0.134 0.082 –
Blade 35 1.0
–0.050 +0.072 0.184
Variable –0.010 +0.111 0.046 –
30 1.0
gauge –0.050 +0.036 0.161 Replace pin
–0.025 +0.134 0.097 – and bushing
Boom 35 1.0
–0.064 +0.072 0.198
–0.025 +0.111 0.061 –
Arm 30 1.0
–0.064 +0.036 0.175
Clearance –0.090 +0.099 0.130 –
between cylin- Bucket 30
–0.130 +0.040 0.229
1.0
3 der bottom sup-
porting shaft –0.010 +0.111 0.046 –
Boom swing 30 1.0
and bushing –0.050 +0.036 0.161
–0.010 +0.134 0.082 –
Blade 35 1.0
–0.050 +0.072 0.184
Variable –0.010 +0.111 0.046 –
30 1.0
gauge –0.050 +0.036 0.161
10-410 16 PC18MR-3
Hydraulic cylinder SEN04316-00
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
539 ± 54.0 Nm {55 ± 5.0 kgm}
gauge
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
324 ± 32.5 Nm {33 ± 3.3 kgm} (Width across flats: 32 mm)
gauge
PC18MR-3 10-410 17
SEN04316-00 Solenoid valve
Solenoid valve 1
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
10-410 18 PC18MR-3
Solenoid valve SEN04316-00
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)
q While the signal current is not flowing from the q While the signal current is flowing from the
PPC lock solenoid valve or travel speed selec- PPC lock solenoid valve or travel speed selec-
tor switch, solenoid (1) is turned OFF. tor switch to solenoid (1), solenoid (1) is turned
Accordingly, spool (2) is pressed up by spring ON.
(3). q Accordingly, spool (2) is pressed down by push
q As a result, ports (P) and (A) are shut off from pin (4).
each other and the pilot pressure does not flow q As a result, ports (P) and (A) are connected to
into the actuator. each other and the pilot pressure flows into the
At the same time, the oil from the actuator actuator.
flows through ports (A) and (T) to the hydraulic At the same time, port (T) is closed and the oil
tank. does not flow to the hydraulic tank.
PC18MR-3 10-410 19
SEN04316-00 Solenoid valve
Control relief valve

Operation
q If the oil pressure from the hydraulic pump
increases, the oil in port (P) pushes plunger (1)
and its reaction force compresses spring (2)
and moves up plunger (1), and then the oil is
relieved through ports (P) and (T).
Set pressure: 3.14 MPa {32 kg/cm2}
10-410 20 PC18MR-3
Variable gauge valve SEN04316-00
Variable gauge valve 1
P1: Control valve port (B7)

P2: Control valve port (A7)
C1: Swivel F (Blade cylinder bottom)
C2: Swivel H (Variable gauge cylinder head)
C3: Swivel G (Variable gauge cylinder bottom)
C4: Swivel E (Blade cylinder head)
PC18MR-3 10-410 21
SEN04316-00 Multi-control valve (If equipped)
Multi-control valve
(If equipped) 1
(1) JIS pattern (2) BACKHOE pattern
Operation pattern selection drawing (The port names correspond to the symbols in the drawing).
10-410 22 PC18MR-3
Multi-control valve (If equipped) SEN04316-00
PC18MR-3 10-410 23
SEN04316-00

©2008 KOMATSU
All Rights Reserved
10-410 24
SEN04317-00
HYDRAULIC EXCAVATOR
PC18MR-3


Hydraulic pump ............................................................................................................................................... 2
Control valve ................................................................................................................................................... 8
PC18MR-3 10-420 1
SEN04317-00 Hydraulic pump
Hydraulic pump 1
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
10-420 2 PC18MR-3
Hydraulic pump SEN04317-00
1. Input shaft
2. Rocker pin
3. Swash plate
4. Piston
5. Cylinder block
6. Valve plate
7. Spring
8. Control piston
PC18MR-3 10-420 3
Function Operation
q This pump converts the engine torque trans- q As shaft (5) revolves, cylinder block (1)
mitted to its shaft into hydraulic pressure and revolves and pistons (2) in it reciprocate
supplies the hydraulic oil according to the load. according to the movement of rocker cam (4)
q The delivery can be changed by changing the to suck and discharge the oil.
swash plate angle. q Accordingly, 9 pistons (2) perform 1 cycle of
q This pump has the constant-horsepower con- suction and discharge each time cylinder block
trol function and the load-sensitive control (1) revolves. If shaft (5) revolves continuously,
function. the oil is sucked and discharged continuously.
q Since the displacement of pistons (2) depends
Structure on the inclination of rocker cam (4), the dis-
q Cylinder block (1) has 9 pistons (2) in it and its charge can be changed by changing the incli-
end is in contact with valve plate (3). Valve nation of rocker cam (4).
plate (3) has suction port (A) and discharge
port (B).
q Rocker cam (4) is fixed to body (S) at a certain
angle. Piston (2) revolves along rocker cam
(4).
a: Suction stroke
b: Discharge stroke
c: Suction
d: Discharge
10-420 4 PC18MR-3
1. Constant-horsepower control q If the discharge pressure increases further, the

q Rocker pin (6) is installed to rocker cam (4) inclination of rocker cam (4) is decreased.
and they are so installed to body (S) that the q At this time, the length of the arm receiving
angle of rocker cam (4) can be changed. combined force (F1) of the pistons is reduced
q Spring (7) and pistons (2) of cylinder block are from (a) to (a'). Accordingly, larger force (F1) is
so arranged that they will be against each necessary for the inclination of rocker cam (4).
other through rocker cam (4). Discharge pres-
sure (P1) is applied to pistons (2).
q While discharge pressure (P1) is lower than
the set value of spring (7), the inclination of
rocker cam (4) is fixed to the maximum posi-
tion by spring (7).
q If discharge pressure (P1) is larger than the set
value of spring (7), the inclination of rocker
cam (4) is reduced by combined force (F1) x
(a) of the pistons and fixed to the point where
discharge pressure (P1) is balanced with the
spring force.
q As a result, the (P) – (Q) curve is so changed

that the engine horsepower will be used effi-
ciently (constant-horsepower control).
PC18MR-3 10-420 5
2. Load-sensitive control 3. All-horsepower control

q In the load-sensitive control mode, the signal q Rod (8) is arranged in the position against
pressure from the LS valve is transmitted to spring (7) and discharge pressure (P2) is
control piston (9), which presses rocker cam applied to it.
(4). q As discharge pressure (P2) is increased, the
q Rocker cam (4) is slanted to change the dis- inclination of rocker cam (4) is reduced.
charge until the above pressure, spring force, q Accordingly, the horsepower used by the
and combined force (F1) of the pistons are bal- whole pump is kept constant, even if pressure
anced. (P2) rises.
q 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.
10-420 6 PC18MR-3
4. LS valve
q The LS valve controls the pump discharge
according to the stroke of the control lever, or
the demand flow for the actuator.
q The LS valve detects the demand flow for the
actuator from differential pressure (dPLS)
between pump discharge pressure (P1L) and
control valve outlet pressure (PLS) and con-
trols pump discharge (Q) ((P1L) is called the
pump discharge pressure, (PLS) the LS pres-
sure, and (dPLS) the LS differential pressure).
q In other words, the pressure loss caused by
flowing of oil through the opening of the control
valve spool (= LS differential pressure (dPLS)
is detected, and then pump discharge (Q) is
controlled to keep that pressure loss constant
and supply the pump discharge according to
the demand of flow for the actuator
PC18MR-3 10-420 7
SEN04317-00 Control valve
Control valve 1
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 neces-
sary.
a The service valve is installed additionally
between the top cover and lower valve.
C : Cooler port (To oil cooler)

P : Pump port (From main pump)
S : Swing motor suction port [To swing motor
port (T)]
T : Tank port (To hydraulic tank)
A1 : To arm cylinder bottom
A2 : To swing motor (L.H.)
A3 : To left travel motor (FORWARD)
A4 : To right travel motor (FORWARD)
A5 : To boom cylinder head
A6 : To bucket cylinder head
A7 : To blade cylinder head or variable gauge cyl-
inder bottom through selector valve
A8 : To boom swing cylinder head
A9 : To attachment actuator
B1 : To arm cylinder head
B2 : To swing motor (R.H.)
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 or variable gauge
cylinder head through selector valve
B8 : To boom swing cylinder bottom
B9 : To attachment actuator
LS : Port (LS) (To pump LS valve)
PP :—
PS : To swing brake (Swing holding brake release
port)
TS : Seal drain port (To tank)
PA1 : From arm IN PPC valve
PA2 : From swing LEFT PPC valve
PA3 : From left travel FORWARD PPC valve
PA4 : From right travel FORWARD PPC valve
PA5 : From boom LOWER PPC valve
PA6 : From bucket DUMP PPC valve
PA8 : From boom swing RIGHT PPC valve
PA9 : From attachment PPC valve
PB1 : From arm OUT PPC valve
PB2 : From swing RIGHT PPC valve
PB3 : From left travel REVERSE PPC valve
PB4 : From right travel REVERSE PPC valve
PB5 : From boom RAISE PPC valve
PB6 : From bucket CURL PPC valve
PB8 : From boom swing LEFT PPC valve
PB9 : From attachment PPC valve.
10-420 8 PC18MR-3
Control valve SEN04317-00
9-spool valve
(1/5)
PC18MR-3 10-420 9
(2/5)
10-420 10 PC18MR-3
1. Suction safety valve (Attachment)

2. Suction valve (Boom swing)
3. Suction valve (Bucket)
4. Suction valve (Boom)
5. Suction valve (Arm)
6. Suction valve (Boom)
7. Suction safety 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, bucket, x Outside
19 length load length load
boom, R.H. travel, L.H. diameter
travel and arm)
181 N 144 N
29 x 17.5 25 —
{18.42 kg} {14.7 kg}
Spool return spring 55.4 N 44.3 N Replace
20 20.25 x 17.6 19 —
(Swing) {5.65 kg} {4.52 kg} spring if
Spool return spring 55.4 N 44.3 N damaged or
21 13.07 x 16.7 8.5 — deformed
(Swing) {5.65 kg} {4.52 kg}
Spool return spring 74.5 N 59.6 N
22 42 x 20 25.4 —
(Blade) {7.6 kg} {6.08 kg}
2.65 N 2.16 N
23 Suction valve spring 36.3 x 4.45 33.3 —
{0.27 kg} {0.22 kg}
15.9 N 12.8 N
24 Suction valve spring 39.62 x 4.5 33.3 —
{1.626 kg} {1.30 kg}
PC18MR-3 10-420 11
(3/5)
10-420 12 PC18MR-3
1. Back pressure check valve

2. Unload valve 15. Pressure compensation valve R (Blade)
3. Pressure compensation valve F (Arm) 16. Pressure compensation valve R (Bucket)
4. Pressure compensation valve F (Swing) 17. Pressure compensation valve R (Boom)
5. Pressure compensation valve F (L.H. travel) 18. Pressure compensation valve R (R.H. travel)
6. Pressure compensation valve F (R.H. travel) 19. Pressure compensation valve R (L.H. travel)
7. Pressure compensation valve F (Boom) 20. Pressure compensation valve R (Swing)
8. Pressure compensation valve F (Bucket) 21. Pressure compensation valve R (Arm)
9. Pressure compensation valve F (Blade) 22. LS bypass valve
10. Pressure compensation valve F (Boom swing) 23. Oil cooler bypass valve
11. Pressure compensation valve F (Attachment) 24. Main relief valve
12. Filter (For pump circuit)
13. Pressure compensation valve R (Attachment) F: Flow control valve
14. Pressure compensation valve R (Boom swing) R: Pressure reducing valve
Unit: mm

Free
Pressure compensation
length x Installed Installed Free Installed
valve spring
25 Outside length load length load
(Boom swing, blade, bucket,
diameter
boom and arm)
7.65 N 6.08 N
16.4 x 9.4 14.5 —
{0.78 kg} {0.62 kg}
Pressure compensation
12.5 N 10.0 N Replace
26 valve spring 22.51 x 8.4 17 —
{1.27 kg} {1.02 kg} spring if
(R.H. travel and L.H. travel)
damaged or
Pressure compensation deformed
6.86 N 5.49 N
27 valve spring 20 x 8.4 12 —
{0.7 kg} {0.56 kg}
(Swing)
90.2 N 72.2 N
28 Unload valve spring 29.1 x 18.7 17 —
{9.2 kg} {7.36 kg}
78.8 N 63.1 N
29 Oil cooler bypass spring 27.2 x 13.2 21 —
{8.04 kg} {6.43 kg}
Back pressure check valve 15.3 N 12.3 N
30 29 x 13.3 21 —
spring {1.56 kg} {1.25 kg}
PC18MR-3 10-420 13
(4/5)
10-420 14 PC18MR-3
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

Free
Replace
Check valve spring spring if
(Boom and arm) damaged or
diameter
deformed
1.96 N 1.57 N
21.9 x 5 15.8 —
{0.20 kg} {0.16 kg}
PC18MR-3 10-420 15
(5/5)
10-420 16 PC18MR-3
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 safety valve
14. Suction safety valve
15. Spool (Attachment)
16. Pressure compensation valve R (Attachment)
17. Pressure compensation valve F (Attachment)
18. Safety valve
19. Air bleeding plug
20. Filter (For safety valve circuit)
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Free
Replace
Check valve spring spring if dam-
(Bucket) aged or
diameter
deformed
1.96 N 1.57 N
21.9 x 5 15.8 —
{0.20 kg} {0.16 kg}
PC18MR-3 10-420 17
SEN04317-00

©2008 KOMATSU
All Rights Reserved
10-420 18
SEN04318-00
HYDRAULIC EXCAVATOR
PC18MR-3


CLSS............................................................................................................................................................... 2
Operation for each function and valve ............................................................................................................ 6
Swing motor .................................................................................................................................................. 20
PPC valve ..................................................................................................................................................... 23
PC18MR-3 10-430 1
SEN04318-00 CLSS
CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a variable capacity pis-
tem, and has the following features. ton pump, control valve, and actuators.
q Fine control not influenced by load q The hydraulic pump consists of the pump body,
q Control enabling digging even with fine control TCC valve and LS valve.
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
10-430 2 PC18MR-3
CLSS SEN04318-00
Basic principle
1. Control of pump swash plate angle
q The pump swash plate angle (pump deliv- q If LS differential pressure (dPLS) becomes
ery) is controlled so that LS differential lower than the set pressure of the LS valve
pressure (dPLS) [the difference between (when the actuator load pressure is high), the
pump discharge pressure (PP) and control pump swash plate moves towards the maxi-
valve outlet port LS pressure (PLS) (load mum position.
pressure of actuator)] is constant. q If the set pressure becomes higher than the set
q [LS differential pressure (dPLS) = Pump pressure of the LS valve (when the actuator
discharge pressure (PP) – LS pressure load pressure is low), the pump swash plate
(PLS)] moves towards the minimum position.
LS differential pressure (dPLS) and pump

swash plate angle
a For details of the operation, see “Hydraulic

pump”.
PC18MR-3 10-430 3
SEN04318-00 CLSS
2. Pressure compensation control
q A pressure compensation valve is

installed to the outlet port side of the con-
trol valve spool to balance the load.
q When two actuators are operated together,
this valve acts to make pressure difference
(dP) between the upstream (inlet port) and
downstream (outlet port) the same, regard-
less of the size of the load (pressure).
q 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.
10-430 4 PC18MR-3
CLSS SEN04318-00
PC18MR-3 10-430 5
SEN04318-00 Operation for each function and valve
Operation for each function and valve 1

Hydraulic circuit diagram and name of valve
10-430 6 PC18MR-3
Operation for each function and valve SEN04318-00
1. Unload valve
Set pressure : LS pressure + 2.9 MPa
{30 kg/cm2}
2. Safety valve
3. Pressure compensation valve
4. Port relief 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 {4.0 kg/cm2}
8. Check valve (For swing holding brake release system)
PC18MR-3 10-430 7
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
q When the control valve is at neutral, pump q On the left side of spool (1), pump discharge
delivery (Q) discharged by the minimum swash pressure (PP) is applied to the area of (S1). On
plate angle is released to the tank circuit. the right side, pump discharge pressure (PP) is
When this happens, pump discharge pressure applied to the area of (S2) and LS pressure
(PP) is set at 1.9 MPa {19.7 kg/cm2} by spring (PLS) is applied to the area of (S3).
(2) inside the valve. [LS pressure (PLS) : 0 q When the control valve is at neutral, LS pres-
MPa {0 kg/cm2}]. sure (PLS) is 0, so only pump discharge pres-
sure (PP) has any effect, and (PP) is set only
by the load of spring (2).
q 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 connected to tank circuit (T) through
the hole of spool (1).
q In this way, pump discharge pressure (PP) is
set to 1.9 MPa {19.7 kg/cm2}.
10-430 8 PC18MR-3
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
q When the control valve is in the fine control q When the control valve is operated finely, LS
mode, if the demand flow for actuator is less pressure (PLS) is generated and applied to
than the value corresponding to the minimum area (S3) at the right end of spool (1). At this
swash plate angle of the pump, pump pressure time, difference between LS pressure (PLS)
(PP) is set to LS pressure (PLS) + 1.9 MPa and pump discharge pressure (PP) is large,
{19.7 kg/cm 2 }. If the difference of pressure since the opening area of the control valve
between pump pressure (PP) and LS pressure spool is narrow.
(PLS) becomes equal to the load of spring (2) q When the difference between pump discharge
(1.9 MPa {19.7 kg/cm 2 }), the unload valve pressure (PP) and LS pressure (PLS) reaches
opens. Accordingly, LS differential pressure the load of spring (2), spool (1) moves to the
(dPLS) is (1.9 MPa {19.7 kg/cm2}) at this time. right and pump circuit (PP) and tank circuit (T)
are connected to each other.
q In other words, pump discharge pressure (PP)
is set to a pressure equal to force of spring (2)
(1.9 MPa {19.7 kg/cm2}) + LS pressure (PLS),
and LS differential pressure (dPLS) becomes
1.9 MPa {19.7 kg/cm2}.
PC18MR-3 10-430 9
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 Operation
q When the control valve is operated, if the q When the control valve is operated large, LS
demand flow for actuator exceeds the value pressure (PLS) is generated and applied to
corresponding to the minimum swash plate area (S3) at the right end of spool (1). At this
angle of the pump, the outflow to tank circuit time, difference between LS pressure (PLS)
(T) is shut off and all of pump delivery (Q) is and pump discharge pressure (PP) is small,
sent to the actuator circuit. since the opening area of the control valve
spool is wide.
q For this reason, the differential pressure
between pump discharge pressure (PP) and
LS pressure (PLS) does not reach the load of
spring (2) (1.9 MPa {19.7 kg/cm2}), so spool (1)
is pushed to the left by spring (2).
q As a result, pump circuit (PP) and tank circuit
(T) are shut off, and all the pump delivery (Q)
flows to actuator circuit (3).
10-430 10 PC18MR-3
Introduction of LS pressure
1. Work equipment valve (boom, arm, bucket, boom swing, blade, swing)
Function Operation
q The LS pressure is the actuator load pressure q When spool (1) is operated, pump pressure
at the outlet port end of the control valve. (PP) flows from flow control valve (2) and
q With the control valve, it actually reduces notch (a) in spool (1) through bridge passage
pump pressure (PP) at reducing valve (3) of (b) to actuator circuit (A).
the pressure compensation valve to the same q At the same time, reducing valve (3) also
pressure as actuation circuit pressure (A), and moves to the right, so pump pressure (PP) is
sends it to the LS circuit (PLS). reduced by the pressure loss at notch (c), and
then applied through LS circuit (PLS) to spring
chamber (PLS1).
q When this happens, LS circuit (PLS) is con-
nected to tank circuit (T) from LS bypass valve
(4) (see the section on the LS bypass valve).
q The actuator circuit pressure (PA) = (A) acts on
the left end of reducing valve (3). The reduced
pump pressure (PP) acts on at the other end.
q 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-3 10-430 11
LS bypass valve
T : Tank circuit
PP : Pump circuit
PLS : LS circuit
1. LS bypass valve
2. Valve cover
Function Operation
q This releases the residual pressure of LS pres- q The pressurized oil for LS circuit (PLS) passes
sure (PLS). from filter (a) of bypass plug (1) through orifice
q It makes the speed of the rise in pressure of LS (b) and flows to tank circuit (T).
pressure (PLS) more gentle. In addition, with
this discarded throttled flow, it creates a pres-
sure loss in the throttled flow of the spool or
shuttle valve, and increases the stability by
lowering the effective LS differential pressure.
10-430 12 PC18MR-3
Pressure compensation valve
Function Operation
q During compound operations, if the load pres- q If the load pressure on the other actuator side
sure becomes lower than the other actuator (right side) is increased during compound
and the oil flow tries to increase, compensation operation, the flow in actuator circuit (A) on this
is received. side (left side) is increased.
[When this happens, the other actuator being q At this time, LS pressure (PLS) of the other
used for compound operation (right side) is at actuator acts on spring chamber (PLS1) and
a higher load than the actuator on this side (left pushes reducing valve (1) and flow control
side).] valve (2) to the left.
q Flow control valve (2) reduces the open area
between pump circuit (PP) and spool upstream
(PPA) to cause a pressure loss between (PP)
and (PPA).
q Flow control valve (2) and reducing valve (1)
are balanced at a position where the difference
between pressures (PA) and (PLS) applied to
both ends of reducing valve (1) becomes the
same as the pressure loss made between (PP)
of flow control valve (2) and (PPA).
q Accordingly, the differences between upstream
pressure (PPA) and downstream pressure (PA)
of both spools used for the compound opera-
tion become the same, and then the oil flow is
divided in proportion to the open area of cut (a)
of each spool.
PC18MR-3 10-430 13
1. Area ratio of pressure compensation valve
Function Area ratio (S1) : (S2) and compensation charac-

q The pressure compensation valve finely teristics
adjusts the ratio of (left) area (S1) of flow con- q When 1.00:
trol valve (2) to (right) area (S2) of reducing [Pump (discharge) pressure (PP) – Spool
valve (1) and decides the compensation char- cut upstream pressure (PPA)] C [LS circuit
acteristics according to the characteristics of pressure (PLS) – Actuator circuit pressure
each actuator. (PA) (= A)]
S1: Area of flow control valve (2) – Area of pis- As a 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 q When above 1.00:
(3) (PP) – (PPA) > (PLS) – (PA) (= A)
As a result, less oil is supplied to the com-
pensated side by the area ratio of the spool.
q When below 1.00:
(PP) – (PPA) < (PLS) – (PA) (= A)
As a result, more oil is supplied to the com-
pensated side by the area ratio of the spool.
10-430 14 PC18MR-3
2. LS introduction throttle of pressure compensation valve
Function Operation
q If the other actuator is relieved during com- q If the other actuator side (right side) is relieved
pound operation, more oil is supplied through during compound operation, each circuit pres-
LS introduction throttle (b) of reducing valve (1). sure (PPA), (PA) of the other actuator becomes
the same as the pump circuit pressure [(PP) =
Relief pressure)].
q At this time, spring chamber pressure (PLS2)
of the other actuator becomes the same as
pump circuit pressure (PP) because of balanc-
ing of reducing valve (1).
q (PLS2) is led through LS introduction throttle
(b) of reducing valve (1) and it becomes (PLS).
Since (PLS) is connected through LS bypass
valve (4) to tank circuit (T), a pressure loss is
made in LS introduction throttle (b) [(PLS) <
(PLS2)].
q Accordingly, even if the other actuator is
relieved, a pressure difference is made
between (PP) and (PLS) and more oil flows
through actuator circuit (A) on this side (left
side).
PC18MR-3 10-430 15
L.H., R.H. Travel junction circuit

1. When traveling in a straight line
Function Operation
q To compensate for any difference in the oil flow q When left and right travel spools (1) are oper-
in the left and right travel circuits when travel- ated, the pump discharge flows from pump cir-
ing in a straight line, the junction circuit opens cuit (PP) and circuits (PA) to actuator circuits
when the left and right travel spools are oper- (B).
ated. q When traveling in a straight line, to make actu-
q In this way, the flow of oil to the left and right ator circuits (PA) equal, left and right reducing
travel motors is almost the same when travel- valves (2) are pushed to the right by the same
ing in a straight line, so there is no travel devia- amount, and notch (a) and the travel junction
tion. circuit are opened.
q When steering the machine, the difference in q In this way, the left and right travel actuator cir-
the load pressure returns the reducing valve of cuits are interconnected by the travel junction
the travel valve on the inside of the turn and circuit, so if any difference occurs in the flow of
the opening of the notch in the travel junction oil to the left and right travel motors, the com-
valve spool becomes smaller, so the machine pensation is carried out to prevent any devia-
can be steered. tion in travel.
10-430 16 PC18MR-3
2. Steering when traveling
Operation
q When traveling in a straight line, if left travel
spool (L.H. 1) is returned to the neutral position
and the steering is operated, a difference (R.H.
B) > (L.H. B) is generated in the load pressure
of left and right travel actuator circuits (PA),
and LS pressure (PLS) becomes the same
pressure as (R.H. B).
q As a result, flow control valve (3) on the left
travel side is pushed to the left by LS circuit
(PLS). Because of this, the opening of the left
notch (a) is made smaller, so it becomes possi-
ble to operate the steering when traveling.
q Damper (b) is provided in the circuit to damper
any excessive characteristics in the opening or
closing of the travel junction circuit if the spool
is operated suddenly.
PC18MR-3 10-430 17
Swing holding brake cancel system
Function Operation
q This system resets the swing holding brake by q The left and right swing PPC pressure and the
using left and right swing PPC pressures and arm IN PPC pressure each pass through
arm IN PPC pressure as signals. check valve (2) inside spring case (1), are out-
put to port (BR) and the swing holding brake is
canceled. [The highest pressure is output to
port (BR)].
q The arm and swing are connected by the pilot
circuit inside the control valve.
10-430 18 PC18MR-3
PC18MR-3 10-430 19
SEN04318-00 Swing motor
Swing motor 1
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 sig- Delivery of motor : 195 cm3/rev
nal) Max. using speed : 57.8 rpm
P : Pilot port Max. using flow rate : 12.0 l/min
T : To tank Relief valve set pressure: 15.2 MPa {155 kg/cm2}
Check valve cracking pressure:
0.02 MPa {0.2 kg/cm2}
10-430 20 PC18MR-3
Swing motor SEN04318-00
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. Geroler 19. Safety valve
9. Valve plate 20. Safety valve
10. Outer face seal 21. Timer valve
11. Inner face seal
PC18MR-3 10-430 21
SEN04318-00 Swing motor
Operation
Note) When the motor revolves in the opposite direction, the oil flows in the opposite direction to the above
figure.
1. Output shaft 5. Valve plate

2. Main drive 6. Valve drive
3. Geroler 7. Disc valve
4. Star 8. Check valve
q The oil from the pump through the control q In other words, output shaft (1) is rotated by
valve flows through disc valve (7) to geroler main drive (2). At the same time, rotation of
(3), and then star (4) of the geroler makes star (4) of geroler (3) is taken out by valve drive
planetary movements. (6) and transmitted to disc valve (7), thus the
q Only the rotation of the planetary movements motor is rotated by the oil flowing in the
is taken out by main drive (2) to rotate output geroler.
shaft (1).
q 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 posi-
tion of the oil flowing to geroler (3) changes in
order accordingly.
10-430 22 PC18MR-3
PPC valve SEN04318-00
PPC valve 1
Work equipment and swing PPC valve
P : From pilot pump through solenoid valve P4 : L.H. PPC valve: swing LEFT port /
P1 : L.H. PPC valve: arm IN port/ R.H. PPC valve: bucket CURL port
R.H. PPC valve: boom RAISE port T : To tank
P2 : L.H. PPC valve: arm OUT port/
R.H. PPC valve: boom LOWER port
P3 : L.H. PPC valve: swing RIGHT port/
R.H. PPC valve: bucket DUMP port
PC18MR-3 10-430 23
SEN04318-00 PPC valve
10-430 24 PC18MR-3
1. Spool
2. Piston
3. Disc
4. Nut (for connecting lever)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm

Free length
Centering spring x Outside
10 length load length load
[for port (P3), (P4)] diameter
Replace spring
17.7 N 14.1 N
42.48 x 15.5 34 — if damaged or
{1.8 kg} {1.44 kg}
deformed
Centering spring 29.4 N 23.5 N
11 44.45 x 15.5 34 —
[for port (P1), (P2)] {3 kg} {2.4 kg}
16.7 N 13.3 N
12 Metering spring 26.53 x 8.15 24.9 —
{1.7 kg} {1.36 kg}
PC18MR-3 10-430 25
Operation q When this happens, spool (1) moves up or

1. At neutral down so that the force of metering spring
q Ports (A) and (B) of the control valve and (2) is balanced with the pressure at port
ports (P1) and (P2) of the PPC valve are (P1).
connected to drain chamber (D) through q The relationship in the position of spool (1)
fine control hole (f) in spool (1). and body (10) (fine control hole (f) is at a
point midway between drain hole (D) and
pump pressure chamber (PP)) does not
change until retainer (9) contacts spool
(1).
q Therefore, metering spring (2) is com-
pressed proportionally to the amount of
movement of the control lever.
q So the pressure at port (P1) also rises in
proportion to the travel of the control lever.
q In this way, the control valve spool moves
to a position where the pressure in cham-
ber (A) [the same as the pressure at port
(P1)] and the force of the control valve
spool return spring are balanced.
2. During fine control (neutral o fine control)

q When piston (4) starts to be pushed by
disc (5), retainer (9) is pushed; spool (1) is
also pushed by metering spring (2), and
moves down.
q When this happens, fine control hole (f) is
shut off from drain chamber (D), and at
almost the same time, it is connected to
pump pressure chamber (PP).
q So pilot pressure oil from the control pump
passes through fine control hole (f) and
goes from port (P1) to port (A).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine
control hole (f) is shut off from pump pres-
sure chamber (PP).
At almost the same time, it is connected to
drain chamber (D) to release the pressure
at port (P1).
10-430 26 PC18MR-3
3. During fine control 4. At full stroke

(when control lever is returned) q When disc (5) pushes down piston (4),
q When disc (5) starts to be returned, spool and retainer (9) pushes down spool (1).
(1) is pushed up by the force of centering q Fine control hole (f) is shut off from drain
spring (3) and the pressure at port (P1). chamber (D), and is connected with pump
q When this happens, fine control hole (f) is pressure chamber (PP).
connected to drain chamber (D) and the q Therefore, the pilot pressure from the
pressure oil at port (P1) is released. solenoid valve passes through fine control
q If the pressure at port (P1) drops too far, hole (f) and flows to chamber (A) from port
spool (1) is pushed down by metering (P1), and pushes the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f')
chamber (D). At almost the same time, it is and flows to drain chamber (D).
connected to pump pressure chamber
(PP).
q The pump pressure is supplied until the
pressure at port (P1) recovers to a pres-
sure that corresponds to the lever posi-
tion.
q When the spool of the control valve
returns, oil in drain chamber (D) flows in
from fine control hole (f') in the valve on
the side that is not working. The oil passes
through port (P2) and enters chamber (B)
to fill the chamber with oil.
PC18MR-3 10-430 27
Travel PPC valve
a For operation, see the sections of the “Work

equipment and swing PPC valve”.
P : From pilot pump through solenoid valve

P1 : R.H. travel FORWARD port
P2 : R.H. travel REVERSE port
P3 : L.H. travel FORWARD port
P4 : L.H. travel REVERSE port
T : To tank
10-430 28 PC18MR-3
1. Valve 4. Plate
2. Body 5. Piston
3. Collar 6. Bolt
Unit: mm

Free length
x Outside
7 Centering spring length load length load Replace spring
diameter
if damaged or
135 N 108 N deformed
52.06 x 15.5 31.9 —
{13.8 kg} {11.0 kg}
16.7 N 13.3 N
8 Metering spring 24.04 x 8.16 23.05 —
{1.7 kg} {1.36 kg}
PC18MR-3 10-430 29
Boom swing and attachment PPC valve
a For operation, see the section of the “Work

equipment and swing PPC valve”.
10-430 30 PC18MR-3
P : From pilot pump through solenoid valve

P1 : To boom swing and attachment valve
P2 : To boom swing and attachment valve
T : To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
No
Check item Criteria Remedy
.
Free length Installed Installed Free Installed
8 Centering spring × Outside Replace
length load length load
diameter spring if dam-
125 N 100 N aged or
33.88 × 15.3 28.4 — deformed
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
9 Metering spring 22.73 × 8.1 22 —
{1.7 kg} {1.36 kg}
PC18MR-3 10-430 31
SEN04318-00

©2008 KOMATSU
All Rights Reserved
10-430 32
SEN04319-00
HYDRAULIC EXCAVATOR
PC18MR-3


500 Work equipment
Work equipment .............................................................................................................................................. 3
Dimensions of each part of work equipment ................................................................................................... 6
PC18MR-3 10-500 1
500 Work equipment
SEN04319-00
10-500 2 PC18MR-3
500 Work equipment
Work equipment SEN04319-00
Work equipment 1
PC18MR-3 10-500 3
500 Work equipment
SEN04319-00 Work equipment
10-500 4 PC18MR-3
500 Work equipment
Work equipment SEN04319-00
Unit: mm

Clearance between mount-
ing pin of revolving frame size Shaft Hole clearance limit
1
and swing bracket and bush-
–0.036 +0.153 0.115 –
ing 55 1.0
–0.090 +0.079 0.243
–0.025 +0.115 0.078 –
2 ing pin of swing bracket and 35 1.0
–0.064 +0.053 0.179
boom and bushing
–0.025 +0.086 0.061 –
3 ing pin of boom and arm and 30 1.0
–0.064 +0.036 0.15
bushing
–0.090 +0.087 0.124 – Replace pin
4 ing pin of arm and bucket 30 1.0
–0.130 +0.034 0.217 and bushing
and bushing
–0.090 +0.087 0.124 –
5 ing pin of link and bucket and 30 1.0
–0.130 +0.034 0.217
bushing
Clearance between mount- –0.090 +0.087 0.124 –
6 30 1.0
ing pin of links and bushing –0.130 +0.034 0.217
–0.090 +0.087 0.124 –
7 ing pin of arm and link and 30 1.0
–0.130 +0.034 0.217
bushing
–0.010 +0.070 0.05 –
8 ing pin of track frame and 30 1.0
–0.050 +0.040 0.12
blade and bushing
PC18MR-3 10-500 5
500 Work equipment
SEN04319-00 Dimensions of each part of work equipment
Dimensions of each part of work equipment 1

Arm section
10-500 6 PC18MR-3
500 Work equipment
Dimensions of each part of work equipment SEN04319-00
Unit: mm
Tolerance
No. Measuring point Standard size
Shaft Hole
–0.01 +0.039
1 — 30
–0.05 +0.000
–0
Arm side 42
–1
2
–0.5
Cylinder head side 40
–0.5
–0.09 +0.086
3 — 30
–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 — 30
–0.130 +0.034
0.
Link side 118
–0.5
17
+1.0
Bucket side 119
–0.5
–0.090 +0.087
18 — 30
–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-3 10-500 7
500 Work equipment
SEN04319-00 Dimensions of each part of work equipment
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 — 11 —
+1.0
9 — 119
–0.5
10 — 44 —
11 — 25 —
12 — 176 ±1
13 — 50 —
14 — 50 —
+0.033
15 — 30
+0.009
10-500 8 PC18MR-3
500 Work equipment
Dimensions of each part of work equipment SEN04319-00
PC18MR-3 10-500 9
SEN04319-00

©2008 KOMATSU
All Rights Reserved
10-500 10
SEN04320-00
HYDRAULIC EXCAVATOR
PC18MR-3


600 Cab and its attachments
Floor................................................................................................................................................................ 2
PC18MR-3 10-600 1
SEN04320-00 Floor
Floor 1
Tilt floor
1. Hinge pin Outline

2. Lock pin q The tilt floor can be tilted open for the ease of
3. Gas spring adjusting of the fan belt, inspection and main-
4. Reset lever tenance such as replacement of the hydraulic
5. Wire hoses, etc.
6. Tilt lock bracket Tilt open angle (a): Approx. 35°
7. Floor assembly
10-600 2 PC18MR-3
Floor SEN04320-00
PC18MR-3 10-600 3
SEN04320-00

©2008 KOMATSU
All Rights Reserved
10-600 4
SEN04321-00
HYDRAULIC EXCAVATOR
PC18MR-3


700 Electrical system
Engine control system..................................................................................................................................... 2

Electric control system .................................................................................................................................... 4
Component parts of system ............................................................................................................................ 9
KOMTRAX system........................................................................................................................................ 10
Monitor system.............................................................................................................................................. 13
Sensors......................................................................................................................................................... 16
PC18MR-3 10-700 1
SEN04321-00 Engine control system
Engine control system 1
1. Battery
2. Starting switch
3. Fuse box
4. Engine stop solenoid
5. Lock lever
6. PPC lock switch
7. Neutral engine start relay
8. Safety relay
9. Starting motor
10. Fuel control lever
11. KOMTRAX terminal
12. KOMTRAX engine cut relay
10-700 2 PC18MR-3
Engine control system SEN04321-00
Starting engine
q If starting switch (2) is set to the "ON" position,
engine stop solenoid (4) sets the governor stop
lever to the "RUN" position. Accordingly, if the
electric system has a failure, the engine stops,
that is, a fail-safe mechanism is formed.
q If starting switch (2) is set to the "START" posi-
tion while lock lever (5) is in the "LOCK" posi-
tion, the start signal flows in starting motor (9)
and the engine starts. If lock lever (5) is in the
"FREE" position, neutral engine start relay (7)
operates to shut off the start signal to starting
motor (9), thus the engine does not start.
q If the machine is equipped with the KOMTRAX
terminal system and receives an engine cut-
out command generated by an external opera-
tion, KOMTRAX terminal (11) turns KOMTRAX
engine cut-out relay (12) ON to shut off the cur-
rent to starting motor (9), thus the engine can-
not start.
Engine speed control

q If fuel control lever (10) is operated, the cable
is extended or retracted to control the engine
speed.
Stopping engine
q If starting switch (2) is set to the "OFF" posi-
tion, engine stop solenoid (4) sets the governor
stop lever to the "STOP" position to stop the
engine.
PC18MR-3 10-700 3
SEN04321-00 Electric control system
Electric control system 1

General system drawing
10-700 4 PC18MR-3
Electric control system SEN04321-00
1. Battery
2. Starting switch
3. Fuse box
4. Monitor panel
5. 2nd travel speed selector switch
6. 2nd travel speed selector solenoid relay
7. Lock lever
8. PPC lock switch
9. PPC lock solenoid relay
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. Travel motor
17. Engine
18. Hydraulic pump
18a. Servo valve
18b. LS valve
18c. PC valve
19. Control valve
19a. Self pressure reducing valve
PC18MR-3 10-700 5
Travel control function
1. Battery Input and output signals

2. Starting switch a. Solenoid power supply
3. Fuse box b. 2nd travel speed selector signal
4. 2nd travel speed selector switch c. Solenoid valve drive signal
5. 2nd travel speed selector solenoid relay
7. Left travel motor
8. Right travel motor
9. Control valve
10. Engine
11. Hydraulic pump
10-700 6 PC18MR-3
Electric control system SEN04321-00
Function
Changing travel speed
2nd travel speed selector Low High
q If the travel speed selector switch of the moni- switch speed speed
tor panel is operated, the motor capacity
2nd travel speed selector
changes, thus the travel speed changes. OFF ON
monitor
2nd travel speed selector
a Even while the machine is traveling at the high OFF ON
solenoid valve
speed (High), if the load changes largely on a
soft ground or on a slope, the travel speed is Motor capacity (cm3/rev) 12.4 6.2
set to the low speed (Low) automatically. At
this time, the 2nd travel speed selector monitor Travel speed (km/h) 2.3 4.3
keeps lighting up.
Travel motor swash plate
Max. Min.
angle
17.8 ± 1 MPa
A
{181 ± 10 kg/cm2}
19.2 ± 1 MPa
B
{196 ± 10 kg/cm2}
PC18MR-3 10-700 7
PPC lock function
1. Battery Function
2. Starting switch q The PPC lock switch is interlocked with the
3. Fuse box lock lever. If the lock lever is set in the LOCK
4. Lock lever position, the PPC lock switch is turned OFF.
5. PPC lock lever q If the PPC lock switch is turned OFF, the cur-
6. PPC lock solenoid relay rent flowing to the PPC lock solenoid valve is
7. PPC lock solenoid valve shut off. Then, the work equipment and
8. Left PPC valve machine unit do not move even if any control
9. Right PPC valve lever or pedal is operated.
10. Travel PPC valve
11. Boom swing PPC valve
12. Engine
13. Hydraulic pump
14. Control valve
Input and output signals

a. PPC lock signal
b. Solenoid power supply
c. Solenoid valve drive signal
10-700 8 PC18MR-3
Component parts of system SEN04321-00
Component parts of system 1

PPC lock solenoid valve
2nd travel speed selector solenoid valve

a See Solenoid valve.
Monitor panel
a See Monitor system.
PC18MR-3 10-700 9
SEN04321-00 KOMTRAX system
KOMTRAX system 1
q The KOMTRAX terminal transmits various

kinds of machine information wirelessly. The
KOMTRAX operator can refer to the informa-
tion at the office to provide various kinds of ser-
vices for customers.
a To provide the services, a separate

arrangement for setting up the KOMTRAX
terminal is required.
Information transmittable from the KOMTRAX

terminal includes the following.
1. Operation information
2. Service meter
3. Position information
4. Fuel level
10-700 10 PC18MR-3
KOMTRAX system SEN04321-00
KOMTRAX terminal
1. GPS antenna connection

2. Connector (A)
3. Connector (B)
4. Connector (C)
5. Communication antenna connection
Outline
q The KOMTRAX terminal can obtain various
kinds of information from network signals or
input signals in the machine and transmit them
through the wireless communication antenna.
It has a CPU (Central Processing Unit) in it and
also has wireless communication function and
GPS (Global Positioning System) function.
q This terminal has LED lamps and 7-segment
indicator lamps used for inspection and trou-
bleshooting on its unit.
PC18MR-3 10-700 11
SEN04321-00 KOMTRAX system
Connector
174480-1 AMP (18 + 12 + 12 pins)
Input/ Input/ Input/

Pin Pin Pin
Signal name Output Signal name Output Signal name Output
No. No. No.
signal signal signal
1 NC 1 NC 1 GND
2 NC 2 NC 2 GND
3 NC 3 NC 3 ACC input Input
4 NC 4 NC 4 R terminal input Input
5 NC 5 NC 5 Fuel sensor input 1 Input
6 NC 6 NC 6 Constant power supply Input
B C
7 Network selection 2 Input 7 NC 7 Constant power supply Input
8 Network selection 1 Input 8 NC 8 Relay output Output
9 CAN shield 9 NC 9 Inspection mode selection signal Input
A Input/
10 CAN (H) Output 10 NC 10 NC
Input/
11 CAN (L) Output 11 NC 11 C terminal input Input
12 Fuel sensor selection 2 Input 12 NC 12 Fuel sensor input 2 Input
13 Fuel sensor selection 1 Input
14 NC
15 NC
16 NC
17 NC
18 NC
10-700 12 PC18MR-3
Monitor system SEN04321-00
Monitor system 1
1. Monitor panel Outline

2. Battery q The machine monitor system uses the net
3. Each sensor work circuit between the controllers and sensor
4. Alarm buzzer installed to all parts of the machine to observe
the condition of the machine. It processes this
Input and output signals information, and display it on a panel to inform
a. Power supply the operator of condition of the machine.
b. Sensor signal
c. Alarm buzzer signal
PC18MR-3 10-700 13
SEN04321-00 Monitor system
Monitor panel
Outline
q The monitor panel has the monitor display function, gauge display function and service meter function.
q The monitor panel has a CPU (Central Processing Unit) in it to process, display and output information.
q If there is a trouble in the monitor panel unit, the monitor does not display normally.

AMP070-20P [CN-F15]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 GND Input 11 Buzzer output Output
2 NC Input 12 Working lamp switch Input
3 NC Input 13 Fuel level sensor Input
4 Wake up switch Input 14 CAN+ Input/Output
5 CAN– Input/Output 15 Speed increase solenoid relay output Output
6 Speed increase Input 16 Engine coolant temperature sensor Input
7 Engine oil pressure switch Input 17 Battery charge level Input
8 Preheating switch Input 18 NC Input
9 Key input Input 91 ACC Input
10 Sensor GND Input 20 Unswitched power supply Input
10-700 14 PC18MR-3
Monitor system SEN04321-00
Operation
Gauge and monitor display unit
Light
Type of
No. Display item Display range Display method Display color source
display
element
When below red When normal: OFF
1a Pilot Red LCD
Fuel level range When below red range: Flashing
1b Gauge Empty - Full Indication with pointer White LED
Display of
2 Service meter 0 – 99999.9 h Operation during run of engine
clock time
3a Gauge 55 – 135°C Indication with pointer White
Coolant When coolant
temperature When normal: OFF
3b Pilot temperature is Red
When above 110°C: Flashing
abnormal
During
4 Caution Preheating During operation: Flashing (18 sec) Green
preheating
Electrical When system is LED
5 Caution When abnormal: Lighting or flashing
system warning abnormal
Engine oil Below specified
6 Caution When abnormal: Flashing Red
pressure pressure
Battery charge When charge is
7 Caution When abnormal: Flashing
level defective
When travel
Travel speed
8 Pilot speed is When speed is increased: Lighting Orange
increase
increased
PC18MR-3 10-700 15
SEN04321-00 Sensors
Sensors 1
q The signal from each sensor is input to the panel directly.
q The sensors are classified into contact type and resistance type.
q 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
q The engine oil pressure sensor is installed to the engine cylinder block and its diaphragm senses oil
pressure. If the oil pressure lowers below the set level, the switch is turned ON.
Coolant temperature sensor
1. Reed switch 4. Magnet

2. Magnet 5. Plug
3. Thermo-ferrite 6. Connector
Function
q The coolant temperature sensor is installed to the engine cylinder block and its thermo-ferrite senses
temperature changes. If the temperature rises above the set level, the switch is turned ON.
10-700 16 PC18MR-3
Sensors SEN04321-00
Fuel level sensor
1. Float
2. Arm
3. Variable resistor
4. Connector
Function
q The fuel level sensor is installed to the top of the fuel tank and its float moves up and down according to
the fuel level in the tank. The movement of the float operates the variable resistor through the arm, and
then signals are generated according to the change of the resistance.
PC18MR-3 10-700 17
SEN04321-00

©2008 KOMATSU
All Rights Reserved
10-700 18
SEN04495-00
HYDRAULIC EXCAVATOR
PC18MR-3

20 Standard value table 1

100 Standard service value table
Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis related parts ................................................................................................ 3
PC18MR-3 20-100 1
SEN04495-00 Standard value table for engine related parts
Standard value table for engine related parts 1
Applicable model PC18MR-3
Engine 3D67E-2
Standard value Service limit

Item Measurement condition Unit
for new machine value
High idle 2,780 ± 50 —
Engine speed Low idle rpm 1,375 ± 50 —
Rated speed 2,600 —
At sudden acceleration Max. 5.0 5.5

Bosch
Exhaust gas color
index
At high idle 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 idle
0.196 – 0.441
At high idle —
Coolant temperature: {2.0 – 4.5}
MPa
Oil pressure Within operating range
{kg/cm2} Min. 0.098 —
Oil: SAE30W
At low idle
{1.0} {—}
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
Fuel injection timing B. T. D. C. °(degree) 19 ± 1 —
Deflection when pressed with finger force of

Fan belt tension mm Approx. 10 —
approx. 98 N{10 kg}
20-100 2 PC18MR-3
Standard value table for chassis related parts SEN04495-00
Standard value table for chassis related parts 1
Machine model PC18MR-3
Cate- Standard value for

Item Measurement conditions Unit Service limit value
gory new machine
• Engine coolant temperature: Within operating

Engine
speed
Speed when pump is 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
Bucket control valve

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

valve
Boom control lever N o RAISE, 80 ± 10 80 ± 10

LOWER
Arm control lever N o IN, OUT 80 ± 10 80 ± 10
Bucket control lever N o CURL, 80 ± 10 80 ± 10

DUMP
Stroke of control lever and pedal
N o Swing to
Swing control lever LEFT, RIGHT 80 ± 10 80 ± 10
• Stop engine.
Boom swing control • Measure at center of lever N o Swing boom 25 ± 5 25 ± 5
pedal grip. to LEFT, RIGHT
• Measure at pedal tip. mm
• Read max. value to stroke N o RAISE,
Blade control lever end (excluding neutral LOWER 50 ± 5 50 ± 5
play).
N o FORWARD,
Travel control lever 100 ± 10 100 ± 10
REVERSE
SLOW i
o FULL
Fuel control lever THROTTLE 160 ± 20 160 ± 20
Work equipment,
Max. 5 Max. 5
swing
Play of control lever
Travel Max. 5 Max. 5
PC18MR-3 20-100 3
SEN04495-00 Standard value table for chassis related parts
Cate- Item Measurement conditions Unit Standard value for Service limit value
gory new machine
15.68 ± 4.9 15.68 ± 9.8
Boom control lever
{1.6 ± 0.5} {1.6 ± 1}
Operating effort of control levers and pedals
15.68 ± 4.9 15.68 ± 9.8

Arm control lever {1.6 ± 0.5} {1.6 ± 1}
Bucket control lever 15.68 ± 4.9 15.68 ± 9.8

{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}
Blade control lever 29.4 ± 9.8 29.4 ± 19.6

{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
• Measure pump outlet pressure. {25 0 } {25 0 }
+ 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
23.0 – 0.49 23.0 – 0.49
Bucket relief pressure + 10 + 10
• Hydraulic oil temperature: 45 – 55°C {235 – 5 } {235 – 5 }
• Run engine at full throttle and measure
relief pressure (Relieve only circuit to be 19.1 ± 0.98 19.1 ± 0.98
Swing relief pressure measured). {195 ± 10} {195 ± 10}
• Measure pump outlet pressure.
Oil pressure
+ 0.98 + 0.98
Boom swing relief pres- MPa 23.0 – 0.49 23.0 – 0.49
sure {kg/cm2} + 10 + 10
{253 – 5 } {253 – 5 }
Blade relief pressure 23.0 ± 0.98 23.0 ± 0.98

{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 }
• Hydraulic oil temperature: 45 – 55°C

• Run engine at full throttle. + 0.39 + 0.39
Control circuit oil pres- 3.72 – 0.1 3.72 – 0.1
• Measure circuit oil pressure when all con-
sure trol levers are in neutral.
+4 +4
{38 – 1 } {38 – 1 }
• Measure pump outlet pressure.
+ 0.98 + 0.98
• Hydraulic oil tempera- When all levers 2.5 0 2.5 0
ture: 45 – 55°C are in neutral + 10 + 10
• Run engine at full throt- {25 0 } {25 0 }
LS differential pressure tle.
• Pump outlet pressure - When arm 1.57 ± 0.1 1.57 ± 0.1
LS pressure lever is moved
IN (half stroke) {16 ± 1} {16 ± 1}
20-100 4 PC18MR-3
gory new machine
• No load, max. reach
• Run engine at full throttle.
• Stop after swinging 1 turn and measure shifting
deg. Max. 40 50
Overrun of swing 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° Max. 2.0 Max. 2.2
Time required to • Measure time required to pass 90°
start swinging and 180° points after starting swing-
ing.
• For measuring posture, see Fig. 180° — —
Swing 1 at end of this section. sec.

Swing
Time required for • Run engine at full throttle.

• Measure time required to swing 5 turns after 34 ± 3 Max. 41
swinging 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° and set its upper
Hydraulic drift of structure at 45° upward. deg. 0 0
swing (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 leakage in 1
minute.
• Hydraulic oil temperature: 45 – 55°C Low
• Run engine at full throttle. speed 31.3 ± 3 31.3 ± 6
• After approach run of at least 10 m on
flat ground, measure time required to
Travel speed travel 20 m. sec.
• ( ): Machine with steel shoe specifica- High
tion speed 16.7 ± 2 16.7 ± 4
• For measuring posture, see Fig.
Travel 1 at end of this section.
• Hydraulic oil temperature: 45 – 55°C Low
• Run engine at full throttle. speed Max. 500 550
• After approach run of at least 10 m on
hard and flat ground, measure travel
Travel deviation mm
Travel
deviation (X) in the travel of 20 m

after approach run. High Max. 500 550
• For measuring posture, see Fig. speed
Travel 2 at end of this section.
• Stop engine.
Hydraulic drift of • Stop machine on slope of 30° with sprocket on
upper side. mm 0 0
travel • Measure hydraulic drift of travel in 5 minutes.
• For measuring posture, see Fig. Travel 3 at
Leakage from travel
motor • Run engine at full throttle. l/min. — —
• Lock shoe to relieve travel circuit.
PC18MR-3 20-100 5
Cate- Item Measurement conditions Unit Standard value Service limit value
gory for new machine
Whole work
equipment • Measure extension and retraction of each cyl-
inder and lowering of bucket tooth tip from Max. 300 450
(Hydraulic drift of
bucket tooth tip) above position.
• Stop machine on level and flat ground.
Boom cylinder • Bucket: Rated load
(Retraction of cyl- (Rated load: 706 N {72 kg}) Max. 35 70
inder) • 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
Hydraulic drift
minutes.
Bucket cylinder • For measuring posture, see Fig. Work equip-
(Retraction of cyl- ment 1 at end of this section. Max. 10 20
inder) mm

• Stop engine
Boom swing cyl- • Bucket: Rated load
inder (Retraction (Rated load: 706 N {72 kg}) Max. 20 30
and extension of • Set machine in above position on slope of 15°
cylinder) with upper structure at right angle to its body
and measure retraction and extension of cylin-
der for 15 minutes.
Blade (Hydraulic • Stop engine
drift of blade tip) • Measure hydraulic drift of blade tip from maxi- Max. 50 Max. 75
mum raising height for 15 minutes.
• Run engine at full throttle.
• Measure time required to move cylin- RAISE 2.0 ± 0.2 2.6
der between extension stroke end
Boom speed and position at which bucket tooth is
Work equipment
in contact with ground.

• For measuring posture, see Fig. LOWER 2.0 ± 0.2 2.6
Work equipment 2 at end of this
section.
• Run engine at full throttle. IN 2.5 ± 0.3 3.1
• Measure time required to move cylin-
der between extension and retrac-
Arm speed tion stroke ends.
Work equipment 3 at end of this OUT 2.2 ± 0.2 2.6
section.
Work equipment speed

• Run engine at full throttle. CURL 2.2 ± 0.2 2.6
Bucket speed der between extension and retrac- sec.
tion stroke ends.
Work equipment 4 at end of this DUMP 1.7 ± 0.2 2.3
section.
• Hydraulic oil temperature: 45 – 55°C Swing
• Run engine at full throttle. boom to 5.0 ± 1.5 8.0
• Measure time required to move cylin- LEFT
Boom swing der between extension and retrac-
speed tion stroke ends.
• For measuring posture, see Fig. Swing
Work equipment 5 at end of this boom to 5.0 ± 1.5 8.0
section. RIGHT
• Run engine at full throttle. RAISE 1.0 ± 0.3 1.6
der between position at which blade
Blade speed is in contact with ground and maxi-
mum blade raising position.
• For measuring posture, see Fig. LOWER 1.0 ± 0.3 1.6
Work equipment 6 at end of this
section.
20-100 6 PC18MR-3
gory new machine
• 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 mea- Max. 2 Max. 3.9
sure time required to raise machine after
bucket touches ground.
• For measuring posture, see Fig. Work
equipment 7 at end of this section.
• Set upper side of boom horizontally, bucket
to DUMP stroke end, and arm to IN stroke
Arm time lag end. Then, move arm IN and measure time Max. 1 Max. 2
required to start it again after it stops tempo-
rarily.
Time lag

equipment 8 at end of this section. sec.
Work equipment

• Set upper side of boom horizontally, arm to
IN stroke end, and bucket to DUMP stroke
Bucket time lag end. Then, CURL bucket and measure time Max. 1 Max. 2
required to start it again after it stops tempo-
rarily.
• 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.
Leakage from each

Internal leakage
Max. 2 10
cylinder
• Run engine at full throttle. cc/min.
• Relieve circuit to be measured.
Leakage from cen- — —
ter swivel joint
Performance of hydrau-
— lic pump See section of Performance of hydraulic pump.
PC18MR-3 20-100 7
Performance of hydraulic pump

Gear pump
Item Measurement conditions Unit Standard value for Service limit value
new machine

Discharge of gear pump • Engine speed: 2,600 rpm l/min. 12.1 10.2
• Measure at set pressure of relief valve.
Piston pump
Discharge
Measurement pressure of Standard Criterion
Item Checkpoint discharge
conditions piston pump (l/min.) (l/min.)
(MPa{kg/cm2})
• 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.
20-100 8 PC18MR-3
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 Travel 2: Travel deviation (Distance of devia-
start swing, and time taken to swing tion)
Swing 2: Hydraulic drift of swing Travel 3: Hydraulic drift of travel
PC18MR-3 20-100 9
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed

equipment
Work equipment 2: Boom speed Work equipment 5: Boom swing speed
Work equipment 3: Arm speed Work equipment 6: Blade speed
20-100 10 PC18MR-3
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-3 20-100 11
SEN04495-00

©2008 KOMATSU
All Rights Reserved
20-100 12
SEN04496-00
HYDRAULIC EXCAVATOR
PC18MR-3

30 Testing and adjusting 1

List of testing, adjusting, and troubleshooting tools ........................................................................................ 3
Measuring engine speed................................................................................................................................. 5
Measurement of exhaust gas color................................................................................................................. 6
Adjusting valve clearance ............................................................................................................................... 7
Testing compression pressure ........................................................................................................................ 9
Testing engine oil pressure ........................................................................................................................... 10
Testing and adjusting fuel injection timing......................................................................................................11
Adjusting engine stop solenoid ..................................................................................................................... 13
Bleeding air from fuel circuit.......................................................................................................................... 14
Testing and adjusting fan belt tension........................................................................................................... 15
Adjusting fuel control lever linkage ............................................................................................................... 16
Measurement of clearance in swing circle bearings ..................................................................................... 17
Testing and adjusting track shoe tension ...................................................................................................... 18
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits............................. 20
Testing and adjusting control circuit basic pressure...................................................................................... 23
Testing and adjusting pump LS differential pressure .................................................................................... 25
Measuring solenoid valve output pressure ................................................................................................... 27
Measuring PPC valve output pressure ......................................................................................................... 29
Adjusting play of work equipment and swing PPC valves ............................................................................ 31
Measuring swing holding brake release pressure......................................................................................... 31
Testing oil leakage from cylinder................................................................................................................... 33
Releasing residual pressure from hydraulic circuit ....................................................................................... 35
PC18MR-3 30-100 1
SEN04496-00
Bleeding air from cylinder.............................................................................................................................. 35

Pressurizing hydraulic tank ........................................................................................................................... 36
How to open and close (tilt) floor................................................................................................................... 37
Inspection procedures for diode.................................................................................................................... 39
How to start operation of KOMTRAX terminal .............................................................................................. 40
Lamp display of KOMTRAX terminal ............................................................................................................ 44
Removal and installation of KOMTRAX terminal .......................................................................................... 47
Preparation work for troubleshooting of electrical system............................................................................. 48
30-100 2 PC18MR-3
List of testing, adjusting, and troubleshooting tools SEN04496-00
List of testing, adjusting, and troubleshooting tools 1
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
Handy smoke
1 799-201-9001 1
checker
Measuring exhaust gas B Bosch index: 0 – 9
color
2 Commercially Smoke meter 1
available
Adjusting valve clear- Commercially Intake : 0.145 – 0.185 mm

C Clearance gauge 1
ance available Exhaust : 0.145 – 0.185 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}

Measuring compression D 2 795-111-1120 Adapter 1 For 3D67E-1 and 2 (YC-2)
pressure
3 795-101-1571 Joint 1 For 3D67E-1 and 2
Pressure gauge: 2.5, 6, 40, 60 MPa

799-101-5002 Hydraulic tester 1 {25, 60, 400, 600 kg/cm2}
1
Measuring engine oil E Digital hydraulic
pressure 790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm2}
tester
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Measuring swing circle Commercially

F Dial gauge 1 —
bearing clearance available

Measuring and adjust- 1
ing oil pressures in work Digital hydraulic
790-261-1204 1 Pressure gauge: 60 MPa {600 kg/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

1
Digital hydraulic
Measuring control circuit 790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm2}
H tester
oil pressure
799-101-5220 Nipple 1
2 Size: 10 x 1.25 mm
07002-11023 O-ring 1

1
Digital hydraulic
790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm2}
tester
Measuring pump LS J
differential pressure 2 799-401-2701 Differential pressure 1 50 MPa {50 kg/cm2}
gauge
799-101-5220 Nipple 2
3 Size: 10 x 1.25 mm
07002-11023 O-ring 2
PC18MR-3 30-100 3
SEN04496-00 List of testing, adjusting, and troubleshooting tools
Symbol
Q’ty
Testing/Adjusting item Part No. Part Name Remarks

1
Measuring solenoid valve K Digital hydraulic
output pressure 790-261-1204 tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-3100 Adapter 1 Size : 02

1
Measuring PPC valve L Digital hydraulic
output pressure 790-261-1204 tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-3100 Adapter 1 Size : 02

1
Measuring swing holding M Digital hydraulic
brake release pressure 790-261-1204 tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-3100 Adapter 1 Size : 02
Measuring leakage from Commercially

N Measuring cylinder 1 —
work equipment cylinder available
Measuring coolant temper- – 799-101-1502 Digital thermometer 1 - 99.9 – 1,299°C

ature 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 and Commercially

– Tester 1 —
resistance available
a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the mon-
itor panel, controllers, sensors, actuators, and wiring harnesses, see Troubleshooting, “T-branch box
and T-branch adapter table”.
30-100 4 PC18MR-3
Measuring engine speed SEN04496-00
Measuring engine speed 1 3) Connect probe [3] to tachometer [4].
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.
q Coolant temperature: Within operating range
q Hydraulic oil temperature : 45 – 55°C
1. Preparation work
1) Open the engine rear cover and stick
reflector tape [1] of tachometer kit A to the
end face of fan pulley (1). 2. Measuring low idle speed
1) Start the engine and set the fuel control
lever in the low idle position.
2) Set all the control levers and pedals in
neutral and measure the engine speed.
3. Measuring high idle speed

lever in the high idle position.
2) Set all the control levers and pedals in
neutral and measure the engine speed.
4. Measuring engine speed when 1 pump is

relieved
2) Using stand [2], set probe [3] straight at lever in the high idle 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
position 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.
PC18MR-3 30-100 5
SEN04496-00 Measurement of exhaust gas color
Measurement of exhaust gas

color 1
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

following condition.
Coolant temperature: Within operating range
k Be careful not to touch the highly heated
2) Connect the probe hose, accelerator switch
parts, while fitting and detaching a mea-
outlet and air hose to the smoke meter B2.
surement tool.
a Keep the pressure of the supplied
a If no compressed air or power is not available
compressed air below 1.5 MPa {15
in the field, use handy smoke checker B1. For
kg/cm2}.
recording official data, use smoke meter B2.
3) Connect the power cable to AC socket.
a Confirm that the smoke meter power
1. Measurement with handy smoke checker
switch is in the OFF position, before
B1
connecting the power cable to an out-
1) Fit a filtering paper to handy smoke
let.
checker B1.
4) Fit a filtering paper by loosening the suc-
2) Insert the exhaust gas intake pipe into the
tion pump cap nut.
exhaust pipe (1).
a Fit the filtering paper securely so that
3) Start the engine.
air may not leak.
4) Accelerate the engine suddenly or run it at
5) Move the smoke meter B2 power switch
high idle and operate the handle of smoke
to the ON position.
checker B1 so that the filter paper will
absorb the exhaust gas.
6) Accelerate the engine suddenly or run it at

high idle and press the accelerator pedal
5) Remove the filter paper and compare it
of smoke meter B2 and collect the
with the attached scale.
exhaust gas into the filter paper.
6) After finishing measurement, remove the
7) Put the polluted filtering paper on non-pol-
measuring instruments and return the
luted filtering paper (more than 10 sheets)
removed parts.
in the filtering paper holder, and read the
indicated value.
2. Measurement with smoke meter B2
1) Insert probe [1] of the smoke meter B2
into the exhaust gas pipe (1) outlet, and
removed parts.
fasten it to the outlet with a clip.
30-100 6 PC18MR-3
Adjusting valve clearance SEN04496-00
Adjusting valve clearance 1 3. While checking through the inspection hole of

the flywheel housing, rotate the crankshaft for-
ward to bring the stamped "1.TC" line (a) of the
a Adjusting instrument for valve clearance flywheel to stamped line (b) in the housing and
Symbol Part No. Part Name set the No. 1 cylinder to the compression top
dead center.
Commercially
C Clearance gauge a Rotate the crankshaft with the crankshaft
available
pulley mounting bolt.
1. Tilt the floor open. For details, see “How to a If you cannot see stamped line (b) easily,
open and close (tilt) floor”. match stamped line (a) to the projection in
the inspection hole.
2. Remove cylinder head cover (1). 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.
4. While the No. 1 cylinder is at the compression

top dead center, adjust the valve clearances
marked with q in the valve arrangement draw-
ing according to the following procedure.
a Valve arrangement drawing
PC18MR-3 30-100 7
SEN04496-00 Adjusting valve clearance
1) Insert clearance gauge C in clearance (c)

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

locknut (5).
a After adjusting all of the valves
marked with q, go to the next proce-
dure.
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 projec-
tion in the inspection hole.
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

parts.
3 Cylinder head cover mounting bolt:
4.9 Nm {0.5 kgm}
30-100 8 PC18MR-3
Testing compression pressure SEN04496-00
Testing compression pressure 1
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 fol- 6. Install adapter D2 and joint D3 to the nozzle
lowing condition. holder mounting part and connect compres-
q Engine oil temperature: 40 – 60°C sion gauge D1.
a Install the packing to the end of the
1. Adjust the valve clearance. For details, see adapter.
“Adjusting valve clearance”. 3 Adapter: 58.8 Nm {6.0 kgm}
a Since the compression gauge cannot be
2. Prepare for testing the engine speed. For pulled out of the revolving frame, keep the
details, see Testing engine speed. floor tilted open.
a If you have removed the air cleaner
3. Open the cooling cover and close the valve of assembly, install it before starting the test.
water separator (1).
7. Crank the engine with the starting motor and

4. Disconnect M4 connectors (2) and (3) of the test the compression pressure.
engine stop solenoid. a Read the compression gauge when its
pointer is stabilized.
5. Remove nozzle holder (4) of the cylinder to a When testing the compression pressure,
measure the compression pressure. test the engine speed, too, and check that
a If you remove the air cleaner assembly it is in the measurement condition range.
temporarily, you can work easily.
8. After finishing testing, remove the testing
instruments and return the removed parts.
3 Nozzle holder: 58.8 Nm {6.0 kgm}
PC18MR-3 30-100 9
SEN04496-00 Testing engine oil pressure
Testing engine oil pressure 1 4. Tilt down the floor and connect the oil pressure
test hose to oil pressure gauge [2] of hydraulic
tester E2.
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 follow-

ing condition.
q Engine coolant temperature: Within oper-
ating range
1. Tilt the floor open. For details, see “How to

open and close (tilt) floor”.
5. Start the engine and measure the engine oil
2. Remove engine oil pressure switch (1). pressure at low idle and high idle.
6. After finishing testing, remove the testing

instruments and return the removed parts.
3 Engine oil pressure switch
Switch: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
Screw: 1.4 – 2.0 Nm {0.14 – 0.2 kgm}
3. Install adapter [1] of hydraulic tester E1 and

pull the oil pressure test hose out of the revolv-
ing frame.
30-100 10 PC18MR-3
Testing and adjusting fuel injection timing SEN04496-00
Testing and adjusting fuel 5. Rotate the crankshaft forward slowly from this
injection timing 1 position about 1.5 turns.
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 tim- holder hole (a) of fuel injection pump (2), stop
ing 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 stamped line (c) in the housing.
open and close (tilt) floor”. a If you cannot see stamped line (c) easily,
check the position of stamped line (b) by
2. Remove 3 fuel injection pipes (1). the projection in the inspection hole.
a If you remove the air cleaner assembly
temporarily, you can work easily.
8. After finishing testing, return the removed

parts.
3. Set the fuel control lever in the high idle posi- 3 Fuel injection pipe sleeve nut:
tion. 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,
during the test. adjust it before connecting the fuel injec-
tion 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 crankshaft
pulley mounting bolt.
a After the fuel rises, wipe it off to check
again.
PC18MR-3 30-100 11
SEN04496-00 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 pump (2).
flywheel is not matched to the stamped line in a Thinly apply gasket sealant (ThreeBond
the flywheel housing or the projection in the 1215 or 1104) to both sides of the shim.
inspection hole, the fuel injection timing is 3 Fuel injection pump mounting bolt/nut:
abnormal. In this case, adjust according to the 9.8 – 11.3 Nm {1.0 – 1.15 kgm}
4. After finishing adjusting, check that the fuel
1. Remove fuel injection pump (2) and check the injection timing is normal according to the
thickness of shims (3). above testing procedure.
2. Adjust the fuel injection timing by increasing or

decreasing the thickness of shims (3).
a If the fuel injection timing is
q early, increase the shim thickness.
q late, decrease the shim thickness
a If the shim thickness is changed by 0.20
mm, the fuel injection timing changes
about 2°.
a The thickness of each shim is indicated by
the number of the identification hole.
q 0.20 mm shim: 2 identification holes
q 0.25 mm shim: 1 identification hole
q 0.30 mm shim: No identification hole
30-100 12 PC18MR-3
Adjusting engine stop solenoid SEN04496-00
Adjusting engine stop solenoid 1 4. After tightening the bolts, push the rear end of
bellows (6) and check that rod (4) and stop
lever (2) move smoothly.
a After the engine stop solenoid is removed and
installed, adjust it according to the following
procedure.
Function
q The engine stop solenoid is a push-type sole-
noid which is normally energized (during oper-
ation) and which has a suction coil and a
holding coil.
q When the starting switch is turned ON, both of
the suction coil and holding coil are energized.
After set time (about 1 second), the suction coil
is de-energized.
q The following figure shows the operating con-
dition of the solenoid.
5. After finishing adjusting, start and stop the
RUN: While the engine is operated (the power
engine to check that the solenoid operates nor-
is applied), the rod is extracted.
mally.
STOP: While the engine is stopped (the power
is not applied), the rod is retracted.
<Precautions for checking operation>
q When the solenoid is energized, if hook (1)
presses (interferes with) stop lever (2) strongly,
the solenoid may be installed wrongly. In this
case, check the installation again (See the fol-
lowing figure).
q 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 start-
ing switch OFF.
1. Insert hook (1) of the solenoid in the U-groove

of stop lever (2) and tighten mounting bolts (3)
temporarily.
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
contact with the stopper.
3 Mounting bolt:
9.8 – 11.3 Nm {1.0 – 1.15 kgm}
PC18MR-3 30-100 13
SEN04496-00 Bleeding air from fuel circuit
Bleeding air from fuel circuit 1
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.
30-100 14 PC18MR-3
Testing and adjusting fan belt tension SEN04496-00
Testing and adjusting fan belt Adjusting

tension 1 a If the belt deflection is abnormal, adjust it
according to the following procedure.
Testing 1. Tilt the floor open. For details, see “How to

1. Tilt the floor open. For details, see “How to open and close (tilt) floor”.
open and close (tilt) floor”.
2. Put a bar between alternator (1) and cylinder
2. Press the center of the belt between the crank- block and fix alternator (1).
shaft pulley and fan pulley with your finger and a Put a piece of wood between the bar and
measure the deflection of the belt. alternator to protect the alternator.
q Force to press belt: Approx. 98 N {10 kg}
q Deflection: 9 – 13 mm 3. Loosen adjustment bolt (2) and mounting bolt
a If the deflection is about 10 mm, the belt (3) of the alternator.
tension is roughly in the normal range.
4. Move alternator (1) to adjust the belt tension.
q Force to press belt for adjustment:
Approx. 98 N {10 kg}
q Deflection for adjustment:
Approx. 7 – 10 mm
5. Tighten adjustment bolt (2) and mounting bolt

(3) to fix alternator (1).
a Check each pulley for breakage, wear of
the V-groove, and contact of the V-belt
and V-groove.
a If the V-belt is so lengthened that the
adjustment allowance is eliminated or it
has a cut or a crack, replace it.
6. After finishing adjusting, return the removed

parts.
PC18MR-3 30-100 15
SEN04496-00 Adjusting fuel control lever linkage
Adjusting fuel control lever

linkage 1
1. Adjusting low idle

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

1) Tilt fuel control lever (1) backward until
governor lever (4) of the fuel injection
pump reaches screw (5) on the high idle
side.
2) Under this condition, tighten stopper bolt
(6) until it reaches fuel control lever (1),
and then return the stopper bolt by 1/2
turn and fix it with the locknut.
a Screw (5) on the high idle side of the
fuel injection pump is not adjustable.
If the high idle speed or power is still
low even when the governor lever
reaches the screw on the high idle
side, check the nozzle holder, etc.
30-100 16 PC18MR-3
Measurement of clearance in swing circle bearings SEN04496-00
Measurement of clearance in 3. Under this condition, set dial gauge F to the

swing circle bearings 1 zero point.
a Swing circle bearing clearance measurement

tools
Mark Part No. Part Name

Commercial
F Dial gauge
product
a Follow the steps explained below, when mea-

suring clearance in the swing circle bearing in
the actual machine.
k Be careful not to put a hand or foot under
the undercarriage, while taking measure-
ment. 4. Hold the arm nearly perpendicular to the
ground, and lower the boom until the track
1. Fix dial gauge F to the track frame and apply shoes will be lifted at the work equipment.
the probe to the underside of outer race (1) a The upper structure is raised at the front
perpendicularly. and lowered at the rear at that time.
a Set dial gauge F at the track frame rear.
5. Read off the value in dial gauge F in this condi-
tion.
a The value indicated in dial gauge F
expresses clearance in the bearings.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
frame.
a At this time, the front side of the upper 6. Return the machine to the posture in Item 2
structure rises and the rear side lowers. 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-

parts.
PC18MR-3 30-100 17
SEN04496-00 Testing and adjusting track shoe tension
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
according to the following procedure.
Testing
1. Run the engine at low idle and move the 1. To heighten tension
machine by the length of track on ground, then 1) Supply grease throungh grease fitting (1).
stop slowly. 2) To check that the tension is normal, run the
engine at low idle and move the machine
2. Place bar [1] on the track shoe between the forward by the length of track on ground,
idler and the shoe plate. then stop slowly.
a As bar [1], use an L-shape steel, etc. 3) After finishing adjustment, check again
which will be deflected less. that the tension is normal according to the
above procedure.
3. Measure maximum clearance (a) between bar
[1] and track shoe.
q Standard maximum clearance (a)
Steel shoe specification: 5 – 15 mm
Rubber shoe specification: 1 – 3 mm
a When steel shoe is installed

You may supply grease until distance (b)
between the idler guide and track frame
end is 0 mm. If the tension is still low, the
pin and bushing are worn excessively. In
this case, turn over or replace the pin and
bushing.
30-100 18 PC18MR-3
Testing and adjusting track shoe tension SEN04496-00
2. To lower tension
1) Loosen valve (2) to discharge the grease.
k Since the valve may jump out
because of the internal high-pres-
sure grease, do not loosen it more
than 1 turn.
2) Tighten valve (2).
3) To check that the tension is normal, run the
engine at low idle and move the machine
forward by the length of track on ground,
then stop slowly.
4) After adjusting, check the tension again
according to the procedure described
above.
PC18MR-3 30-100 19
SEN04496-00 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits
Testing and adjusting oil 3) Install nipple G2 and pull the oil pressure
pressures in work equipment, test hose out of the revolving frame.
travel, swing, and blade circuits 1
a Measuring instruments for oil pressures in

work equipment, travel, swing, and blade cir-
cuits
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
travel, swing, and blade circuits under the fol- G1.
lowing condition. a Use oil pressure gauges of 40 MPa
q Hydraulic oil temperature: 45 – 55°C {400 kg/cm2} for both hoses.
k Release the residual pressure from the
hydraulic tank. For details, see “Releasing
residual pressure from hydraulic circuit”.
1. Preparation work
1) Open the battery cover and tilt the floor
open. For details, see “How to open and
close (tilt) floor”.
a You can connect the measuring
instruments without tilting the floor
open. If the floor is tilted open, how-
ever, you can work easily.
2) Remove pump discharge pressure pickup
plug (1).
5) Pressurize the hydraulic tank. For details,
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
pressure
a The variable gauge circuit is operated by
applying the blade circuit pressure
through the variable gauge selector valve.
1) Start the engine and move the cylinder to
be measured to the stroke end.
2) Run the engine at high idle and relieve the
cylinder and measure the oil pressure.
a The relief pressure of the main relief
30-100 20 PC18MR-3
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits SEN04496-00
4. Measuring travel circuit relief pressure Adjusting

1) Start the engine and lock the travel mech- 1. Adjusting unload pressure
anism on the side to be measured. a The unload pressure cannot be adjusted.
k Set pin [1] between the sprocket
and track frame to lock the travel 2. Adjusting relief pressure of work equip-
mechanism securely. ment circuit and travel circuit
a If the relief pressure of the work equip-
ment circuit and travel circuit is abnormal,
adjust main relief valve (2) of the control
valve according to the following proce-
dure.
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
5. Measuring swing circuit relief pressure

1) Start the engine and lock the swing mech-
anism with the work equipment securely.
k Stick the bucket into the ground or
press it against the blade. 1) While fixing adjustment screw (3), loosen
2) Run the engine at high idle and relieve the locknut (4).
swing circuit and measure the oil pres- 2) Turn adjustment screw (3) to adjust the
sure. pressure.
a The relief pressure of the swing motor a If the adjustment screw is
safety valve is indicated. q turned to the right, the pressure
a The swing motor safety valves are rises.
installed to the right and left sides. q turned to the left, the pressure
Accordingly, measure the relief pres- lowers.
sures on both sides respectively. a Quantity of adjustment per turn of
a The swing motor relief pressure is adjustment screw: 12.6 MPa {128 kg/
lower than the main relief pressure. cm2}
3) While fixing adjustment screw (3), tighten
6. Work after finishing measurement locknut (4).
After finishing measurement, remove the mea- 3 Locknut: 59 – 79 Nm {6 – 8 kgm}
parts.
PC18MR-3 30-100 21
SEN04496-00 Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits
4) After finishing adjustment, check again 1) While fixing adjustment screw (7), loosen
that the oil pressure is normal according to locknut (8).
the above described measurement proce- 2) Turn adjustment screw (7) to adjust the
dure. pressure.
a If the adjustment screw is
3. Adjusting relief pressure of swing circuit q turned to the right, the pressure
a If the relief pressure of the swing circuit is rises.
abnormal, adjust safety valves (5) and (6) q turned to the left, the pressure
according to the following procedure. lowers.
q Safety valve (5): a Quantity of adjustment per turn of
For right swing relief valve (A) adjustment screw: Approx. 4.5 MPa
q Safety valve (6): {46 kg/cm2}
For left swing relief valve (B) 3) While fixing adjustment screw (7), tighten
a When adjusting the safety valves of the locknut (8).
swing motor, tilt the floor open. For 3 Locknut: 3.92 Nm {0.4 kgm}
details, see “How to tilt (open and close)
floor”.
4) After finishing adjustment, check again

that the oil pressure is normal according to
the above described measurement proce-
dure.
30-100 22 PC18MR-3
Testing and adjusting control circuit basic pressure SEN04496-00
Testing and adjusting control 3. Install nipple H2 and pull the oil pressure test
circuit basic pressure 1 hose out of the revolving frame.
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.
q Hydraulic oil temperature: 45 – 55°C 4. Tilt down the floor and connect the hose to oil
k Release the residual pressure from the pressure gauge [1] of hydraulic tester H1.
hydraulic tank. For details, see “Releasing a Use an oil pressure gauge of 6 MPa {60
residual pressure from hydraulic circuit”. 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 instru-
ments 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 con-
trol levers and pedals in neutral and measure
the oil pressure.

parts.
PC18MR-3 30-100 23
SEN04496-00 Testing and adjusting control circuit basic pressure
Adjusting
a If the control circuit basic pressure is abnor-
mal, adjust relief valve (2) of the 2-spool sole-
noid valve according to the following
procedure.
a When adjusting the main relief valve of the
control valve, tilt the floor open. For details,
see “How to tilt (open and close) floor”.
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
q turned to the right, the pressure rises.
q 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-

nut (4).
3 Locknut: 9.8 Nm {1.0 kgm}
4. After finishing adjustment, check again that the

oil pressure is normal according to the above
described measurement procedure.
30-100 24 PC18MR-3
Testing and adjusting pump LS differential pressure SEN04496-00
Testing and adjusting pump LS 3. Install nipples J3 and pull the oil pressure mea-
differential pressure 1 surement hose out of the revolving frame.
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
a Measure the LS differential pressure under the
the high pressure side (back side) and
following condition.
connect the LS pressure to the low pres-
q Hydraulic oil temperature: 45 – 55°C
k Release the pressure from the hydraulic
sure side (lower side).
Since the differential pressure gauge
tank. For details, see “Releasing pressure
needs a 12-V power source, connect it to
from hydraulic circuit”.
a battery.
a When using oil pressure gauge:
1. Open the battery cover, then tilt the floor open.
Use the oil pressure gauge of 40 MPa
For details, see “How to open and close (tilt)
{400 kg/cm²}.
floor”.
Since the differential pressure is about 2.5
a You can connect the measuring instru-
MPa {25 kg/cm²} at maximum, measure it
ments without tilting the floor open. If the
by installing the same gauge to the pickup
floor is tilted open, however, you can work
plugs alternately.
easily.
2. Remove pump discharge pressure pickup

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

6. Run the engine and operate the work equip-

ment to set the boom top horizontally.
PC18MR-3 30-100 25
SEN04496-00 Testing and adjusting pump LS differential pressure
7. While running the engine at high idle, measure Adjusting

the pump discharge pressure and LS pressure a If the LS differential pressure is abnormal,
(actuator load pressure) simultaneously under adjust LS valve (3) according to the following
the following condition. procedure.
q Work equipment, travel, swing, and blade a When adjusting the LS valve, remove the bat-
circuits: Set all the levers in neutral and tery cover.
move the arm IN.
a Move the arm lever halfway to move the
arm IN and measure the oil pressure dur-
ing this operation.
a Calculation of LS differential pressure
(when oil pressure gauge is used):
LS differential pressure =
Pump discharge pressure – LS pres-
sure
a If the LS differential pressure is as follows,
it is normal.
Work equipment, travel,
LS differential pressure
swing, and blade levers
Unload pressure (See
Set all levers in neutral 1. Loosen hose sleeve nut (4).
“Standard value table”)
Specified LS differential
Set arm lever in IN 2. Fixing plug (5), loosen locknut (6).
pressure (See “Stan-
position (halfway)
dard value table”)
3. Turn plug (5) to adjust the differential pressure.
a If the plug is
q turned to the right, the differential
pressure rises.
parts.
q turned to the left, the differential pres-
sure lowers.
a Quantity of adjustment (LS differential
pressure) per turn of plug:
127 kPa {13 kg/cm²}
a Tighten hose sleeve nut (4) temporarily
and turn the plug, while checking the LS
differential pressure.
4. Fixing plug (5), tighten locknut (6).

3 Locknut:
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
5. Tighten hose sleeve nut (4).
30-100 26 PC18MR-3
Measuring solenoid valve output pressure SEN04496-00
Measuring solenoid valve

output pressure 1
a Measuring instruments for solenoid valve out-

put 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. 5. Tilt down the floor and connect the hose to oil
a Measure the solenoid valve output pressure pressure gauge [2] of hydraulic tester K1.
under the following condition. a Use oil pressure gauge of 6 MPa {60 kg/
q Hydraulic oil temperature: 45 – 55°C 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.
q Hose (1): PC lock solenoid valve
q Hose (2): 2nd travel speed selection sole-
noid valve

7. Run the engine at high idle, turn the solenoid

valve ON or OFF, and measure the oil pres-
sure.
a For the conditions for turning the solenoid
valve ON and OFF, see “Operation table
of solenoid valves”.
a If the output pressure of each solenoid
valve is as shown in “Operation table of
solenoid valves”, it is normal.
3. Install adapter K2 and connect the discon-
nected hose again. 8. After finishing measurement, remove the mea-
4. Install nipple [1] of hydraulic tester K1 and pull parts.
the oil pressure measurement hose out of the
revolving frame.
a The figure shows the measuring instru-
ments connected to the outlet hose of the
PPC lock selection solenoid valve.
PC18MR-3 30-100 27
SEN04496-00 Measuring solenoid valve output pressure
Operation table of solenoid valves
State of Output pressure of

No. Solenoid valve Operating condition
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) +2
{32 0 kg/cm²}
30-100 28 PC18MR-3
Measuring PPC valve output pressure SEN04496-00
Measuring PPC valve output

pressure 1
a Measuring instruments for PPC valve output

pressure
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 con-
trol circuit is normal. 5. Tilt down the floor and connect the hose to oil
a Measure the PPC valve output pressure under pressure gauge [2] of hydraulic tester L1.
the following condition. a Use oil pressure gauge of 6 MPa {60 kg/
q Hydraulic oil temperature: 45 – 55°C 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
circuit.

7. Run the engine at high idle, set the control

lever or pedal of the circuit to be measured in
the neutral position and stroke end, and mea-
sure the oil pressure.
a If the output pressure of PPC valve is as
follows, it is normal.
Control lever/pedal PPC valve output pressure
3. Install adapter L2 and connect the discon- 0 MPa
Neutral
nected hose again. {0 kg/cm²}
+ 0.2
3.14 0 MPa
4. Install nipple [1] of hydraulic tester L1 and pull Stroke end
+2
{32 kg/cm²}
the oil pressure measurement hose out of the 0
revolving frame.
a The figure shows the measuring instru- 8. After finishing measurement, remove the mea-
ments connected to the hose of the ARM suring instruments and return the removed
IN circuit. parts.
PC18MR-3 30-100 29
SEN04496-00 Measuring PPC valve output pressure
Connection diagram of PPC valve and control valve (ISO pattern)

a The port position of each PPC valve is the position seen from the operator's seat side. Colors of hose
bands are shown in ( ).
30-100 30 PC18MR-3
Adjusting play of work equipment and swing PPC valves SEN04496-00
Adjusting play of work equipment Measuring swing holding brake

and swing PPC valves 1 release pressure 1
a If the play of the left or right work equipment a Measuring instruments for swing holding brake
control lever is excessive, adjust it according to release pressure
the 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

a Before measuring the swing holding brake
touches the heads of 4 pistons (4).
release pressure, check that PPC valve output
a At this time, do not move the pistons.
pressure (swing LEFT, swing RIGHT, and arm
IN) is normal.
4. Fix disc (3) and tighten locknut (2) to the speci-
a Measure the swing holding brake release pres-
fied torque.
sure under the following condition.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
q Hydraulic oil temperature : 45 – 55°C
5. Install boot (1).
6. Install the PPC valve assembly.
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.
PC18MR-3 30-100 31
SEN04496-00 Measuring swing holding brake release pressure
3) Install adapter M2 and connect the discon- 6) Pressurize the hydraulic tank. For details,
nected hose again. see “Pressurizing hydraulic tank”.
7) Run the engine at high idle, set all the
4) Install nipple [1] of hydraulic tester M1 and control levers in the neutral position and
pull the oil pressure measurement hose operating position, and measure the oil
out of the revolving frame. pressure.
a If the swing holding brake release
pressure 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.
5) Tilt down the floor and connect the hose to
<Reference:
oil pressure gauge [2] of hydraulic tester
Release pressure and release signal pressure>
M1.
q The swing holding brake release pressure is
a Use oil pressure gauge of 6 MPa {60
the output pressure of the PPC solenoid valve,
kg/cm²}.
which is led to the swing motor.
q If the swing holding brake does not operate,
check the release pressure (output pressure of
the PPC solenoid valve) first.
q The swing holding brake release signal pres-
sure is the PPC circuit pressure for swing
LEFT, swing RIGHT, and arm IN, which is led
to the swing motor through the shuttle valve in
the control valve.
q If the release pressure is normal but the swing
holding brake is not released, check the
release signal pressure, and then check the
output pressure of the PPC valves for swing
LEFT, swing RIGHT, and arm IN.
q If the output pressure of each PPC valve is
normal but the release signal pressure is not
normal, the shuttle valve in the control valve
may be malfunctioning.
q If both of the output pressure of each PPC
valve and the release signal pressure are nor-
mal, the swing holding brake in the swing
motor may be malfunctioning.
30-100 32 PC18MR-3
Testing oil leakage from cylinder SEN04496-00
Testing oil leakage from cylinder 1 k Take care not to disconnect the
hose on the cylinder bottom side.
a Use the following part to block the
a Testing instruments for oil leakage from cylin- hose side.
der. 07376-70315 (Plug #03)
Commercially
N Measuring cylinder
available
1. Testing leakage from boom cylinder

1) Run the engine and move the boom cylin-
der to the RAISE stroke end.
k Release the residual pressure in
the boom cylinder circuit. For
details, see “Releasing residual
pressure from hydraulic circuit”.
2) Disconnect hose (1) on the cylinder head
side and block the hose side with a plug.
k Take care not to disconnect the
hose on the cylinder bottom side. 3) Run the engine at high idle and relieve the
a Use the following part to block the arm circuit by moving the arm IN.
hose side. k Take care not to "move the arm
07376-70210 (Plug #02) OUT".

4) Measure the oil leakage for 1 minute after
30 seconds since relieving is started.
removed parts.
3. Measuring oil leakage from bucket cylinder

1) Run the engine and move the bucket cyl-
inder to the CURL stroke end.
the bucket cylinder circuit. For
boom circuit by raising the boom.
k Take care not to "lower the boom".
hose side.
07376-70210 (Plug #02)
removed parts.
2. Measuring oil leakage from arm cylinder

1) Run the engine and move the arm cylinder
to the IN stroke end.
kRelease the residual pressure in
the arm cylinder circuit. For
PC18MR-3 30-100 33
SEN04496-00 Testing oil leakage from cylinder
3) Run the engine at high idle and relieve the 5. Measuring oil leakage from blade cylinder
bucket circuit by curling the bucket. 1) Run the engine and push up the track
k Take care not to "dump the shoe on the blade side with the work
bucket". equipment and set a block under the track
4) Measure the oil leakage for 1 minute after shoe.
30 seconds since relieving is started. a Raise the track shoe to a degree that
5) After finishing measurement, remove the the blade will not touch the ground
measuring instruments and return the when it is lowered to the stroke end.
removed parts. 2) Lower the blade cylinder to the stroke end.
4. Measuring oil leakage from boom swing the blade cylinder circuit. For
cylinder details, see “Releasing residual
1) Run the engine and move the boom swing pressure from hydraulic circuit”.
cylinder to the left stroke end. 3) Disconnect hose (5) on the cylinder head
k Release the residual pressure in side and block the hose side with a plug.
the boom swing cylinder circuit. k Take care not to disconnect the
For details, see “Releasing resid- hose on the cylinder bottom side.
ual pressure from hydraulic cir- a Use the following part to block the
cuit”. hose side.
2) Disconnect hose (4) on the cylinder head 07367-70210 (Plug #02)
hose side.
07367-70210 (Plug #02)

blade circuit by lowering the blade.
k Take care not to "raise the blade".
3) Run the engine at high idle and relieve the measuring instruments and return the
boom swing circuit by swinging the boom removed parts.
to the left.
k Take care not to "swing the boom
to the right".
removed parts.
30-100 34 PC18MR-3
Releasing residual pressure from hydraulic circuit SEN04496-00
Releasing residual pressure from Bleeding air from cylinder 1

hydraulic circuit 1
a If a cylinder was removed and installed or its
1. Releasing residual pressure from hydrau- piping was disconnected and reconnected,
lic tank bleed air according to the following procedure.
k The hydraulic tank is enclosed and a If a cylinder was replaced, bleed air from it
pressurized. When removing a hose or before connecting the work equipment. In par-
a plug connected to the hydraulic tank, ticular, the boom cylinder does not move to the
release the residual pressure from the lowering stroke end, if it is installed to the work
hydraulic tank according to the follow- equipment.
ing procedure.
1) Lower the work equipment to the ground 1. Run the engine at low idle for about 5 minutes.
in a stable posture and stop the engine.
2) Remove bolt (1) and plate (2). 2. Running the engine at low idle, raise and lower
3) Slowly loosen oil filler cap (3) of the the boom 4 – 5 times.
hydraulic tank to release the air from the a Stop the piston rod about 100 mm before
tank. each stroke end. Do not relieve the oil.
3. Running the engine at high idle, perform step 2.
4. Running the engine at low idle, move the pis-

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

der, boom swing cylinder, and blade cylinder
according to steps 2 – 4.
2. Releasing residual pressure from hydrau-

lic cylinder circuit
k When disconnecting the piping
between a hydraulic cylinder and the
control valve, release the residual pres-
sure from the piping according to the
1) Run the engine at low idle and lower the
work equipment to the ground, taking care
not to relieve the cylinder at the stroke
end, and then stop the engine.
k If the engine is stopped while the
hydraulic cylinder is relieved at the
stroke end, do not perform the fol-
lowing 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 pip-
ing gradually to release the residual pres-
sure 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 pre-
vent the residual pressure from blow-
ing out the oil.
PC18MR-3 30-100 35
SEN04496-00 Pressurizing hydraulic tank
Pressurizing hydraulic tank 1
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 idle, set the work equip-

ment in the pressurizing position, and stop the
engine.
a Extract the boom, arm, and bucket cylin-
ders 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.
30-100 36 PC18MR-3
How to open and close (tilt) floor SEN04496-00
How to open and close (tilt) floor1
a When checking or maintaining the underside of

the floor or inside of the revolving frame, open
and close (tilt) the floor according to the 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

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

8. Insert 2nd lock pin (8) in lock hole (b) securely
and rotate it until lock hook (c) is hitched on fix-
6. While pulling floor lock release lever (4) toward
ing pin (9) securely.
the rear of the machine with the left hand, hold
a Check that the lock pin is hitched on the
handrail (5) with the right hand and push up
fixing pin and it does not come off.
the floor toward the front of the machine (about
a The 2nd locking is completed and the floor
35°).
k Do not put any part of your body under
opening (tilting open) work is finished.
the floor while opening or closing the
floor.
a If the floor does not rise, the release lever
may not be in the release position.
a Since the gas spring assists you in open-
ing the floor, the operating effort is
increased when the ambient temperature
is low.
PC18MR-3 30-100 37
SEN04496-00 How to open and close (tilt) floor
When closing (tilting close) 3. Install 2 floor fixing bolts (2).

a Before closing the floor, check that the wiring, a If the fixing bolts are damaged, replace
piping, and seats in the floor and revolving them with new ones.
frame are free from damage and abnormality. 3 Fixing bolt:
156.8 – 196 Nm {16 – 20 kgm}
1. Remove lock pin (8) and insert it in storage
hole (d). 4. Close engine rear cover (1).
a If you cannot remove the lock pin, pull it a The floor closing (tiling close) work is fin-
out while holding the handrail and pushing ished.
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°).
k Do not put any part of your body under
the floor while opening or closing the
floor.
a While checking that the wiring and piping
are not caught or damaged, pull down the
floor slowly.
30-100 38 PC18MR-3
Inspection procedures for diode SEN04496-00
Inspection procedures for diode 1
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
a The conductive direction of each diode is (–) to the cathode (N) of diode.
marked on its surface as shown below. ii) Put the red probe (+) of the test lead
to the cathode (N) and the black
probe (–) to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
q If the needle does not swing in Case
i), but swings in Case ii): Normal (but
the breadth of swing (i.e. resistance
value) will differ depending on a cir-
cuit tester type or a selected mea-
surement range)
q If the needle swings in either case of
i) and ii): Defective (short-circuited
internally)
q If the needle does not swing in any
1. When using digital type circuit tester case of i) and ii): Defective (short-cir-
1) Switch the testing mode to diode range cuited internally)
and confirm the indicated value.
a Voltage of the battery inside is dis-
played 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.
q No change in the indicated value: No
continuity (defective).
q Change in the indicated value: Conti-
nuity established (normal) (Note)
Note: A silicon diode shows a value
between 460 and 600.
PC18MR-3 30-100 39
SEN04496-00 How to start operation of KOMTRAX terminal
How to start operation of

KOMTRAX terminal 1
In the case where the KOMTRAX terminal has

already been installed at the plant before ship-
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, model number and

serial number
Notify the model, model number and serial 4) Turn the starting switch ON and keep that
number of the machine to the KOMTRAX oper- condition for 5 seconds.
ations administrator. q Check that the 7-segment indicator
lamp indicates a bar.
2. Registration of machine
The KOMTRAX operations administrator regis-
ters the machine using a KOMTRAX client per-
sonal computer.
a For the procedure, see “Manual for
KOMTRAX operations administrator”.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted on the machine after shipment:
a Implement the following procedure in the
case where the KOMTRAX terminal is ret-
rofitted after shipment of the machine (ret-
rofitted machine).
5) Disconnect test connectors F33 and F34
1. Sign-up test on machine side and keep that condition for 5 seconds.
a Complete procedures 4) – 6) in 60 sec- 6) Reconnect test connectors F33 and F34
onds. and keep that condition for 5 seconds.
1) Park the machine in a place sufficiently a If the KOMTRAX terminal detects dis-
apart from buildings etc. where its top is connection or reconnection of the
seen from every direction so that it can connectors, the dot of the 7-segment
receive the radio waves from the satellite. indicator lamp blinks 2 – 3 times.
a The inspection cannot be completed a If procedures 4) – 6) are not com-
normally indoors. Be sure to perform pleted in 60 seconds, repeat from 2).
the inspection outdoors.
2) Turn the starting switch OFF and wait for
at least 5 seconds and then go to the next
step.
3) Check visually that the test connectors
under KOMTRAX terminal (1) are con-
nected.
a Test connectors: F33, F34 (male,
female)
30-100 40 PC18MR-3
How to start operation of KOMTRAX terminal SEN04496-00
7) Check that the 7-segment indicator lamp a Go to the next step if you can check
of the KOMTRAX terminal is displaying that the display is “normal”.
normally. a If the display is “abnormal”, repeat
a If the indication is normal, the 7-seg- from procedure 2) again. (“–” is dis-
ment indicator lamp (a) is displayed played continuously.)
for 30 seconds after 6) is completed. 8) Turn the starting switch to the START
(“d”, “0” and “–” are displayed repeat- position, keep it more than 5 seconds, and
edly.) check that the engine does not start.
q Display of the 2nd letter “0” may a If the engine starts, repeat from pro-
be different from the first. cedure 2).
q Display of the 3rd letter “–” a If the engine starts again, the engine
changes 30 seconds after the start lock function does not work nor-
operation of 6). mally. Stop the inspection and check
of the relays and wiring harnesses for
trouble.
9) Return the starting switch to the ON posi-
tion and keep it there for 5 seconds.
a Do not return the starting switch to
the OFF position.
10) Turn the starting switch to the START
position again and ensure that the engine
starts.
11) Check that the 7-segment indicator lamp
of the KOMTRAX terminal is indicating
normally without stopping the engine.
a Go to the next step if you ensured
that the display is [normal]. (It takes
from 90 seconds to 15 minutes before
the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
external abnormality on the GPS
antenna or cable. If there is any
abnormality, repair it and repeat from
procedure 1) again.
a If [Reception trouble] is indicated,
check if there is any external abnor-
mality on the appearance of the com-
munication antenna or cable. If there
is any abnormality, repair it then
repeat from procedure 1) again.
a If [GPS position data detection trou-
ble and reception trouble] is indi-
cated, check if there is any external
abnormality on the GPS antenna or
cable and communication antenna or
cable. If there is any abnormality,
repair it and repeat from procedure 1)
again.
a If [Network trouble] is indicated,
check the display of [LED-4] referring
to “Lamp display of KOMTRAX termi-
nal”. (If CAN is not recognized, check
the CAN harness of the KOMTRAX
terminal, and then if there is any
abnormality, repair it and repeat from
procedure 1) again.)
PC18MR-3 30-100 41
SEN04496-00 How to start operation of KOMTRAX terminal
[A]: Normal finish (It takes at least 90 seconds 12) Turn the starting switch OFF.
for the system to display this) 13) Check that the 7-segment indicator lamp
[B]: GPS position data detection trouble is indicating normally in 10 seconds.
“Check the GPS antenna and cable for a If you checked that the display is
external abnormality.” [Normal], that is the end of the sign-
(It takes 90 seconds – 5 minutes) up test.
[C]: Incomplete receiving a If the display shows [Abnormal],
“Check the communication antenna and re peat from procedure 1) again
cable for external abnormality.” because the sign-up test has not
(It takes 30 seconds – 1 minute) been completed successfully.
[D]: Network trouble or wiring harness trouble
“The network type selection input does not
agree with the obtained network data.”
“Check the machine wiring for an error.”
a If the display is not any of the above, call

Customer Support Division.
a It takes 90 seconds – 5 minutes for the
system to display “Normal finish” after the
operation of 6).
30-100 42 PC18MR-3
How to start operation of KOMTRAX terminal SEN04496-00
2. Application for the start of use

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

registers the machine using KOMTRAX
client personal computer.
a For the procedure, see “Manual for
KOMTRAX operations administrator”.
a Now the terminal is ready for use.
PC18MR-3 30-100 43
SEN04496-00 Lamp display of KOMTRAX terminal
Lamp display of KOMTRAX terminal 1
CPU LED 7-segment and dot for CPU

1. LED-1 (R signal and ACC signal) 6. 7-segment (Sign-up test status and operation
2. LED-2 (Starting output status) status)
3. LED-3 (S-NET status and C signal status) 7. Dot (GPS positioning status and test connector
4. LED-4 (Fuel sensor and CAN connection sta- disconnection/connection status))
tus)
5. LED-5 (Downloading and writing status)
30-100 44 PC18MR-3
Lamp display of KOMTRAX terminal SEN04496-00
In the KOMTRAX system, various information and processing details are displayed on the LED of the upper
surface of the KOMTRAX terminal. Therefore, if a defect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side must be completed in advance in order
to use KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna must not be off or damaged.
q The communication antenna cable must not be broken and must be connected to the KOMTRAX termi-
nal normally.
q The GPS antenna must not be off or damaged.
q The GPS antenna cable must not be broken and must be connected to the KOMTRAX terminal nor-
mally.
PC18MR-3 30-100 45
SEN04496-00 Lamp display of KOMTRAX terminal
1. Contents of CPU LED, 7-segment and dot

displays
a The LED displays must be checked with the starting switch in the ON or START position or with the
engine started.
No. LED (Color) Name/Function Display (*1) Contents of display

ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
LED-1
1 signal and alternator
(Green) Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
R signal
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
LED-2 Starting output ON Engine control signal: ON
2
(Red) status OFF Engine control signal: OFF
S-NET connection Fast blinking Starting switch C signal: ON
LED-3 status and starting
3 ON Starting switch C signal: OFF, S-NET connection: Made
(Yellow) switch C signal
status OFF Starting switch C signal: OFF, S-NET connection: Not made
ON CAN: Connected, (Fuel sensor: Disconnected)
Fuel sensor and Fast blinking CAN: Connected, (Fuel sensor: Connected)
LED-4
4 CAN connection
(Green) Slow blinking CAN: Disconnected, (Fuel sensor: Connected)
status
OFF CAN: Disconnected, (Fuel sensor: Disconnected)
Downloading and ON Downloading and writing mode: ON
5 LED-5
writing status OFF Downloading and writing mode: OFF (Normal mode)
Before execution of sign-up test
When sign-up test is not completed, “–” (bar) is always
Sign-up status [–]
displayed.
During sign-up test
Sign-up progress * For display during sign-up test, see “How to start operation
*
status of KOMTRAX terminal”.
After completion of sign-up test
[C] If server initialization communication is not completed, [C] is
6 7-segment Initialization displayed.
communication ON “ON” indicates that machine is within communication range.
incompletion status Fast blinking “Fast blinking” indicates that machine is out of communication
range.
Operation status
[0 – 9] Figure indicates number of mails waiting for to be sent (9 is
Number of unsent displayed when number is 9 or larger).
mails or within/out ON “ON” indicates that terminal is capturing satellite.
of communication [0 – 9] Figure indicates number of mails waiting for to be sent (9 is
range status displayed when number is 9 or larger).
Fast blinking Fast blinking indicates that terminal has not captured satellite.
GPS connector ON GPS positioning has been executed. See *2.
positioning/
Dot OFF GPS positioning has not been executed. See *2.
7 Test connector
(Red)
disconnection and If sign-up test connector is disconnected or connected, dot
connection status Fast blinking
blinks 2 – 3 times.
*1 Types and periods of blinking

Fast blinking: Blinking at cycles of about 1 second (ON for 0.5 seconds o OFF for 0.5 seconds)
Slow blinking: Blinking at cycles of about 4 seconds (ON for 2 seconds o OFF for 2 seconds)
*2 It may take more than 1 minute from turning on the starting switch to the completion of positioning even
in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio
waves.
30-100 46 PC18MR-3
Removal and installation of KOMTRAX terminal SEN04496-00
Removal and installation of Installation

KOMTRAX terminal 1 q Carry out installation in the reverse order to
removal.
Removal
1. Turn the starting switch to the OFF position.
2. Remove the cover, garnish, etc. to expose

KOMTRAX terminal (1).
3. Remove the cab wiring harness from

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

and GPS antenna cable from KOMTRAX ter-
minal (1).
5. Remove all mounting bolts (2) and washers (3)

of the KOMTRAX terminal.
Reference: The mounting bolt size is M8.
6. Remove KOMTRAX terminal (1) from bracket

(4).
a When handling the KOMTRAX terminal,
take care not to give an impact on it.
(Never hit it against another part or drop
it.)
PC18MR-3 30-100 47
SEN04496-00 Preparation work for troubleshooting of electrical system
Preparation work for

troubleshooting of electrical
system 1
a When carrying out troubleshooting of an elec-

tric circuit related to the KOMTRAX terminal,
expose the related connectors according to the
a The KOMTRAX terminal is installed at the right
front of the operator seat.
1. Remove the top cover of the KOMTRAX termi-

nal.
2. Remove KOMTRAX terminal (1).
3. Insert or connect a troubleshooting T-adapter

to connector F32 of KOMTRAX terminal (1).
a Cable (2) is for the communication
antenna (system 1).
a Cable (3) is for the GPS antenna.
30-100 48 PC18MR-3
Preparation work for troubleshooting of electrical system SEN04496-00
PC18MR-3 30-100 49
SEN04496-00

©2008 KOMATSU
All Rights Reserved
30-100 50
SEN04497-00
HYDRAULIC EXCAVATOR
PC18MR-3

40 Troubleshooting 1
100 General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures of troubleshooting ........................................................................................... 5
Connection table for connector pin numbers .................................................................................................. 8
T- branch box and T- branch adapter table ................................................................................................... 44
PC18MR-3 40-100 1
SEN04497-00 Points to remember when troubleshooting
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k 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 con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
40-100 2 PC18MR-3
Sequence of events in troubleshooting SEN04497-00
Sequence of events in troubleshooting 1
PC18MR-3 40-100 3
SEN04497-00 Checks before troubleshooting
Checks before troubleshooting 1
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 coolant

7. Check for clogging of air cleaner — Clean or replace
8. Check hydraulic oil level, type of oil — Add oil
9. Check for clogging of hydraulic oil strainer — Clean, drain
10. Check for clogging of hydraulic oil filter — Replace
11. Check final drive oil level, type of oil — Add oil
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
mechanical equipment
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
1. Check for abnormal noise, smell — Repair
equipment
2. Check for oil leakage — Repair

3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 10 – 15V Charge or 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 Disconnect
—
to 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
40-100 4 PC18MR-3
Classification and procedures of troubleshooting SEN04497-00
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
E-mode Troubleshooting of electric system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a corresponding phenomenon from
"Phenomena looking like troubles and troubleshooting Nos.", and then go to explanation of the troubleshoot-
ing.
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 Charge lamp (Charge level monitor) does not light up q
13 Charge lamp (Charge level monitor) does not go off q
Phenomena related to work equipment, travel, swing, and blade
14 Speed or power of whole work equipment, travel, swing, and blade is low H-1
15 Engine speed lowers extremely or engine stalls H-2
16 Work equipment, travel, swing, and blade systems do not work E-14 H-3
17 Abnormal sound comes out from around hydraulic pump H-4
18 Fine control performance or response is low H-5
Phenomena related to work equipment
19 Speed or power of boom is low H-6
20 Speed or power of arm is low H-7
21 Speed or power of bucket is low H-8
22 Speed or power of boom swing is low H-9
23 Work equipment does not move singly H-10
24 Hydraulic drift of work equipment is large H-11
25 Time lag of work equipment is large H-12
PC18MR-3 40-100 5
SEN04497-00 Classification and procedures of troubleshooting
Troubleshooting
No. Phenomena looking like troubles
E-mode H-mode S-mode
Phenomenon related to compound operation
26 During compound operation of work equipment, speed of part loaded more is low H-13
Phenomena related to travel
27 Machine deviates during travel H-14
28 Speed or power of travel is low H-15
29 Machine is not steered well or steering power is low H-16
30 Travel speed does not change H-17
31 Travel motor does not work (only 1 side) H-18
Phenomena related to swing
32 Speed or power of swing is low H-19
33 Machine does not swing H-20
34 Swing acceleration is low H-21
35 Machine overruns largely when it stops swinging H-22
36 Large shock is made when machine stops swinging H-23
37 Large sound is made when machine stops swinging H-24
38 Hydraulic drift of swing is large H-25
Phenomena related to blade and variable gauge
39 Speed or power of blade is low H-26
40 Blade does not move E-15 H-27
41 Hydraulic drift of blade is large H-28
42 Variable gauge does not move E-15 H-29
Phenomena related to hydraulic breaker
43 Troubleshooting for hydraulic breaker H-30
Phenomena related to monitor panel
44 When starting switch is turned ON, any item does not operate E-3
45 When starting switch is turned ON, some item does not operate E-4
46 Alarm buzzer is abnormal E-5
47 Engine oil pressure caution is turned ON E-6
48 Charge level caution is turned ON E-7
49 Travel speed shifting system does not operate normally H-17
50 Preheating does not operate or preheater does not become hot E-8
51 Coolant temperture gauge is abnormal E-9
52 Fuel level gauge is abnormal E-10
53 Service meter does not operate while engine is running E-11
54 2nd travel speed is not selected E-12
Other phenomena
55 Lock lever does not operate normally E-14 H-3
H-27
56 Blade/Variable gauge selector system does not operate normally E-15
H-29
57 Night lamp of machine monitor and working lamp do not light up E-16
40-100 6 PC18MR-3
Classification and procedures of troubleshooting SEN04497-00
PC18MR-3 40-100 7
SEN04497-00 Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2007.12)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
40-100 8 PC18MR-3
Connection table for connector pin numbers SEN04497-00
PC18MR-3 40-100 9
40-100 10 PC18MR-3
PC18MR-3 40-100 11
40-100 12 PC18MR-3
PC18MR-3 40-100 13
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PC18MR-3 40-100 43
SEN04497-00 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table 1

(Rev. 2008.02)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
40-100 44 PC18MR-3
T- branch box and T- branch adapter table SEN04497-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
PC18MR-3 40-100 45
SEN04497-00 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
40-100 46 PC18MR-3
T- branch box and T- branch adapter table SEN04497-00
PC18MR-3 40-100 47
SEN04497-00

©2008 KOMATSU
All Rights Reserved
40-100 48
SEN04498-00
HYDRAULIC EXCAVATOR
PC18MR-3

200 Troubleshooting of electrical
system (E-mode)
Before carrying out troubleshooting for electrical system (E-mode) ............................................................... 2
Information contained in troubleshooting table ............................................................................................... 4
E-1 Engine does not start ............................................................................................................................... 5
E-2 Engine does not stop.............................................................................................................................. 12
E-3 When starting switch is turned ON, any item does not operate ............................................................. 14
E-4 When starting switch is turned ON, some items do not operate ............................................................ 16
E-5 Alarm buzzer is abnormal....................................................................................................................... 17
E-6 Engine oil pressure caution is turned ON............................................................................................... 19
E-7 Charge level caution is turned ON ......................................................................................................... 20
E-8 Preheating system does not operate or preheater does not become hot .............................................. 22
E-9 Coolant temperature gauge is abnormal ................................................................................................ 24
E-10 Fuel level gauge is abnormal ............................................................................................................... 28
E-11 Service meter does not operate while engine is running ...................................................................... 32
E-12 2nd travel speed is not selected........................................................................................................... 35
E-13 Working lamp does not light up ............................................................................................................ 38
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK,
work equipment still moves.................................................................................................................. 40
E-15 Blade/Variable gauge selector system does not operate normally....................................................... 43
PC18MR-3 40-200 1
200 Troubleshooting of electrical system (E-mode)
SEN04498-00 Before carrying out troubleshooting for electrical system (E-mode)
Before carrying out troubleshooting for electrical system (E-mode) 1
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)
Fuse
Type of power supply Fuse No. Destination of power
capacity
Constant power supply
M2 45 A Starting switch (Terminal B)
(Battery)
Fuse box 1 (FB1)
Fuse
Type of power supply Fuse No. Destination of power
capacity
1
Battery power source (Between terminals 10 A Radio circuit
1 and 7)
2 Work lamp circuit
Battery relay (Between terminals 30 A
2 and 8) Fuel pump circuit
3 Engine stop solenoid circuit

Drive (Between terminals 30 A
3 and 9) Safety relay circuit
PPC lock solenoid valve circuit

4 Acceleration solenoid circuit
Control (Between terminals 20 A
4 and 10) Variable solenoid circuit
Monitor panel circuit
Horn circuit
5
Other accessory (Between terminals 20 A Rotary lamp circuit (if equipped)
5 and 11)
Travel alarm (if equipped)
Room lamp circuit

6 Wiper circuit
Cab accessory (Between terminals 30 A
6 and 12) Washer circuit
Heater circuit
40-200 2 PC18MR-3
Before carrying out troubleshooting for electrical system (E-mode) SEN04498-00
Location of fuse and fuse numbers
PC18MR-3 40-200 3
SEN04498-00 Information contained in troubleshooting table
Information contained in troubleshooting table 1
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.
Cause that presumably • Short circuit
Presumed
cause and triggered failure in ques- Independent wiring harnesses are in contact with each other abnor-
standard value tion mally.
(The assigned No. is for <Precaution for Troubleshooting>
in normalcy
filing purpose only. It does 1)Connector No. display method and handling of T-adapter
not stand for any priority) Insert or connect T-adapters in the following manner before starting
troubleshooting unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector
No., disconnect the connector and insert the T-adapter into both male
and female sides.
• If there is an indication of "male" or "female" in a specific connector
3 No., disconnect the connector and connect the T-adapter with only
one side of either "male" or "female".
2)Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit
tester in the following manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front
or the wiring harness.
• Connect the negative (–) lead with the pin No. indicated at the
front or the wiring harness.
Relative circuit diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• "Connector No. and pin No." from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the same wiring harness.
• Arrow ( ): Indicates the rough location on the machine
40-200 4 PC18MR-3
E-1 Engine does not start SEN04498-00
E-1 Engine does not start 1

Failure
(1) When the starting switch is set in START, the starting motor does not revolve.
information
• Since the engine starting circuit has the lock function, the engine does not start unless the PPC lock
Relative
lever is in the LOCK position.
information
• The lock lever is installed to the right and left.

Low charge level of battery Battery voltage Electrolyte specific gravity
1 or low electrolyte specific
Min. 12 V Min. 1.26
gravity
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 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) Position of lock lever Resistance
tion) LOCK Min. 1 Mz
Between (1) and (2)
FREE Max. 1 z
Presumed
cause and
Defective right PPC lock out turning starting switch.
standard value
in normalcy 6 switch (Internal disconnec- F5 (male) Position of lock lever Resistance
tion) LOCK Min. 1 Mz
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 dis-
connection) 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 chassis ground
8
(Internal 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-3 40-200 5
SEN04498-00 E-1 Engine does not start

aPrepare with starting switch OFF, then hold starting switch in START
and carry out troubleshooting.
Starting motor Starting switch Voltage
Between T-M2 (B)
Defective starting motor Power input 10 – 15 V
9 and (E)
(Internal defect)
Between M3 (ST)
Start input 10 – 15 V
and (E)
If the power input and start input are normal but the starting motor does
not revolve, the starting motor is defective.
aPrepare with starting switch OFF, then hold starting switch ON and
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
Presumed Resistance Max. 1 z
(female) (2)
cause and
standard value Wiring harness between M2 (female) (1) and T-
Resistance Max. 1 z
in normalcy 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 Wiring harness between F2 (female) (1) and F6
harness (Disconnection or (female) (2) Resistance Max. 1 z
11
defective contact of con-
Wiring harness between F6 (female) (1) and R1
nector) Resistance Max. 1 z
(female) (1)
Wiring harness between R1 (female) (2) and
Resistance Max. 1 z
chassis ground (T-M6)
Wiring harness between T-F4 (C) and R1
Resistance Max. 1 z
(female) (6)
Wiring harness between R1 (female) (3) and R4
Resistance Max. 1 z
(female) (4)
Wiring harness between R4 (female) (2) and M3
Resistance Max. 1 z
(female) (ST)
Wiring harness between T-M1 (+) and T-M2 (B) Resistance Max. 1 z
Wiring harness between starting motor (E) and
Resistance Max. 1 z
chassis ground
40-200 6 PC18MR-3

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
Between F2 (female) (1) – F6 (female) (2) wiring
Presumed Resistance Min. 1 z
harness and chassis ground
cause and Grounding fault in wiring
standard value 12 harness (Contact with Between R4 (female) (2) – M3 (female) (ST) wir-
Resistance Min. 1 z
in normalcy ing harness and chassis ground
ground circuit)
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-3 40-200 7
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 inject 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 Between (A) and (C) Holding voltage 10 – 15 V
3 solenoid (Internal discon-
nection 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 are normal but the solenoid rod
does not operate, the solenoid is defective.
aPrepare with starting switch OFF, then keep starting switch OFF and
turn it ON and carry out troubleshooting in each case.
F13 Voltage
Defective engine stop Between (4) and (3) Input voltage 10 – 15 V
4 solenoid timer (Internal
defect) For 1 sec: 10 – 15 V
Between (1) and (2) Output voltage
After 1 sec: Max. 1 V
If the input voltage is normal but the output voltage is not normal, the
Presumed timer is defective.
cause and aPrepare with starting switch OFF, then keep starting switch OFF and
standard value turn it ON and carry out troubleshooting in each case.
in normalcy Defective engine stop R5 Voltage
solenoid relay (Internal For 1 sec: 10 – 15 V
5
disconnection or short cir- Between (e) and (g) Coil voltage
cuit) 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 Resistance Max. 1 z
harness (Disconnection or
7
defective contact of con- Wiring harness between F13 (female) (1) – R5 Resistance Max. 1 z
nector) (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
40-200 8 PC18MR-3

Between T-F3 (ACC) – FB1 (3) wiring harness
Resistance Min. 1 Mz
and chassis ground
Presumed Between FB1 (9) – M4 (female) (A) or R5
cause and Grounding fault in wiring (female) (B) or F13 (female) (4) or circuit branch Resistance Min. 1 Mz
standard value 8 harness (Contact with end and chassis ground
in normalcy ground circuit) Between F13 (female) (1) – R5 (female) (e) wir-
ing harness and chassis ground
Between F13 (female) (2) – R5 (female) (g) wir-
Between R5 (female) (G) – M4 (female) (B) wir-
PC18MR-3 40-200 9
Circuit diagram related to engine preheating, start, charge, and stop
40-200 10 PC18MR-3
PC18MR-3 40-200 11
SEN04498-00 E-2 Engine does not stop
E-2 Engine does not stop 1

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.
Defective starting switch
1 Starting switch Position of switch Resistance
(Internal short circuit)
Presumed aCarry out troubleshooting with starting switch OFF.
cause and Defective engine stop When the connector (Right No.) of the engine stop solenoid
2
standard value solenoid (Internal defect) is disconnected, if the engine does not stop, the solenoid M4
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. 1 V
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. 1 V
(4) or circuit branch end and chassis ground
40-200 12 PC18MR-3
E-2 Engine does not stop SEN04498-00
Circuit diagram related to engine preheating, start, charge, and stop
PC18MR-3 40-200 13
SEN04498-00 E-3 When starting switch is turned ON, any item does not operate
E-3 When starting switch is turned ON, any item does not operate 1
• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the
monitor panel.
Failure 1) The warning lamps and indicators do not light up (for 3 seconds).
information 2) The buzzer does not sound (for 1 second).
• The fuel level gauge and coolant temperature gauge do not operate even a while after the starting
switch is turned ON.
Relative • Before starting troubleshooting, check that fuses No. (4) – (10) and No. (1) – (7) and fusible link are
information not broken.
Causes Standard value in normalcy and references for troubleshooting

1) Turn starting switch OFF.
2) Disconnect connector F7.
3) Turn starting switch ON.
Between F7 (female) (20) and ground Voltage 10 – 15 V
2) Remove fuses No. (4) – (10) and No. (1) – (7).
Presumed Disconnection in wiring Between FB1 (1) and ground Voltage 10 – 15 V
cause and harness (Disconnection in Between FB1 (4) and ground Voltage 10 – 15 V
1
standard value wiring harness or defective 1) Turn starting switch OFF.
in normalcy contact in connector) 2) Remove starting switch.
Between T-F1 and ground Voltage 10 – 15 V
3) Connect T-adapter to female side of F7.
Wiring harness between F7 (female) (1) and
Resistance Max. 1 z
ground
2 Defective monitor panel If the floor wiring harness is normal, the monitor panel is defective.
40-200 14 PC18MR-3
E-3 When starting switch is turned ON, any item does not operate SEN04498-00
Related circuit diagram
PC18MR-3 40-200 15
SEN04498-00 E-4 When starting switch is turned ON, some items do not operate
E-4 When starting switch is turned ON, some items do not operate 1
• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the
monitor panel.
Failure 1) Some warning lamps and indicators do not light up (for 3 seconds).
information 2) The buzzer does not sound (for 1 second).
• The fuel level gauge and coolant temperature gauge do not operate even a while after the starting
switch is turned ON.
Relative
• Distinguish this fault from “E-3 When starting switch is turned ON, any item does not operate”.
information
Presumed Causes Standard value in normalcy and references for troubleshooting

cause and
standard value See Structure, function and maintenance standard, “Monitor
1 Defective monitor panel
system”.
in normalcy
40-200 16 PC18MR-3
E-5 Alarm buzzer is abnormal SEN04498-00
E-5 Alarm buzzer is abnormal 1

1) Alarm buzzer does not sound
• When the starting switch is turned from OFF to ON, the self-check buzzer does not sound (for 1 sec-
Failure ond).
information • When the starting switch is turned ON and the 2nd travel speed selection switch and light switch are
pressed, the selection sound (a short sound) is not heard.
Relative • Before starting troubleshooting, check that fuse No. (4) – (10) is not broken.
information • Refer to troubleshooting E-3, too.

Sounds
Connect F7 (female) (11) to ground. Buzzer only when
connected.
2) Insert T-adapter in connector F8.
Presumed 3) Turn starting switch ON.
cause and 2 Defective alarm buzzer Sounds
standard value Connect T-adapter box No. 1 to ground. Buzzer only when
in normalcy connected.
Between F8 (2) and ground Voltage 10 – 15 V
2) Disconnect connectors F7 and F8.
Disconnection in wiring 3) Connect T-adapter to F7 (female) and F8 (female).
harness (Disconnection in
3 Wiring harness between F7 (female) (11)
wiring harness or defective Resistance Max. 1 z
and F8 (female) (1)
contact in connector)
Wiring harness between fuse (10) and F8
Resistance Max. 1 z
(female) (2)
PC18MR-3 40-200 17
SEN04498-00 E-5 Alarm buzzer is abnormal
2) Alarm buzzer does not stop sounding

Failure
• Alarm buzzer does not stop sounding.
information
Relative • Before starting troubleshooting, check that fuse No. (4) – (10) is not broken.

1 Defective monitor panel 3) Turn starting switch ON.
Presumed
cause and Disconnect connector F7, and turn starting Stops
Buzzer sounding.
switch ON.
standard value
in normalcy 1) Turn starting switch OFF.
Short circuit with chassis 2) Disconnect connectors F7 and F8.
2 ground in wiring harness 3) Connect T-adapter to F7 (female) and F8 (female).
(Contact with ground circuit) Between wiring harness between F7
(female) (11) and F8 (female) (1) and ground
a For the related circuit diagram, see 1).
40-200 18 PC18MR-3
E-6 Engine oil pressure caution is turned ON SEN04498-00
E-6 Engine oil pressure caution is turned ON 1

• The monitor panel performs the following operations to notify abnormal engine oil pressure while the
Failure engine is running.
information 1) The engine oil pressure caution lamp flashes.
2) The buzzer sounds.
• Check that the engine oil pressure is normal.
• When the starting switch is turned from OFF to ON, the monitor panel performs the following opera-
Relative
information tions. This does not indicate a fault.
1) The engine oil pressure caution lamp and charge level caution lamp light up.
2) The buzzer does not sound.

Short circuit with chassis 2) Disconnect T-M3 and connector F7.
1 ground in wiring harness 3) Connect T-adapter to F7 (female).
Presumed Resistance Min. 1 Mz
(female) (7) and T-M3 and ground
cause and
standard value 1) Turn starting switch OFF.
in normalcy 2) Disconnect T-M3.
2 Defective monitor panel 3) Start engine.
Oil pressure
While T-M3 is disconnected caution Stopped
Defective engine oil pressure If the monitor panel and wiring harnesses are normal, the engine oil
3
switch pressure switch is defective.
PC18MR-3 40-200 19
SEN04498-00 E-7 Charge level caution is turned ON
E-7 Charge level caution is turned ON 1

• The monitor panel performs the following operations to notify abnormal charge level while the engine
Failure is running.
information 1) The charge level caution lamp flashes.
2) The buzzer sounds.
• Check that the fan belt tension is normal.
• When the starting switch is turned from OFF to ON, the monitor panel performs the following opera-
Relative
information tions. This does not indicate a fault.
1) The engine oil pressure caution lamp and charge level caution lamp light up.
2) The buzzer does not sound.

1) Prepare with starting switch OFF.
Defective alternator 2) Start engine and carry out troubleshooting.
1
(Internal disconnection) Between M7 (1) and ground (just after
Voltage 10 – 15 V
starting engine)
2) Disconnect connectors M7 and F7.
Disconnection in wiring 3) Connect T-adapter to female side of F7.
2 Wiring harness between battery (+) terminal
and alternator terminal B
Presumed contact in connector)
cause and Wiring harness between M7 (female) (1) and
Resistance Max. 1 z
standard value F7 (female) (17)
Short circuit with chassis 3) Connect T-adapter to female side of F7.
3 ground in wiring harness
(female) (17) and M7 (female) (1) and Resistance Min. 1 Mz
ground
2) Insert T-adapter in F7.
4 Defective monitor panel 3) Start engine.
Between F7 (17) and ground (just after
Voltage 10 – 15 V
starting engine)
40-200 20 PC18MR-3
E-7 Charge level caution is turned ON SEN04498-00
PC18MR-3 40-200 21
SEN04498-00 E-8 Preheating system does not operate or preheater does not become hot
E-8 Preheating system does not operate or preheater does not become
hot 1
• When the starting switch is set to HEAT, the following preheating system of the monitor panel does
Failure not operate.
information 1) The preheating indicator flashes (for about 18 seconds).
2) The buzzer sounds at start and end of preheating.
Relative • Check that the fusible link is not broken.

If the fusible link is burned, the circuit probably has a grounding
1 Defective fusible link
fault.
1) Prepare with starting switch OFF.
Defective air heater 2) Turn starting switch ON and carry out troubleshooting.
2
Between T-M5 (female) (1) and ground Voltage 10 – 15 V
Presumed 1) Turn starting switch OFF.
cause and Defective starting switch 2) Disconnect negative (–) terminal of battery.
3
standard value (Internal defective contact)
Between T-F1 and T-F5 or T-F6 Resistance Max. 1 z
in normalcy
2) Disconnect related connectors and terminals.
Disconnection in wiring 3) Connect T-adapter to female side of F7.
4 Wiring harness between T-M5 (female) (1)
and T-F5, T-F6 or F7 (female) (8)
Wiring harness between T-F1 and M2 (2) (1)
Resistance Max. 1 z
and positive (+) terminal of battery
40-200 22 PC18MR-3
E-8 Preheating system does not operate or preheater does not become hot SEN04498-00
PC18MR-3 40-200 23
SEN04498-00 E-9 Coolant temperature gauge is abnormal
E-9 Coolant temperature gauge is abnormal 1

1) The pointer of the gauge does not move from C on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from C on the panel.
information
• Check that the coolant temperature is normal.
Relative
• While the starting switch is in OFF, the pointer does not move from C. This is not abnormal.
information
• Refer to troubleshooting E-3, too.

Disconnection in wiring 3) Connect T-adapter to M6 (female) and F7 (female).
1 Wiring harness between F7 (female) (10)
and M6 (female) (1)
Wiring harness between F7 (female) (16)
Resistance Max. 1 z
and M6 (female) (2)
2) Disconnect connector M6.
Presumed 3) Connect T-adapter to M6 (male).
cause and M6 (male) Temperature Resistance
standard value
in normalcy 25°C 38.18 – 47.77 kz
30°C 31.59 – 39.07 kz
Defective coolant temperature
2 80°C 6.199 – 6.935 kz
sensor
85°C 5.386 – 5.975 kz
Between (1) and (2)
90°C 4.695 – 5.166 kz
95°C 4.107 – 4.483 kz
100°C 3.604 – 3.903 kz
105°C 3.157 – 3.426 kz
If the wiring harness and coolant temperature sensor are normal,
the monitor panel is defective.
40-200 24 PC18MR-3
E-9 Coolant temperature gauge is abnormal SEN04498-00
PC18MR-3 40-200 25
SEN04498-00 E-9 Coolant temperature gauge is abnormal
2) The pointer of the gauge does not move from H on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from H on the panel.
information
Relative • Check that the coolant temperature is normal.

Disconnection in wiring 3) Connect T-adapter to M6 (female) and F7 (female).
1 Wiring harness between F7 (female) (10) or
wiring harness or defective Resistance Min. 1 Mz
M6 (female) (1) and ground
Wiring harness between F7 (female) (16) or
Presumed 3) Connect T-adapter to M6 (male).
cause and M6 (male) Temperature Resistance
standard value
in normalcy 25°C 38.18 – 47.77 kz
30°C 31.59 – 39.07 kz
2 80°C 6.199 – 6.935 kz
sensor
85°C 5.386 – 5.975 kz
Between (1) and (2)
90°C 4.695 – 5.166 kz
95°C 4.107 – 4.483 kz
100°C 3.604 – 3.903 kz
105°C 3.157 – 3.426 kz
40-200 26 PC18MR-3
E-9 Coolant temperature gauge is abnormal SEN04498-00
3) Temperature indicated by gauge is very different from actual temperature
Failure • When the starting switch is turned ON, the temperature indicated by the gauge is very different from
information the actual temperature.
Relative • Check that the coolant temperature is normal.

3) Connect T-adapter to M6 (male).
M6 (male) Temperature Resistance
25°C 38.18 – 47.77 kz
Presumed 30°C 31.59 – 39.07 kz
cause and 1 80°C 6.199 – 6.935 kz
sensor
standard value
in normalcy 85°C 5.386 – 5.975 kz
Between (1) and (2)
90°C 4.695 – 5.166 kz
95°C 4.107 – 4.483 kz
100°C 3.604 – 3.903 kz
105°C 3.157 – 3.426 kz
PC18MR-3 40-200 27
SEN04498-00 E-10 Fuel level gauge is abnormal
E-10 Fuel level gauge is abnormal 1

1) The pointer of the gauge does not move from E on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from E on the panel.
information
• Check that the fuel level is normal.
Relative
• While the starting switch is in OFF, the pointer does not move from E. This is not abnormal.
information

3) Connect T-adapter to M8 (female) and F7 (female).
Disconnection in wiring Wiring harness between F7 (female) (13)
Resistance Max. 1 z
harness (Disconnection in and M8 (female) (1)
1
wiring harness or defective 1) Turn starting switch OFF.
contact in connector) 2) Disconnect connectors M8.
3) Connect T-adapter to M8 (female).
Presumed Wiring harness between M8 (female) (2) and
cause and Resistance Max. 1 z
ground
standard value
in normalcy
Resistance
2 Defective fuel level sensor M8 (male) Position of float
( ) is reference value.
FULL 0 +2
–0 z
Between (2) and (3) 1/2 (50) z
EMPTY 150 ± 10 z
If the wiring harness and fuel level sensor are normal, the monitor
panel is defective.
40-200 28 PC18MR-3
E-10 Fuel level gauge is abnormal SEN04498-00
PC18MR-3 40-200 29
SEN04498-00 E-10 Fuel level gauge is abnormal
2) The pointer of the gauge does not move from F on the panel
Failure
• When the starting switch is turned ON, the pointer of the gauge does not move from F on the panel.
information
Relative • Check that the fuel level is normal.

Short circuit with chassis 2) Disconnect connectors M8 and F7.
1 ground in wiring harness 3) Connect T-adapter to M8 (female) and F7 (female).
(Contact with ground circuit) Wiring harness between F7 (female) (13)
and M8 (female) (1)
cause and 2) Disconnect connector M8.
standard value 3) Connect T-adapter to M8 (male).
in normalcy Resistance
2 Defective fuel level sensor M8 (male) Position of float
FULL 0 +2
–0 z
Between (2) and (3) 1/2 (50) z
EMPTY 150 ± 10 z
panel is defective.
40-200 30 PC18MR-3
E-10 Fuel level gauge is abnormal SEN04498-00
3) Fuel level indicated by gauge is very different from actual oil level
Failure • When the starting switch is turned ON, the fuel level indicated by the gauge is very different from the
information actual temperature.
Relative • Check that the fuel level is normal.

Presumed Resistance
cause and 1 Defective fuel level sensor M8 (male) Position of float
standard value
FULL 0 +2
–0 z
in normalcy
Between (2) and (3) 1/2 (50) z
EMPTY 150 ± 10 z
panel is defective.
PC18MR-3 40-200 31
SEN04498-00 E-11 Service meter does not operate while engine is running
E-11 Service meter does not operate while engine is running 1

1) Engine oil pressure caution is turned ON
Failure 1) Service meter (Operating hour integrator) does not
Engine oil pressure caution is turned ON.
information operate while engine is running.
• While the engine is running, the service meter operates even if the machine does not move at all.
• While the engine is stopped, the service meter does not operate.
Relative
information
a Carry out troubleshooting “E-6 Engine oil pressure caution is turned ON” first, then carry out the fol-
lowing troubleshooting.

Presumed Disconnection in wiring 3) Connect T-adapter to F7 (female).
cause and harness (Disconnection in 4) Turn starting switch to START (Do not hold for long time,
1
standard value wiring harness or defective however).
in normalcy contact in connector)
2 Defective monitor panel If the wiring harness is normal, the monitor panel is defective.
40-200 32 PC18MR-3
E-11 Service meter does not operate while engine is running SEN04498-00
2) Charge warning is displayed, too

Failure 2) Service meter (Operating hour integrator) does not
Charge warning is displayed, too.
information operate while engine is running.
Relative
information
a Carry out the troubleshooting for “E-7 Charge level caution is turned ON” first, then carry out the fol-
lowing troubleshooting.

Presumed Disconnection in wiring 3) Connect T-adapter to F7 (female).
cause and harness (Disconnection in 4) Turn starting switch to START (Do not hold for long time,
1
standard value wiring harness or defective however).
in normalcy contact in connector)
2 Defective monitor panel If the wiring harness is normal, the monitor panel is defective.
3) Engine oil pressure and charge does not indicate warning

Failure 3) Service meter (Operating hour integrator) does not Engine oil pressure and charge does not
information operate while engine is running. indicate warning.
Relative
information
a If the service meter still does not work after the troubleshooting for E-6 and E-7, the possible cause is
as follows.
Presumed Causes Standard value in normalcy and references for troubleshooting

cause and
standard value If any abnormality is not detected by 1) and 2), the monitor panel is
in normalcy defective.
PC18MR-3 40-200 33
SEN04498-00 E-11 Service meter does not operate while engine is running
40-200 34 PC18MR-3
E-12 2nd travel speed is not selected SEN04498-00
E-12 2nd travel speed is not selected 1

1) Monitor panel does not respond and 2nd travel speed is not selected
• When the 2nd travel speed selection switch is pressed while the engine is running, the monitor panel
Failure does not make the following responses.
information 1) Turning ON/OFF of 2nd travel speed indicator
2) Changing sound by buzzer (Short sound)
Relative
—
information
a Carry out troubleshooting E-3.
PC18MR-3 40-200 35
SEN04498-00 E-12 2nd travel speed is not selected
2) Monitor panel responds but 2nd travel speed is not selected

Failure
• Monitor panel responds but 2nd travel speed is not selected.
information
Relative
information

1 Defective fuse (4) – (10) If the fuse is burned, the circuit probably has a grounding fault.
2) Disconnect negative (–) terminal of battery.
Defective starting switch Starting switch Position Resistance
2
(Internal defective contact)
Between terminals B OFF Min. 1 Mz
and ACC ON Max. 1 z
2) Disconnect connector R3.
3) Connect T-adapter to R3 (male).
Between (1) and (2) 86 – 106 z
Between (3) and (6) Max. 1 z
Defective 2nd travel speed Between (3) and (5) Min. 1 Mz
3
selection relay
2) Insert T-adapter in R3.
2nd travel speed
R3 Voltage
selection switch
Between (5) and
ON 10 – 15 V
ground
cause and 2) Disconnect connector M10.
Defective 2nd travel speed 3) Connect T-adapter to M10 (male).
standard value 4
selection solenoid
in normalcy M10 Between (1) and (2) Resistance 10.5 – 12 z
(male) Between (1) and body Resistance Min. 1 Mz
2) Disconnect T-F3 and connectors F7, R3 and M10.
3) Connect T-adapter to F7, R3 and M10 (female).
Wiring harness between T-F3 and fuse (4) or
Disconnection in wiring Resistance Max. 1 z
between (10) and R3 (female) (3)
5 Wiring harness between R3 (female) (5) and
M10 (female) (1)
Wiring harness between F7 (female) (6), F10
Resistance Max. 1 z
(2), (1) and R3 (female) (1)
Wiring harness between R3 (female) (2) and
Resistance Max. 1 z
ground
2) Disconnect T-F3 and connectors F7, R3 and M10.
3) Connect T-adapter to F7, R3 and M10 (female).
Between wiring harness between fuse (10)
Short circuit with chassis and R3 (female) (3) and ground
6 ground in wiring harness Between wiring harness between R3
(Contact with ground circuit) (female) (5) and M10 (female) (1) and Resistance Min. 1 Mz
ground
Between wiring harness between F7
(female) (6), F10 (2), (1) and R3 (female) (1) Resistance Min. 1 Mz
and ground
40-200 36 PC18MR-3
E-12 2nd travel speed is not selected SEN04498-00
PC18MR-3 40-200 37
SEN04498-00 E-13 Working lamp does not light up
E-13 Working lamp does not light up 1

Failure
• Working lamp does not light up.
information
Relative
information

1 Defective fuse (2) – (8) If the fuse is burned, the circuit probably has a grounding fault.
2) Disconnect connector W2.
3) Connect T-adapter to W2 (female).
2 Defective lamp 4) Turn starting switch ON.
5) Turn lamp switch ON.
Between W2 (female) (A) and ground Voltage 10 – 15 V
2) Disconnect relay F9.
3 Defective lamp switch F9 (female) Lamp switch operation Resistance
Presumed
(1) and (2) ON Max. 1 z
cause and Between (2) and (4)
standard value (3) and (4) OFF Min. 1 Mz
Disconnection in wiring 2) Disconnect connectors F9 and W2.
harness (Disconnection in 3) Connect T-adapter to W2 (female).
4
wiring harness or defective
contact in connector) Wiring harness between F9 (female) (2), W1
Resistance Max. 1 z
(1) and W2 (female) (A).
2) Disconnect connectors F9 and W2.
Short circuit with chassis 3) Connect T-adapters to W2 (female).
5 ground in wiring harness Between wiring harness between fuse (8) and
(Contact with ground circuit) ground
Between wiring harness between F9 (female)
(2), W1 (2) and W2 (female) (A) and ground
40-200 38 PC18MR-3
E-13 Working lamp does not light up SEN04498-00
PC18MR-3 40-200 39
SEN04498-00 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still
E-14 When work equipment lock (PPC basic pressure lock)

lever is set in LOCK, work equipment still moves 1
Failure • When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still
information moves. (Without blade)
Relative
information

Defective fuse (2) – (12), (3) –
1 If fuse is broken, circuit probably has ground fault.
(13)
2) Disconnect cable from negative (–) terminal of battery.
Defective starting switch Starting switch Position Resistance
2
(Internal defective contact) Between (T-F1) termi- OFF Min. 1 Mz
nal B – (T-F3) termi-
nal ACC ON Max. 1 z
Defective PPC lock switch 3) Connect T-adapter to F2 (male).
3 (left) (Internal defective F6 (male) Lock lever position Resistance
contact)
Free Max. 1 z
Between (1) – (2)
Lock Min. 1 Mz
Defective PPC lock switch 3) Connect T-adapter to F6 (male).
Presumed (right) (Internal defective
4 F6 (male) Lock lever position Resistance
cause and contact)
standard value a Canopy specification only Free Max. 1 z
Between (1) – (2)
in normalcy Lock Min. 1 Mz
2) Disconnect relay R2.
3) Connect T-adapter to R2 (male).
Between (1) – (2) 86 – 106 z
Defective PPC lock relay Between (3) – (6) Max. 1 z
5 (Internal disconnection,
defective contact or sticking) Between (3) – (5) Min. 1 Mz
2) Insert T-adapter in relay R2.
R2 Lock lever position Voltage
Between (5) – ground Lock 10 – 15 V
Defective PPC lock solenoid 2) Disconnect connector M9.
6 (Internal disconnection or 3) Connect T-adapter to M9 (male).
short circuit) Between (1) – (2) Resistance 10.5 – 12 z
M9 (male)
Between (1) – body Resistance Min. 1 Mz
40-200 40 PC18MR-3
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still SEN04498-00

2) Disconnect related connector.
3) Set PPC lock switch in LOCK.
Wiring harness between (T-F3) terminal B –
Resistance Max. 1 z
fuse (7) – R2 (female) (3)
Disconnection in wiring Wiring harness between R2 (female) (5) –
Resistance Max. 1 z
harness (Disconnection in M9 (female) (1)
7
wiring or defective contact in Wiring harness between (T-F3) terminal
connector) ACC – fuse (10) – F2 (2) or between (1) – F6
(2) or between (1) – R2 (female) (1) Resistance Max. 1 z
Presumed a F14 is installed to only canopy specifica-
cause and tion.
standard value
in normalcy Wiring harness between R2 (female) (2) –
Resistance Max. 1 z
ground
2) Disconnect related connector.
3) Set PPC lock switch in LOCK.
Between wiring harness fuse (7) – R2
Ground fault in wiring harness (female) (3) and ground Resistance Min. 1 Mz
8 (Contact with GND or GND
circuit) Between wiring harness R2 (female) (5) –
Between wiring harness fuse (10) – F2 (2) or
(1) – F6 (2) or (1) – R2 (female) (1) and Resistance Min. 1 Mz
ground
PC18MR-3 40-200 41
SEN04498-00 E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still
40-200 42 PC18MR-3
E-15 Blade/Variable gauge selector system does not operate normally SEN04498-00
E-15 Blade/Variable gauge selector system does not operate normally 1

Failure
(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 vari-
information able 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 aPrepare with starting switch OFF, then carry out troubleshooting with-
cause and out turning starting switch.
standard value Defective variable gauge M11 (male) Resistance
in normalcy selector solenoid valve
2 Between (1) and (2) 5.5 ± 0.4 z
(Internal disconnection or
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.
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power carry out troubleshooting.
3 source (Contact with 12V
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-3 40-200 43
SEN04498-00 E-15 Blade/Variable gauge selector system does not operate normally
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 vari-
information able gauge selector solenoid valve.

If the fuse is broken, the circuit probably has a grounding fault (See
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
3 M11 (male) Resistance
(Internal disconnection or
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.
Presumed 4
short circuit) D3 (male) Resistance/Continuity
cause and Between (1) and (2) Min. 1 Mz (No continuity)
standard value
in normalcy
Wiring harness between T-F3 (ACC) – FB1 (4) Resistance Max. 1 z
Disconnection in wiring
Wiring harness between FB1 (10) – F1 (female)
harness (Disconnection or Resistance Max. 1 z
5 (3)
defective contact of con-
nector) Wiring harness between F1 (female) (2) – M11
Resistance Max. 1 z
(female) (1)
Wiring harness between M11 (female) (2) –
Resistance Max. 1 z
Between T-F3 (ACC) – FB1 (4) wiring harness
Grounding fault in wiring and chassis ground
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
40-200 44 PC18MR-3
E-15 Blade/Variable gauge selector system does not operate normally SEN04498-00
Circuit diagram related to blade/variable gauge selector switch
PC18MR-3 40-200 45
SEN04498-00

©2008 KOMATSU
All Rights Reserved
40-200 46
SEN04499-00
HYDRAULIC EXCAVATOR
PC18MR-3

300 Troubleshooting of hydraulic and
mechanical system (H-mode)
Information contained in troubleshooting table ............................................................................................... 3
H-1 Speed or power of whole work equipment, travel, swing, and blade is low ............................................. 4
H-2 Engine speed lowers extremely or engine stalls ...................................................................................... 5
H-3 Whole work equipment, travel system, swing system, and blade do not move ....................................... 6
H-4 Abnormal sound comes out from around hydraulic pump........................................................................ 7
H-5 Fine control performance or response is low ........................................................................................... 7
H-6 Speed or power of boom is low ................................................................................................................ 8
H-7 Speed or power of arm is low................................................................................................................... 9
H-8 Speed or power of bucket is low ............................................................................................................ 10
H-9 Speed or power of boom swing is low.....................................................................................................11
H-10 Work equipment does not move singly .................................................................................................11
H-11 Work equipment hydraulic drift is large ................................................................................................ 12
H-12 Time lag of work equipment is large..................................................................................................... 13
H-13 In compound operation of work equipment, speed of part loaded more is low .................................... 13
H-14 Machine deviates during travel ............................................................................................................ 14
H-15 Travel speed or travel power is low...................................................................................................... 16
H-16 Machine is not steered well or steering power is low ........................................................................... 16
H-17 Travel speed does not change ............................................................................................................. 17
H-18 Travel motor does not work (one side only) ......................................................................................... 17
H-19 Speed or power of swing is low............................................................................................................ 18
PC18MR-3 40-300 1
300 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04499-00
H-20 Machine does not swing....................................................................................................................... 20

H-21 Swing acceleration performance is low ................................................................................................ 22
H-22 Machine overruns when it stops swinging............................................................................................ 23
H-23 Large shock is made when machine stops swinging ........................................................................... 24
H-24 When upper structure stops swinging, it makes large sound ............................................................... 24
H-25 Hydraulic drift of swing is large............................................................................................................. 25
H-26 Speed or power of blade is low ............................................................................................................ 26
H-27 Blade does not move............................................................................................................................ 27
H-28 Hydraulic drift of blade is large ............................................................................................................. 27
H-29 Variable gauge does not move............................................................................................................. 28
H-30 Troubleshooting for hydraulic breaker .................................................................................................. 29
40-300 2 PC18MR-3
Information contained in troubleshooting table SEN04499-00
Information contained in troubleshooting table 1
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 fail-
Presumed
cause and ure <Contents>
(The attached No. for filing • The standard values in normalcy by which to judge "good" or "no
standard value 3
and reference purpose good" about presumed causes.
in normalcy
only. It does not stand for • References for making judgement of "good" or "no good"
any priority)
4
PC18MR-3 40-300 3
SEN04499-00 H-1 Speed or power of whole work equipment, travel, swing, and blade is low
H-1 Speed or power of whole work equipment, travel, swing, and blade
is low 1
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 inter- The gear pump performance may be lowered or the gear pump may
2
nal defect of gear pump have a defect in it. Check the gear pump directly.
aPrepare with engine stopped, then run engine at high idle and carry out
troubleshooting.
Control lever Control circuit basic pressure
+0.39
Malfunction of relief valve 3.72 –0.10 MPa
3 All levers in neutral
in 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.
troubleshooting.
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 inter- The piston pump performance may be lowered or the piston pump may
5
Presumed nal defect of piston pump have a defect in it. Check the piston pump directly.
cause and aPrepare with engine stopped, then run engine at high idle and carry out
standard value troubleshooting.
in normalcy
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.
troubleshooting.
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.
troubleshooting.
Malfunction of unload Control lever Unload pressure
8
valve +0.98
2.5 0 MPa
All levers in neutral +10
{235 0 kg/cm²}
40-300 4 PC18MR-3
H-2 Engine speed lowers extremely or engine stalls SEN04499-00
H-2 Engine speed lowers extremely or engine stalls 1

Failure
• Engine speed lowers extremely or engine stalls.
information

troubleshooting.
Control lever LS differential pressure
+0.98
2.5 0 MPa
All levers IN neutral
Malfunction or defective {25 +10
1 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
Presumed
valve directly.
cause and
The LS circuit orifices (on the pump side and control valve side) may be
standard value 2 Clogged LS circuit orifice
in normalcy clogged. Check them directly.
troubleshooting.
Arm-IN relief
valve {235 +10
–5 kg/cm²}
If none of causes 1 – 3 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).
PC18MR-3 40-300 5
SEN04499-00 H-3 Whole work equipment, travel system, swing system, and blade do not move
H-3 Whole work equipment, travel system, swing system, and blade do
not move 1
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 gear pump directly.
Low performance or inter- The gear pump performance may be lowered or the gear pump may
3
nal defect of gear pump have a defect in it. Check the gear pump directly.
troubleshooting.
Control lever Control circuit basic pressure
+0.39
Malfunction of relief valve 3.72 –0.10 MPa
in 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.
troubleshooting.
PPC lock solenoid valve output
Lock lever
pressure
Malfunction of PPC lock
5 0 MPa
Presumed solenoid valve LOCK
cause and {0 kg/cm²}
standard value +0.2
3.14 0 MPa
in normalcy 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 them directly.
Low performance or inter- The piston pump performance may be lowered or the piston pump may
7
nal defect of piston pump have a defect in it. Check the piston pump directly.
troubleshooting.
Arm-IN relief
valve {235 +10
–5 kg/cm²}
troubleshooting.
Malfunction of unload Control lever Unload pressure
9
valve +0.98
2.5 0 MPa
All levers in neutral
{25 +10
0 kg/cm²}
40-300 6 PC18MR-3
H-4 Abnormal sound comes out from around hydraulic pump SEN04499-00
H-4 Abnormal sound comes out from around hydraulic pump 1

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.
Presumed Clogging of hydraulic tankThe hydraulic tank cap may be clogged and negative pressure may be
3
cause and cap applied to the tank. Check the cap directly.
standard value Clogging of hydraulic tankThe hydraulic tank strainer may be clogged and negative pressure may
in normalcy 4
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 1

Failure
• Fine control performance or response is low.
information

troubleshooting.
Control levers LS differential pressure
+0.98
2.5 0 MPa
Malfunction or defective All levers in neutral
1 {25 +10
adjustment of LS valve 0 kg/cm²}
1.57 ± 0.1 MPa
Presumed Arm IN (Half stroke)
{16 ± 1 kg/cm²}
cause and
standard value If normal oil pressure is not obtained by adjustment, the LS valve may be
in normalcy malfunctioning or may have internal defect. Check the LS valve directly.
Clogging of LS circuit ori- The LS circuit orifices (on pump side and control valve side) may be
2
fice clogged. Check them directly.
troubleshooting.
Malfunction of unload Control levers Unload pressure
3
valve +0.98
2.5 0 MPa
{25 +10
0 kg/cm²}
PC18MR-3 40-300 7
SEN04499-00 H-6 Speed or power of boom is low
H-6 Speed or power of boom is low 1

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
Relative
power 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.

troubleshooting.
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 con-
2 The boom control valve spool may have a malfunction. Check it directly.
Presumed trol valve (spool)
cause and Malfunction of boom con-
The pressure compensation valve of the boom control valve may be mal-
standard value 3 trol valve (pressure com-
function. Check it directly.
in normalcy pensation 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- troubleshooting.
6
inder Boom cylinder Leakage from cylinder
Relieve by raising boom 10 cc/min
40-300 8 PC18MR-3
H-7 Speed or power of arm is low SEN04499-00
H-7 Speed or power of arm is low 1

Failure
• Speed or power of arm is low.
information
Relative
information

troubleshooting.
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
Malfunction of arm control
cause and The pressure compensation valve of the arm control valve may be mal-
3 valve (pressure compen-
standard value function. Check it directly.
sation valve)
in normalcy
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, and
suction valves
blade, too.)
Defective seal of arm cylin- troubleshooting.
6
der Arm cylinder Leakage from cylinder
Relieved in arm-IN operation 10 cc/min
PC18MR-3 40-300 9
SEN04499-00 H-8 Speed or power of bucket is low
H-8 Speed or power of bucket is low 1

Failure
• Speed or power of bucket is low.
information
Relative
information

troubleshooting.
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 bucket CURL 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
Malfunction of bucket con-
cause and The pressure compensation valve of the bucket control valve may be
3 trol valve (pressure com-
standard value malfunction. Check it directly.
pensation valve)
in normalcy
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, and
suction valves
blade, too.)
Defective seal of bucket troubleshooting.
6
cylinder Bucket cylinder Leakage from cylinder
Relieved in bucket-CURL operation 10 cc/min
40-300 10 PC18MR-3
H-9 Speed or power of boom swing is low SEN04499-00
H-9 Speed or power of boom swing is low 1

Failure
• Speed or power of boom swing is low.
information
Relative
information

troubleshooting.
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
swing {32 +20 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 and Malfunction of boom swing
The pressure compensation valve of the boom swing control valve may
standard value 3 control valve (pressure
have a malfunction. Check it directly.
in normalcy 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 troubleshooting.
6
swing cylinder Boom swing cylinder Leakage from cylinder
Relieved at left swing 10 cc/min
H-10 Work equipment does not move singly 1

(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.

troubleshooting.
Work equipment control lever
PPC valve output pressure
Presumed and pedal
cause and 1 Malfunction of PPC valve 0 MPa
standard value Set lever in neutral
{0 kg/cm²}
in normalcy +0.2
3.14 0 MPa
Operate lever
{32 +20 kg/cm²}
Malfunction of control
2 The control valve spool may have a malfunction. Check it directly.
valve (spool)
PC18MR-3 40-300 11
SEN04499-00 H-11 Work equipment hydraulic drift is large
H-11 Work equipment hydraulic drift is large 1

(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.

troubleshooting.
Work equipment cylinder Leakage from cylinder
Defective seal of hydraulic
Presumed 1 Relieved by boom RAISE
cylinder
cause and Relieved by arm IN
standard value 10 cc/min
Relieved by bucket CURL
in normalcy Relieved by boom SWING LEFT
2 The control valve spool may be malfunctioning. Check it directly.
valve (spool)
Malfunction of control The suction valve of the control valve may be malfunctioning. Check it
3
valve (suction valve) directly.
40-300 12 PC18MR-3
H-12 Time lag of work equipment is large SEN04499-00
H-12 Time lag of work equipment is large 1

(1) Time lag of boom is large.
Failure
(2) Time lag of arm is large.
information
(3) Time lag of bucket is large.
Relative
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Malfunction of control The suction valve of the control valve may have a malfunction. Check it
1
in normalcy valve (suction valve) directly.
H-13 In compound operation of work equipment, speed of part loaded

more is low 1
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.
Presumed More load Less load
Combination of operations
cause and Malfunction of pressure side side
standard value 1 compensation valve on RAISE boom + Move arm IN Boom Arm
in normalcy 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
PC18MR-3 40-300 13
SEN04499-00 H-14 Machine deviates during travel
H-14 Machine deviates during travel 1

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,
deformation, and damage.
troubleshooting.
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 +2
{32 0 kg/cm²}
Output difference of above Max. 0.4 MPa
Presumed between right and left {Max. 4 kg/cm²}
cause and Malfunction of travel con-
standard value 3 The travel control valve spool may be malfunctioning. Check it directly.
trol valve (spool)
in normalcy Malfunction of travel con-
The pressure compensation valve (with right and left junction mecha-
nism) of the travel control valve may be malfunctioning. Check it directly.
pensation valve)
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
5
swivel joint travel motor with each other. If the turning direction becomes oppo-
site, 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
(motor unit) travel 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.)
40-300 14 PC18MR-3
H-14 Machine deviates during travel SEN04499-00
Failure
(2) Machine deviates when it starts (It does not deviate during ordinary travel).
information

troubleshooting.
0 MPa
Malfunction of travel PPC Set in neutral
1 {0 kg/cm²}
Presumed
valve +0.2
cause and Operate to drive left-right, 3.14 0 MPa
standard value forward-reverse {32 +20 kg/cm²}
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.
PC18MR-3 40-300 15
SEN04499-00 H-15 Travel speed or travel power is low
H-15 Travel speed or travel power is low 1

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,
deformation, and damage.
troubleshooting.
Presumed Travel lever PPC valve output pressure
cause and Malfunction of travel PPC 0 MPa
2 Neutral
standard value valve {0 kg/cm²}
in normalcy +0.2
or reverse {32 +20 kg/cm²}
Malfunction of travel con-
3 The travel control valve spool may be malfunctioning. Check it directly.
trol valve (spool)
The pressure compensation valve of the travel control valve may be mal-
functioning. Check it directly.
pensation valve)
H-16 Machine is not steered well or steering power is low 1

Failure
• Machine is not steered well or steering power is low.
information

troubleshooting.
Malfunction of travel PPC 0 MPa
1 Neutral
valve {0 kg/cm²}
Presumed +0.2
cause and Operated to right, left, forward, 3.14 0 MPa
standard value or reverse {32 +20 kg/cm²}
trol valve (spool)
The pressure compensation valve of the travel control valve may be mal-
pensation valve)
Defective seal of center
4 The seal of the center swivel joint may be defective. Check it directly.
swivel joint
40-300 16 PC18MR-3
H-17 Travel speed does not change SEN04499-00
H-17 Travel speed does not change 1

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
Relative
load decreases, the travel speed is set high again.)
information

troubleshooting.
2nd travel speed
Travel speed shifting 2nd travel speed
selection solenoid
Presumed Malfunction of 2nd travel switch selection monitor
valve output pressure
cause and 1 speed selection solenoid
standard value valve 0 MPa
Low speed mode OFF
in normalcy {0 kg/cm²}
+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) 1

Failure
• Travel motor does not work (one side only).
information

troubleshooting.
Malfunction of travel PPC 0 MPa
1 Neutral
valve {0 kg/cm²}
Presumed +0.2
cause and
standard value or reverse {32 +20 kg/cm²}
trol valve (spool)
Malfunction of travel motor
The counterbalance valve of the travel motor may be malfunctioning.
3 (with counterbalance
Check it directly.
valve)
Malfunction of travel motor The motor unit of the travel motor may be malfunctioning. Check it
4
(motor unit) directly.
PC18MR-3 40-300 17
SEN04499-00 H-19 Speed or power of swing is low
H-19 Speed or power of swing is low 1

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
Causet Standard value in normalcy and references for troubleshooting

troubleshooting.
Swing holding brake
Work equipment control levers
Malfunction of shuttle release signal pressure
Presumed 1 valve for swing holding 0 MPa
brake (inside control valve) All levers in neutral
standard value Operated to swing LEFT +0.2
in normalcy 3.14 0 MPa
Operated to swing RIGHT +2
Operated to arm IN {32 0 kg/cm²}
Malfunction of swing con-
2 The swing control valve spool may be malfunctioning. Check it directly.
trol valve (spool)
Malfunction of swing motor The parking brake section (timer valve and parking brake) of the swing
3
(parking brake section) motor may be malfunctioning. Check it directly.
40-300 18 PC18MR-3
H-19 Speed or power of swing is low SEN04499-00
Failure
(2) Speed or power of swing is low in only one direction.
information

troubleshooting.
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}
troubleshooting.
Swing holding brake
Presumed Work equipment control levers
cause and 2 valve for swing holding 0 MPa
standard value brake All levers in neutral
{0 kg/cm²}
in normalcy
Operated to swing LEFT +0.2
3.14 0 MPa
trol valve (spool)
troubleshooting.
Malfunction of swing motor
4 Work equipment control levers Swing relief pressure
(safety valve)
19.1 ± 0.98 MPa
Relieved by swing (to right and left)
{195 ± 10 kg/cm²}
Malfunction of swing motor The suction valve of the swing motor may be malfunctioning. Check it
5
(suction valve) directly.
PC18MR-3 40-300 19
SEN04499-00 H-20 Machine does not swing
H-20 Machine does not swing 1

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
Relative
system, swing system, and blade system do not work".)
information

troubleshooting.
Swing holding brake
1 valve for swing holding 0 MPa
Presumed {0 kg/cm²}
cause and Operated to swing LEFT +0.2
standard value 3.14 0 MPa
in normalcy Operated to arm IN {32 0 kg/cm²}
trol valve (spool)
3
Malfunction of swing motor The motor unit of the travel motor may be malfunctioning. Check it
4
40-300 20 PC18MR-3
H-20 Machine does not swing SEN04499-00
Failure
(2) Machine does not swing in only one direction.
information

troubleshooting.
valve {0 kg/cm²}
+0.2
troubleshooting.
Swing holding brake
Presumed 2 valve for swing holding 0 MPa
standard value Operated to swing LEFT +0.2
3.14 0 MPa
in normalcy Operated to swing RIGHT +2
trol valve (spool)
The load check valve in the spool of the swing control valve may be mal-
4 trol valve (load check valve
in spool)
troubleshooting.
(safety valve)
19.1 ± 0.98 MPa
{195 ± 10 kg/cm²}
6
PC18MR-3 40-300 21
SEN04499-00 H-21 Swing acceleration performance is low
H-21 Swing acceleration performance is low 1

Failure
(1) Swing acceleration performance is low in both directions.
information
Relative
information

Presumed 1 The swing control valve spool may be malfunctioning. Check it directly.
trol valve (spool)
cause and
standard value Malfunction of swing motor The parking brake section (timer valve and parking brake) of the swing
2
in normalcy
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 one direction.
information

troubleshooting.
valve {0 kg/cm²}
+0.2
Presumed Malfunction of swing con-
cause and 2 The swing control valve spool may be malfunctioning. Check it directly.
trol valve (spool)
standard value
in normalcy The load check valve in the spool of the swing control valve may be mal-
3 trol valve (load check valve
in spool)
troubleshooting.
(safety valve)
19.1 ± 0.9 MPa
{195 ± 10 kg/cm²}
5
40-300 22 PC18MR-3
H-22 Machine overruns when it stops swinging SEN04499-00
H-22 Machine overruns when it stops swinging 1

Failure
(1) Machine overruns when it stops swinging in both directions.
information
Relative
information

Presumed
cause and 1 The swing control valve spool may be malfunctioning. Check it directly.
trol valve (spool)
standard 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 one direction.
information

troubleshooting.
valve {0 kg/cm²}
+0.2
Presumed Operated to swing RIGHT
cause and {32 +20 kg/cm²}
standard value Malfunction of swing con-
in normalcy trol valve (spool)
troubleshooting.
(safety valve)
19.1 ± 0.9 MPa
{195 ± 10 kg/cm²}
4
PC18MR-3 40-300 23
SEN04499-00 H-23 Large shock is made when machine stops swinging
H-23 Large shock is made when machine stops swinging 1

Failure
• Large shock is made when machine stops swinging.
information
information • When starting troubleshooting, set the hydraulic oil temperature to 45 – 55°C.

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

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 and The swing motor safety valves may have a malfunction. Check the
standard value 2 valves directly. (They may be checked by exchanging with each other
(safety valve)
and checking change of the phenomenon.)
in normalcy
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.)
40-300 24 PC18MR-3
H-25 Hydraulic drift of swing is large SEN04499-00
H-25 Hydraulic drift of swing is large 1

Failure
(1) While swing holding brake is applied, hydraulic drift of swing is large.
information

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

Defective seal of swing The seal of the swing control valve spool may be defective. Check it
1
control valve (spool) directly.
Presumed The seal of the safety valve of the swing motor may be defective. Check
Defective seal of swing
cause and 2 it directly. (The sealing condition can be judged by replacing the right
standard value motor (safety valve)
and left safety valves and checking the change of the phenomenon.)
in normalcy 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.)
PC18MR-3 40-300 25
SEN04499-00 H-26 Speed or power of blade is low
H-26 Speed or power of blade is low 1

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.

Malfunction of blade con-
1 The blade control valve spool may have a malfunction. Check it directly.
trol valve (spool)
Presumed Malfunction of variable The variable gauge solenoid valve may be malfunctioning. Check it
cause and 2 gauge selector solenoid directly. (If the solenoid valve is not changed normally, the variable
standard value valve gauge probably moves when the blade is operated.)
in normalcy aPrepare with engine stopped, then run engine at high idle and carry out
Defective seal of blade cyl- troubleshooting.
3
inder Blade cylinder Leakage from cylinder
Relieved by lowering blade 10 cc/min
40-300 26 PC18MR-3
H-27 Blade does not move SEN04499-00
H-27 Blade does not move 1

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
system, 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.

Malfunction of blade con-
1 The blade control valve spool may have a malfunction. Check it directly.
trol valve (spool)
Malfunction of variable The variable gauge solenoid valve may be malfunctioning. Check it
Presumed 2 gauge selector solenoid directly. (If the solenoid valve is not changed normally, the variable
cause and valve gauge probably moves when the blade is operated.)
standard value aPrepare with engine stopped, then run engine at high idle and carry out
in normalcy Defective seal of blade cyl- troubleshooting.
3
Deformation of blade cylin-
4 The blade cylinder or blade is deformed. Check them directly.
der or blade
H-28 Hydraulic drift of blade is large 1

Failure
• Hydraulic drift of blade is large.
information

Defective seal of blade
Presumed 1 The seal of blade control valve spool may be defective. Check it directly.
control valve (spool)
cause and
standard value
Defective seal of blade cyl- troubleshooting.
in normalcy 2
PC18MR-3 40-300 27
SEN04499-00 H-29 Variable gauge does not move
H-29 Variable gauge does not move 1

Failure
• Variable gauge does not move.
information
• Since the blade circuit pressure is also used for the variable gauge, check that the blade moves nor-
Relative
mally before carrying out troubleshooting. (If the blade does not move normally, carry out trouble-
information
shooting for "H-27 Blade does not move".)

Malfunction of variable The variable gauge solenoid valve may be malfunctioning. Check it
Presumed 1 gauge selector solenoid directly. (If the solenoid valve is not changed normally, the blade proba-
cause and valve bly moves when the variable gauge is operated.)
standard value Defective variable gauge
in normalcy 2 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.
40-300 28 PC18MR-3
H-30 Troubleshooting for hydraulic breaker SEN04499-00
H-30 Troubleshooting for hydraulic breaker 1

Failure
(1) Breaker does not strike.
information
Relative
• Before carrying out troubleshooting, check that hydraulic tank oil level is normal.
information

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

Presumed 1 Low engine speed Increase engine speed.
cause and Malfunction of control
2 Disassemble and check that valve body and control valve slide normally.
standard value valve
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

Presumed Add nitrogen gas.
Low accumulator gas
cause and 1 5.4 MPa
pressure Gas pressure
standard value {55 kg/cm²}
in normalcy Broken accumulator dia-
2 Replace.
phragm
Failure
(4) Much oil or little black oil leaks through chisel socket.
information
Relative
—
information

cause and 1 Worn U-packing Replace.
standard value 2 Damaged U-packing Remove flaws of hammer piston and replace packing.
in normalcy 3 Grease leakage This is not abnormal phenomenon.
PC18MR-3 40-300 29
SEN04499-00 H-30 Troubleshooting for hydraulic breaker
Failure
(5) High-pressure hose swings abnormally.
information
Relative
information

Adjust nitrogen gas pressure.
High accumulator gas
1 5.4 MPa
Presumed pressure Gas pressure
{55 kg/cm²}
cause and
Add nitrogen gas.
standard value Low accumulator gas
in normalcy 2 5.4 MPa
pressure 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

cause and 1 Worn or hardened O-ring Replace.
standard value
in normalcy 2 Loosened bolt and nut Retighten.
40-300 30 PC18MR-3
H-30 Troubleshooting for hydraulic breaker SEN04499-00
PC18MR-3 40-300 31
SEN04499-00

©2008 KOMATSU
All Rights Reserved
40-300 32
SEN04500-00
HYDRAULIC EXCAVATOR
PC18MR-3

400 Troubleshooting of engine (S-mode)
Troubleshooting chart ..................................................................................................................................... 2
PC18MR-3 40-400 1
SEN04500-00 Troubleshooting chart
Troubleshooting chart 1
a This troubleshooting chart is transferred from the Shop Manual for 3D67E-2 Engine.
Symptom Probable Cause Solution
Engine Does Not No fuel Replenish fuel
Start Air in the fuel system Bleed
Water in the fuel system Change fuel and repair or replace
fuel system
Fuel hose clogged Clean or replace
Fuel filter clogged Replace
Excessively high viscosity of fuel or engine oil Use specified fuel or engine oil
at low temperature
Fuel with low cetane number Use specified fuel
Fuel leak due to loose injection pipe retaining Tighten retaining nut
nut
Incorrect injection timing Adjust
Fuel camshaft worn Replace
Injection nozzle clogged Clean or replace
Injection pump malfunctioning Repair or replace
Seizure of crankshaft, camshaft, piston, Repair or replace
cylinder or bearing
Compression leak from cylinder Replace head gasket, tighten
cylinder head screw, glow plug and
nozzle holder
Improper valve timing Correct or replace timing gear
Piston ring and cylinder worn Replace
Excessive valve clearance Adjust
Stop solenoid malfunctioning Replace
Starter Does Not Battery discharged Charge
Run Starter malfunctioning Repair or replace
Wiring disconnected Connect
Engine Fuel filter clogged or dirty Replace
Revolution Is Air cleaner clogged Clean or replace
Not Smooth
Fuel leak due to loose injection pipe retaining Tighten retaining nut
nut
Incorrect nozzle injection pressure Adjust
Injection nozzle stuck or clogged Repair or replace
Governor malfunctioning Repair
W1046115
40-400 2 PC18MR-3
Troubleshooting chart SEN04500-00

Either White or Excessive engine oil Reduce to specified level
Blue Exhaust Piston ring and cylinder worn or stuck Repair or replace
Gas Is Observed
Either Black or Overload Reduce the load
Dark Gray Low grade fuel used Use specified fuel
Exhaust Gas Is
Observed Fuel filter clogged Replace
Air cleaner clogged Clean or replace
Deficient nozzle injection Repair or replace nozzle
Deficient Output Incorrect injection timing Adjust
Engine’s moving parts seem to be seizing Repair or replace
Deficient nozzle injection Repair or replace nozzle
Compression leak Check the compression pressure
and repair
Excessive Piston ring’s gap facing the same direction Shift ring gap direction
Lubricant Oil Oil ring worn or stuck Replace
Consumption
Piston ring groove worn Replace piston
Valve stem and valve guide worn Replace
Crankshaft bearing and crank pin bearing Replace
worn
Oil leaking due to defective seals or packing Replace
Fuel Mixed into Injection pump’s plunger worn Repair or replace
Lubricant Oil Deficient nozzle injection Repair or replace nozzle
Injection pump broken Replace
Water Mixed into Head gasket defective Replace
Lubricant Oil Cylinder block or cylinder head flawed Replace
W1047740
PC18MR-3 40-400 3
SEN04500-00 Troubleshooting chart

Low Oil Engine oil insufficient Replenish
Pressure Oil strainer clogged Clean
Relief valve stuck with dirt Clean
Relief valve spring weaken or broken Replace
Excessive oil clearance of crankshaft bearing Replace
Excessive oil clearance of crankpin bearing Replace
Excessive oil clearance of rocker arm Replace
Oil passage clogged Clean
Different type of oil Use specified type of oil
Oil pump defective Replace
High Oil Different type of oil Use specified type of oil
Pressure Relief valve defective Replace
Engine Engine oil insufficient Replenish
Overheated Fan belt broken or elongated Replace or adjust
Coolant insufficient Replenish
Radiator net and radiator fin clogged with dust Clean
Inside of radiator corroded Clean or replace
Coolant flow route corroded Clean or replace
Radiator cap defective Replace
Overload running Reduce the load
Head gasket defective Replace
Unsuitable fuel used Use specified fuel
Battery Quickly Battery electrolyte insufficient Replenish distilled water and
Discharged charge
Fan belt slips Adjust belt tension or replace
Wiring disconnected Connect
Rectifier defective Replace
Alternator defective Replace
Battery defective Replace
W1049318
40-400 4 PC18MR-3
Troubleshooting chart SEN04500-00
PC18MR-3 40-400 5
SEN04500-00

©2008 KOMATSU
All Rights Reserved
40-400 6
SEN04620-00
HYDRAULIC EXCAVATOR
PC18MR-3

50 Disassembly and assembly1

100 General information on disassembly
and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools ................................................................................................................................ 9
PC18MR-3 50-100 1
100 General information on disassembly and assembly
SEN04620-00 How to read this manual
How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The “Removal” section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q General tools that are necessary for removal
q Also the following information is described are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in the “Removal” section
tuted and should always be used are explained and listed below.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a: Know-how or precautions for work
2) Distinction of new and existing special [*1] : This mark shows that there are instructions or
tools precautions for installing parts.
6 : This mark shows the amount of oil or coolant
N: Tools newly developed for this
model. They respectively have a to be drained.
4 : Weight of part or component
new part number.
R: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other Installation
models. They can be used without q Except where otherwise instructed, installation
any modification. of parts is done in the reverse order to
3) Circle mark Q in sketch column: removal.
q The sketch of the special tool is pre- q Instructions and precautions for installing parts
sented in the section of “Sketches of are shown with [*1] mark in the “Installation”
special tools”. Section, identifying which step the instructions
q This mark means part No. of special are intended for.
General tools that are necessary for installa-
* *** ****
tools starting with 79 T- -
and that they can not be supplied
q
tion are described as [1], [2]•••etc. and their
from Komatsu in Japan (i.e. locally part names, part numbers and quantities are
made parts). not described.
q Marks shown in the “Installation” section stand
for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
50-100 2 PC18MR-3
How to read this manual SEN04620-00
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are deemed neces- q In “Disassembly” section, the work procedures,
sary for disassembly or assembly of parts precautions and know-how for carrying out
are described as A1,•••X1 etc. and their those procedures, and quantity of the oil and
part names, part numbers and quantities coolant drained are described.
are described in the special tool list. q General tools that are necessary for disassem-
q Also the following information is described bly are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used sembly” section are as follows.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a : Know-how or precautions for work
2) Distinction of new and existing special 6: Quantity of oil or coolant drained
tools
N : Tools newly developed for this
model. They respectively have a
new part number. Assembly
R : Tools with upgraded part numbers. q In “Assembly” section, the work procedures,
They are remodeled from already precautions and know-how for carrying out
available tools for other models. those procedures, and quantity of the oil and
Blank : Tools already available for other coolant added are described.
models. They can be used without q General tools that are necessary for assembly
any modification. are described as [1], [2]•••etc. and their part
3) Circle mark Q in sketch column: names, part numbers and quantities are not
q The sketch of the special tool is pre- described.
sented in the section of “Sketches of q The meanings of the symbols used in “Assem-
special tools”. bly” section are as follows.
k : Precautions related to safety in execution
q This mark means part No. of special
* *** ****
tools starting with 79 T- -
and that they can not be supplied
of work
a : This mark gives guidance or precautions
from Komatsu in Japan (i.e. locally when doing the procedure.
2 : Type of coating material
made parts).
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
PC18MR-3 50-100 3
SEN04620-00 Coating materials list
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
50-100 4 PC18MR-3
Coating materials list SEN04620-00
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
PC18MR-3 50-100 5
SEN04620-00 Coating materials list
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
50-100 6 PC18MR-3
Special tool list SEN04620-00
Special tool list 1
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t.........Cannot be substituted, must always be installed (used)
q.........Extremely useful if available or, can be substituted with commercially available
part.
a New/Remodel: N.........Tools with new part numbers, newly developed for this model.
: R.........Tools with upgraded part numbers, remodeled from items already available for
other mode.ls
: Blank:...Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
“Sketches of special tools”).
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
idler assembly 790-101-5021 • Grip 1
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

Disassembly, assembly of Disassembly, assembly of
recoil spring assembly M 792-371-1400 Sleeve t 1 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
Disassembly, assembly
of center swivel joint T 790-101-2540 • Washer 1 Separation of rotor and
swivel joint
assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
PC18MR-3 50-100 7
SEN04620-00 Special tool list
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of

1 hydraulic cylinder assem-
790-101-1102 Hydraulic pump t 1 bly
Removal, installation of
2 790-330-1100 Wrench assembly t 1
cylinder head
Commercially Width across
available Socket t 1 flats: 32 mm
Removal,
Commercially installation Width across
3 available Socket t 1 of piston flats: 36 mm
nut
Commercially Width across
available Socket t 1
flats: 41 mm
790-201-1702 Push tool KIT t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1 Press fitting

4 of bushing
For arm,
790-201-1721 • Push tool 1 swing, vari-
able gauge
790-201-1731 • Push tool 1 For arm,
Disassembly, assembly blade
of hydraulic cylinder U
assembly
790-101-5021 • Grip 1
01010-50816 • Bolt 1 Press fitting

5 of dust seal
For bucket,
790-201-1530 • Plate 1 swing, vari-
able 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,
07281-00609
60 q 1
bucket, 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

Disassembly, assembly
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
6 796-170-2160 Handle t 1
of cover
7 796-170-2170 Valve assembly t 1 Charging with nitrogen gas
50-100 8 PC18MR-3
Sketches of special tools SEN04620-00
Sketches of special tools 1

Note) Komatsu cannot accept any responsibility for special
tools manufactured according to these drawings.
V1 Stand
V2 Shaft
PC18MR-3 50-100 9
SEN04620-00 Sketches of special tools
V3 Shaft
V4 Shaft
50-100 10 PC18MR-3
Sketches of special tools SEN04620-00
V5 Shaft
PC18MR-3 50-100 11
SEN04620-00

©2008 KOMATSU
All Rights Reserved
50-100 12
SEN04621-00
HYDRAULIC EXCAVATOR
PC18MR-3


Removal and installation of fuel injection pump assembly.............................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 3
Removal and installation of hydraulic oil cooler assembly .............................................................................. 5
Removal and installation of engine and hydraulic pump assembly ................................................................ 6
PC18MR-3 50-200 1
SEN04621-00 Removal and installation of fuel injection pump assembly
Removal and installation of fuel 7. Remove 4 mounting bolts (10) and fuel injec-
injection pump assembly 1 tion pump (9).
a While turning lever (R), remove the fuel
Removal injection pump.
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
q Carry out installation in the reverse order to
removal.
3. Close fuel valve (A). [*1]

3 Air hose (1) clamp:
4. Remove fuel injection tubes (4) together. 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}
3 Air hose (2) clamp:
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.
50-200 2 PC18MR-3
Removal and installation of radiator assembly SEN04621-00
Removal and installation of 4) While pulling back lever (5) with the left
radiator assembly 1 hand, raise the floor frame with the right
hand and push it forward until it is locked.
Removal (The floor frame is locked when pin (C) is
k Lower the boom to bring the work equip- caught in lock plate (D).)
ment in contact with the ground. a If the floor frame is floating, lever (5)
does not move (it is not in the reset
1. Tilt up the floor frame. position) and you cannot tilt up the
1) Lower boom (1) so that bar (B) will not floor frame. (Let a person on the rear
touch the boom when the floor frame is part of the floor frame to set the floor
tilted up. frame down, and then pull lever (5).)
k When opening and closing the
2) Remove mat (2) and open cover (3).
floor, do not put any part of body
under the floor.
a Angle between bar (B) and boom (1) when

floor frame is tilted up
5) Take lock pin (6) (red) out of part (H) of
bracket (E) (red) and insert it in the posi-
tion shown below.
k Check that lock pin (6) is fixing pin
(P).
3) Remove bolts (4). [1]
PC18MR-3 50-200 3
SEN04621-00 Removal and installation of radiator assembly
2. Drain the coolant. Installation

6 Coolant: 1.0 l q Carry out installation in the reverse order to
removal.
3. Disconnect reservoir tank hose (7).
[*1]
4. Disconnect clip (8), brackets (9) and remove 3 Floor frame mounting bolt:
cover (10). 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 (11). [*2]
6. Disconnect radiator upper hose (12). [*2]
7. Remove radiator assembly (13).

a When removing the radiator assembly,
take care not to damage its core.
50-200 4 PC18MR-3
Removal and installation of hydraulic oil cooler assembly SEN04621-00

hydraulic oil cooler assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Loosen the oil filler cap of the hydraulic [*1]
tank gradually to release the internal pres- a When the floor frame tilted up is lowered,
sure of the hydraulic tank. hose (5) touches it easily. To prevent this,
be sure to connect hose (5) so that it will
1. Tilt up the floor frame. For details, see go under flange (F). (Part A)
“Removal and installation of radiator assem-
bly”. q Refilling with oil (Hydraulic tank)
a Add oil through the oil filler to the specified
2. Drain the hydraulic oil. level. Run the engine to circulate the oil
through the system. Then, check the oil
6 Hydraulic oil: 15.2 l level again.
3. Open cover (1). 5 Hydraulic oil: 15.2 l
4. Disconnect reservoir tank hose (2). q Bleeding air

a Bleed air. For details, Testing and adjust-
5. Disconnect clip (3). ing, “Bleeding air from each part”.
6. Remove sponge (4) and cover (1).
7. Disconnect hoses (5) and (6) from the hydrau-

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

cooler assembly (7).
a When removing the hydraulic oil cooler
assembly, take care not to damage its
core.
PC18MR-3 50-200 5
SEN04621-00 Removal and installation of engine and hydraulic pump assembly
Removal and installation of 4. Drain the fuel.

engine and hydraulic pump 6 Fuel: 19 l (When full)
assembly 1
5. Drain the coolant.
Removal
6 Coolant: 3.1 l
k Loosen the oil filler cap of the hydraulic
tank gradually to release the internal pres-
6. Drain the hydraulic oil.
sure of the hydraulic tank.
6 Hydraulic oil: 15.2 l
“Removal and installation of radiator assembly”. 7. Disconnect air hoses (3) and (4) and remove
air cleaner (5). [*2]
2. Lift off roof (1).
4 Roof: 17 kg
8. Disconnect fuel hoses (6).
3. Lift off canopy pole (2). [*1] 9. Remove water drain valve bracket (7) and dis-
4
connect the fuel hose from back side.
Canopy pole: 50 kg
4 Canopy: 68 kg
50-200 6 PC18MR-3
Removal and installation of engine and hydraulic pump assembly SEN04621-00
10. Disconnect fuel return hose (8). 18. Sling counterweight and fuel tank assembly
(17) temporarily.
11. Remove cover (9).

19. Remove mounting bolts (18), (19) and (20).
12. Remove battery (10).
20. Move counterweight and fuel tank assembly

13. Disconnect hydraulic hose (11). (17) backward.
14. Disconnect clips (12) and (13).
15. Disconnect ground (14).
16. Remove bracket (15).
17. Disconnect bracket (16).
PC18MR-3 50-200 7
21. Disconnect drain hose (21) attached to fuel 26. Remove fan (26) and fan guard (27). [*4]
tank.
27. Disconnect connectors (28) and (29) and

22. Lift off counterweight and fuel tank assembly heater terminal (30).
(17). [*3]
4
28. Disconnect clip (31).
Counterweight and fuel tank assembly
(17): 180 kg
29. Disconnect connector (32) and terminal (33)

from the alternator.
23. Remove pin (22).
24. Remove bracket (23). from the starting motor.
a Fuel control cable (24) and fuel filter (F)
come off, too. 31. Disconnect terminal (36).
25. Remove radiator assembly (25). For details,

see “Removal and installation of radiator
assembly”.
50-200 8 PC18MR-3
32. Disconnect engine ground cable (37) from 35. Sling engine and hydraulic pump assembly
under the starting motor. (41) temporarily.
36. Remove 4 mounting bolts (42). [*5]
33. Disconnect gear pump hose (38) and piston

pump hose (39).
37. Lift off engine and hydraulic pump assembly
(43).
a Check that all the wires and pipes are dis-
connected.
a When lifting off the assembly, take care
that it will not interfere with other parts.
4 Engine and hydraulic pump assembly:
130 kg
34. Disconnect hose (40).
PC18MR-3 50-200 9
Installation [*5]
q Carry out installation in the reverse order to 2 Engine mounting bolt: Adhesive (LT-2)
removal. 3 Engine mounting bolt:
59 – 74 Nm {6 – 7.6 kgm}
[*1]
3 Canopy mounting bolt: q Refilling with coolant
98 – 122.5 Nm {10 – 12.5 kgm} a Add coolant through the coolant filler to
the specified level. Run the engine to cir-
[*2] culate the coolant through the system.
3 Air hose (2) clamp: Then, check the coolant level again.
5
8.8 ± 0.49 Nm {0.9 ± 0.05 kgm} Coolant: 3.1 l
Air hose (3) clamp:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
q Refilling with oil (Hydraulic tank)
[*3] a Add oil through the oil filler to the specified
3 Counterweight mounting bolt level. Run the engine to circulate the oil
Right side: 152 – 191 Nm {15.5 – 19.5 kgm} through the system. Then, check the oil
Left side: 456 – 568 Nm {46.5 – 58 kgm} level again.
5
a Fuel hose (6) may be flattened between Hydraulic oil: 15.2 l
the counterweight (F) and frame. To pre-
vent this, check that the route of hose (6)
is on the upside of (F). q Bleeding air
a Bleed air. For details, Testing and adjust-
ing, “Bleeding air from each part”.
k Run the engine and check that air
comes (is pushed) out from the radia-
t o r. I f a i r d o e s n o t c o m e ( i s n o t
pushed) out, check to see if the cooling
fan is installed in reverse.
[*4]
a Take care of the installed direction of the fan.
Install fan (26) so that it will be as shown in the
figure at left when seen from above.
a If fan (26) is installed in the correct direction, its
pulley (44) is seen clearly.
50-200 10 PC18MR-3
PC18MR-3 50-200 11
SEN04621-00

©2008 KOMATSU
All Rights Reserved
50-200 12
SEN04622-00
HYDRAULIC EXCAVATOR
PC18MR-3


300 Power train
Removal and installation of swing circle assembly ......................................................................................... 2
PC18MR-3 50-300 1
300 Power train
SEN04622-00 Removal and installation of swing circle assembly
Removal and installation of swing circle assembly 1
Removal Installation
1. Remove the revolving frame assembly. For q Carry out installation in the reverse order to
details, see “Removal and installation of removal.
revolving frame assembly”.
[*1]
2. Disconnect grease hoses (1) and (2). 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
3. Remove 18 mounting bolts (3). [*1]
59 – 74 Nm {6 – 7.5 kgm}
(Target: 65.7 Nm {6.7 kgm})
4. Install hanging bolts and lift off swing circle
assembly (4). [*2]
[*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 figure.
2 Inner race tooth surface:
Grease (G2-LI)
50-300 2 PC18MR-3
300 Power train
Removal and installation of swing circle assembly SEN04622-00
PC18MR-3 50-300 3
SEN04622-00

©2008 KOMATSU
All Rights Reserved
50-300 4
SEN04623-00
HYDRAULIC EXCAVATOR
PC18MR-3


Removal and installation of track shoe assembly ........................................................................................... 2
Disassembly and assembly of idler assembly ................................................................................................ 3
Disassembly and assembly of recoil spring .................................................................................................... 5
Disassembly and assembly of track roller assembly ...................................................................................... 7
Assembly of travel motor assembly ................................................................................................................ 9
Removal and installation of floor frame assembly ........................................................................................ 18
Removal and installation of revolving frame ................................................................................................. 22
PC18MR-3 50-400 1
SEN04623-00 Removal and installation of track shoe assembly
Removal and installation of track 2. Lower the floated track frame a little and
shoe assembly 1 remove track shoe assembly (2) from idler (J)
side first, then from sprocket (S) side.
Removal
1. Swing the upper structure by 90° and raise the
machine by using the work equipment.
3. Pull out track shoe assembly (2) to this side

and lift it off.
4 Rubber shoe: 55 kg
2. Loosen valve (1) to discharge the grease and Steel shoe: 85 kg
loosen track shoe tension. [*1]
k Since valve (1) may jump out because
of the internal high-pressure grease, Steel shoe
do not loosen it more than 1 turn. 1. Move master link (3) forward.
2. Remove cutter pin (4) and master pin (5).
Rubber shoe
1. Loosen the track shoe assembly (2).
3. Spread the link.
Installation
removal.
[*1]
a Adjust the track shoe tension. For details,
see Testing and adjusting, “Testing and
adjusting track shoe tension”.
50-400 2 PC18MR-3
Disassembly and assembly of idler assembly SEN04623-00
Disassembly and assembly of Assembly

idler assembly 1 1. Using tool L1, press fit 2 bearings (6) to idler
(7).
Special tools 2 Inside of bearing: Grease (G2-LI)
New/Remodel
Symbol
Necessity
Part No. Part name
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
Disassembly
2. Install shaft (5) and fix it with snap ring (4).
1. Remove plate (1).
2. Remove supports (2).
3. Using tool L2, install 2 oil seals (3) to the idler.

2 Oil seal lip: Grease (G2-LI)
a Take care that dirt will not stick the oil
3. Remove oil seal (3).
seals.
a After installing the oil seal to either side,
4. Remove snap ring (4) and shaft (5).
supply grease into the idler.
2 Inside of idler:
5. Remove bearings (6) from idler (7).
Grease (G2-LI), Approx. 36 cc
PC18MR-3 50-400 3
SEN04623-00 Disassembly and assembly of idler assembly
4. Install supports (2) to shaft (5) of the idler.

2 Mounting bolt: Adhesive (LT-2)
5. Install plate (1).

6. Install idler cushion assembly. (Steel shoe

specification)
50-400 4 PC18MR-3
Disassembly and assembly of recoil spring SEN04623-00
Disassembly and assembly of 2) Using tool M, set the recoil spring to the
recoil spring 1 press.
k Since the installed load of the
spring is large and dangerous, set
a The recoil spring is used for only the steel shoe the spring securely.
specification.
3) Apply hydraulic pressure gradually to
Special tools compress the spring and remove nut (6).
a Compress the spring until you can
New/Remodel
loosen the nut.
Symbol
Necessity
Part No. Part name a Installed load of spring:
Sketch
6,860 N {700 kg}
Q'ty
M 792-371-1400 Sleeve t 1 4) Release the hydraulic pressure gradually
to release spring (8), and then remove
Disassembly stopper (7) and spring (8) from cylinder
1. Piston (9).
1) Remove grease fitting (1) and valve (2) a Free length of spring: 200 mm
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).
PC18MR-3 50-400 5
SEN04623-00 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
fitting, return them about 2 turns.
3) Install rod (3) and push it into cylinder
2) Using tool M, set the recoil spring to the assembly (4), and then press the grease
press. out of valve (2) and bleed air from cylinder
k Since the installed load of the (9).
spring is large and dangerous, set 4) Tighten valve (2).
the spring securely. 3 Valve (2):
3) Apply hydraulic pressure gradually to 59 – 74 Nm {6 – 7.5 kgm}

compress the spring to installed height (a), 5) Tighten grease fitting (1).
and then install nut (6). a Direct grease fitting (1) toward out-
a Installed height (a) of spring: 168 mm side (the side panel) of the machine.
a Installed load of spring:
6.86 kN {700 kg}
50-400 6 PC18MR-3
Disassembly and assembly of track roller assembly SEN04623-00
Disassembly and assembly of Assembly

track roller assembly 1 q Assembly parts
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
Disassembly
1. Remove plates (1).
2. Remove oil seals (2).
3. Remove snap rings (3) and shaft (4).
4. Remove bearings (5) from track roller.
1. Using tool L3, press fit bearings (5) to track

roller (6).
2 Inside of bearing: Grease (G2-LI)
PC18MR-3 50-400 7
SEN04623-00 Disassembly and assembly of track roller assembly
2. Install shaft (4) and fix it with snap rings (3).
3. Using tool L4, install oil seals (2) to the track

roller (6).
2 Oil seal lip: Grease (G2-LI)
a Take care that dirt will not stick to the oil
seals.
a After installing the oil seal to either side,
supply grease into track roller (6).
2 Inside of track roller (6):
Grease (G2-LI), Approx. 44 cc
a Precautions for installing to machine

3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
50-400 8 PC18MR-3
Assembly of travel motor assembly SEN04623-00
Assembly of travel motor

assembly 1
Only the assembly procedure is described in this

section.
General precautions for disassembly and

assembly
a Check the disassembled parts for abnormal
wear and seizure, and then remove burrs from
them before assembling.
a Replace the seals and snap rings with new
ones.
a Hexagonal wrenches of 5 mm and 8 mm (1
piece each) are necessary.
Sectional structure drawing and introduced parts
PC18MR-3 50-400 9
SEN04623-00 Assembly of travel motor assembly
Assembly
1. Hydraulic motor section
q 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
drawing.
a Plug (6): See photo in 4).
a Spool assembly (2) cannot be disas- 3) Install spool (8), spool (9), and spring (10)
sembled. to 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 struc-
ture drawing.)
50-400 10 PC18MR-3
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-3 50-400 11
q 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.
50-400 12 PC18MR-3
15) Install rocker cam (28) to body 2 (20). 18) Set steel plate (32) in body 2 (20), match-
2 Sliding surface of rocker cam (28): ing 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 relation-
16) Insert cylinder barrel assembly (30) in ship between the O-rings and backup
body 2 (20) so that shoe (29) will meet rings.
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), match-

ing it to the groove.
PC18MR-3 50-400 13
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).
a Install floating seal (42) with the seal-
5
ing surface up.
Inside of body 2 (20):
Hydraulic oil (approx.100 cm3)
21) Install valve plate (39) and springs (40)

(14 pieces) to body 1 (1) and combine
them with body 2 (20).
a Install the valve plate with the copper
side up (on the cylinder barrel side).
2 Sliding surface (Copper side) of
valve plate: Hydraulic oil
2 Back side (Steel side) of valve
plate:
Grease (G2-LI) (for prevention of
fall)
a Install springs (40) (14 pieces) to the
places marked with q in the following
figure.
50-400 14 PC18MR-3
2) Install bearing inner race (44) and steel 4) Install body (47) to hydraulic motor (41).
balls (45) having the retainer to hydraulic a Clamp the reduction gear unit flange
motor (41) in order. (1 set) and hydraulic motor flange with a C-
a Take care of the directions of the clamp, a hydraulic press, etc.
bearing inner race and retainer. (See
the sectional structure drawing.)
a The steel balls may come off the
retainer. Take care not to lose them.
5) Install steel balls (48) having the retainer

and bearing inner race (49) to the hydrau-
lic motor in order.
a Take care of the directions of the
bearing inner race and retainer. (See
the sectional structure drawing.)
a The steel balls may come off the
retainer. Take care not to lose them.
3) Set the O-ring to seal ring (46) and install

them to body (47).
a Insert seal ring (46) with the sealing
surface up.
PC18MR-3 50-400 15
6) Fix the bearing with snap ring (50). 9) Install sun gear and carrier 2 assembly
a Adjust the preload on the bearing by (58) to body (47).
the thickness of the snap ring. a Sun gear: (57) --- See the sectional
structure drawing.
a Sun gear and carrier 2 assembly (58)
is supplied only as an assembly.
(Including sun gear (57).)
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. 10) Install O-ring (59) to body (47).
2 O-ring (59): Grease (G2-LI)
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)
50-400 16 PC18MR-3
12) Supply hydraulic oil and install cover (60). 14) Tighten socket head plugs (63) (G3/8).
a Tighten the plug on the side of the let-
5 Hydraulic oil (330 cc)
ters of DRAIN first. (Lock the cover
a Take care not to damage the O-ring. with the flange of the plug.)
a Match the letters of "DRAIN" on the 3 Socket head plug (63):
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 direc-
tion.
PC18MR-3 50-400 17
SEN04623-00 Removal and installation of floor frame assembly
Removal and installation of floor 5. Disconnect connector (4).

frame assembly 1
Removal
bly”.

4 Roof: 17 kg
6. Disconnect clips (5) – (7).
3. Lift off canopy pole (2). [*1]

4 Canopy pole: 50 kg
4 Canopy: 68 kg
7. Disconnect connectors (8) – (11).
4. Remove battery (3).
50-400 18 PC18MR-3
Removal and installation of floor frame assembly SEN04623-00
8. Remove cover (12). 13. Disconnect connectors (22) – (24).

a Since the connectors do not have No.
labels, record their destinations.
9. Disconnect connectors (13) – (15) and termi-

nals (16) and (17).
14. Disconnect clip (25) and ground wire (26).
10. Remove clip (18).
15. Disconnect 8 work equipment PPC hoses (27).
[*2]
a Hose band colors
q White, green, brown, and orange
Blue, yellow, red, and black

from the starting motor.
12. Disconnect terminal (21).
16. Disconnect blade control cable (28).
PC18MR-3 50-400 19
SEN04623-00 Removal and installation of floor frame assembly
17. Disconnect PPC hoses (29) and (30). 20. Disconnect PPC hoses (34) and (35) from the
a Hose band colors control valve. [*5]
q (29): Red and green
q (30): No band
a Prepare plugs before disconnecting the
hoses.
a Prepare tags to record the destinations of
the hoses.
21. Disconnection of fuel control cable (38)

1) Remove pin (36).
a Record the position of the pin hole.
2) Loosen locknuts (37). [*6]
a Before loosening the locknuts, record
the installed dimension.
18. Disconnect 4 travel PPC hoses (31). [*3] 3) Pull out fuel control cable (38) toward the
a Hose band colors: floor frame.
Right front: Black and yellow, a Check the route of the cable.
Right rear: Yellow and green,
Left front: Yellow and brown,
Left rear: Yellow and orange
19. Disconnect 2 swing PPC hoses (32) and (33).

[*4]
a Hose band colors:
Left side: Red and white,
Right side: Blue and white
22. Sling floor frame assembly (39) temporarily.
50-400 20 PC18MR-3
Removal and installation of floor frame assembly SEN04623-00
23. Remove 2 upper mounting bolts (40) of 27. Lift off floor frame assembly (39).
4
damper (41).
k Since damper (41) is pressed strongly,
Floor frame assembly: 132 kg
a Before lifting off the assembly, check that
it may jump out to the right or left.
all the wires and pipes are disconnected.
Take care. After removing the upper
mounting bolts, do not stand near the
damper.
Installation
24. Pull out lock pin (42) and remove pin (43).
q Carry out of installation in the reverse order to
removal.
[*1]
3 Canopy mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
[*2] [*3] [*4] [*5]

a When connecting the hoses, check their
band colors.
[*6]
a Adjust the cable tension. For details, see
Testing and adjusting, “Adjusting fuel con-
trol lever”.
25. Sling up floor frame assembly (39) a little to
expand damper (41) fully. (Damper (41) jumps q Refilling with oil (Hydraulic tank)
out.) a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
26. Remove right and left pins (44). through the system. Then, check the oil
level again.
q Bleeding air
a Bleed air. For details, see Testing and
adjusting, “Bleeding air from each part”.
PC18MR-3 50-400 21
SEN04623-00 Removal and installation of revolving frame
Removal and installation of 7. Remove hose (4).

revolving frame 1
Removal
1. Stop the machine with the work equipment
extended.
a When draining the hydraulic oil, swing the
upper structure 30° to the left. (Do not
swing 90°.)
8. 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.

3. Remove the floor frame assembly. For details,

see “Removal and installation of floor frame
assembly”.
4. Remove the work equipment assembly. For

details, see “Removal and installation of work
equipment assembly”.
5. Remove plate (1). 9. Disconnect hoses (A), (B), (C), and (D) from
the control valve assembly.
6. Pull out pin (2) and remove boom cylinder a The hoses have labels on them.
assembly (3). [*1] a (A) – (H) of the hose labels are the name
a Hoses (H) were disconnected from the of the connecting ports of the center
control valve in the section of the work swivel joint.
equipment assembly.
4 Boom cylinder: 25 kg
50-400 22 PC18MR-3
Removal and installation of revolving frame SEN04623-00
10. Disconnect hose (T) from the hydraulic tank. 14. Sling revolving frame assembly (10) tempo-
rarily.
a Wind the sling onto the rear part.
15. Remove 16 revolving frame mounting bolts

(11). [*3]
16. Lift off revolving frame assembly (10).

a Check that all the pipes are disconnected
and take care not to damage the center
swivel joint.
4 Revolving frame assembly: 750 kg
11. Disconnect hose (H) and nipple (5) from center

swivel joint assembly (7).
12. Remove lever (6) from center swivel joint

assembly (7). [*2]
13. Disconnect lubrication hoses (8) and (9).
PC18MR-3 50-400 23
SEN04623-00 Removal and installation of revolving frame
Installation
removal.
[*1]
k When aligning the pin holes, never
insert your fingers in them.
2 Pin and sliding surface on swing bracket
side: Molybdenum disulfide lubricant
(LM-P)
2 Grease after installation:
Grease (Hyper White Grease)
[*2]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
157 – 196 Nm {16 – 20 kgm}
[*3]
2 Revolving frame assembly mounting
bolt: Adhesive (LT-2)
3 Revolving frame assembly mounting
bolt: 59 – 74 Nm {6 – 7.5 kgm}
(Target: 65.7 Nm {6.7 kgm})

level again.
q Bleeding air
50-400 24 PC18MR-3
Removal and installation of revolving frame SEN04623-00
PC18MR-3 50-400 25
SEN04623-00

©2008 KOMATSU
All Rights Reserved
50-400 26
SEN04624-00
HYDRAULIC EXCAVATOR
PC18MR-3


500 Hydraulic system
Disassembly and assembly of hydraulic pump assembly............................................................................... 2
Disassembly and assembly of control valve assembly ................................................................................. 12
Removal and installation of hydraulic system and center swivel joint assembly........................................... 18
Disassembly and assembly of center swivel joint assembly......................................................................... 20
Removal and installation of swing motor assembly ...................................................................................... 22
Disassembly and assembly of swing motor assembly .................................................................................. 23
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 30
Disassembly and assembly of hydraulic breaker assembly.......................................................................... 34
PC18MR-3 50-500 1
SEN04624-00 Disassembly and assembly of hydraulic pump assembly
Disassembly and assembly of hydraulic pump assembly 1

a Packing (14), oil seal (37), seal washer (9), and Special tool
O-rings must be replaced when the pump as- q Oil seal driving jig: Tool S
sembly is assembled again. Accordingly, be
sure to prepare new ones before disassembling.
(Supplied parts: Seal kit)
a Hexagonal wrench: 4, 5, 8 and 10 mm (1 piece
each) are necessary.
a Bolt: M10 x 80 (2 pieces) are necessary.
50-500 2 PC18MR-3
Disassembly and assembly of hydraulic pump assembly SEN04624-00
Disassembly
k Never adjust or remove the set screw
(ADJ).
If it is adjusted or removed, the engine may
stall.
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).
PC18MR-3 50-500 3
2. Removal of adjustment unit (ADJ) 4. Separation of body S (12) and body H (10)
a If it is obliged to disassemble adjustment 1) Remove 2 of 7 hexagon socket head bolts
unit (ADJ), record projection (K) of the (13) M10 x 60.
screw in advance. 2) Install 2 temporary mounting bolts M10 x
Loosen hexagon nut (7) fully and remove set 80 instead of the removed bolts, and then
screw (8) and seal washer (9). loosen the other 5 bolts.
a This work is required since there is an
internal spring.
3) Loosen the 2 temporary mounting bolts
and separate the bodies.
3. Removal of LS valve
Remove LS valve (11) from body H (10).
a The spool may fall from the LS valve.
Take care.
a Hit the spring insertion part of body H
(10) lightly with a plastic hammer, and
the bodies are separated easily.
5. Disassembly of body H (10)

1) Remove packing (14) from body H (10).
50-500 4 PC18MR-3
2) Remove spring guide (15) and valve plate 7) Remove plug (26), O-ring (27), steel ball
(16) from body H (10). (28), and filter (29) from body H (10).
a Record the direction (each side) of a Turn the filter counterclockwise with a
valve plate (16). flat-head screwdriver to remove it
from the body.
3) Pull control piston (18) out of sleeve (17).

4) Remove sleeve (17). 6. Disassembly of body S (12) assembly
a An O-ring is fitted. 1) Remove spring T1 (30) from body S (12).
2) Remove spring holder (31).
5) Remove plug (20), O-ring (21), and choke

(22) from body H (10). 3) Remove cylinder barrel assembly (32).
6) Remove plug (23), O-ring (24), and choke
(25) from body H (10).
PC18MR-3 50-500 5
4) Remove rocker cam (33) and rocker pins q Inspection and measurement
(34). a Check of wear of oil seal mounting part
Wear Z 0.025 mm
5) Remove snap ring (35) on the shaft drive

shaft side from body S (12). 7. Cylinder barrel assembly (32)
6) Hit shaft (36) lightly with a plastic hammer a Only cylinder barrel assembly (32) or
to pull oil seal (37) and the assembly of assembly of piston (40) and shoe (41) is
shaft (36) and bearing (38) out of body S supplied.
(12). 1) Remove shoe holder (42) from cylinder
barrel (39). (Piston (40) and shoe (41) are
removed together.)
2) Remove barrel holder (43) and retainer

(44).
3) Remove needle (45).
50-500 6 PC18MR-3
q Inspection and measurement of pis- 4) Remove snap ring (46) from inside of cyl-
ton assembly and cylinder barrel inder barrel (39), and then remove retainer
a Check visually that piston assembly (47), spring C (48), and retainer (47) in
and cylinder barrel are free from a order.
flaw, scuff mark, abnormal wear, etc.
(Check the sliding parts in particular.)
a Check clearance between outside
diameter (d) of piston (40) and inside
diameter (D) of cylinder barrel (39).
(D) – (d) Z 0.050 mm
Assembly
k If foreign matter enters the pump, the pump
will be broken. Take care.
a Axial moving distance of piston (40) removal.
and shoe (41)
(E) Z 0.2 mm 1. Cylinder barrel assembly (32)
1) Install retainer (47), spring C (48), retainer
(47), and snap ring (46) in order.
a See the figure above.
2) Install needle (45), retainer (44), and bar-
rel holder (43) to cylinder barrel (39).
a Take care of installing position of
retainer (44).
PC18MR-3 50-500 7
3) Install shoe holder (42), in which piston 3) Install snap ring (35) to body S (12) on the
(40) and shoe (41) assembly is inserted, shaft drive shaft side.
to cylinder barrel (39). 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.)
2. Body S (12) assembly

1) Install shaft (36) and bearing (38) assem-
bly to body S (12).
a Be sure to replace oil seal (37) with
new one. 4) Put rocker pin (34) in the spherical hole of
2 Oil seal (37): rocker cam (33) and install them to the
Apply a little quantity of grease spherical hole of body S (12).
(G2-LI) to lip and outside. 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)
and set spherical part (B) of the spring
holder in the hole of rocker cam (33).
2) Drive oil seal (37) with oil seal driving jig

TOOL S. Hit the jig lightly with a hammer.
a Place body S (12) on body H (10)
temporarily for the ease of work.
50-500 8 PC18MR-3
3. Body H 5) Install O-ring (19) and sleeve (17) to body

1) Install choke (22), O-ring (21), and plug H (10).
(20) to body H (10). 3 Tightening torque for sleeve (17):
2) Install choke (25), O-ring (24), and plug 49.0 – 58.8 Nm {5 – 6 kgm}
(23) to body H (10).
6) Install control piston (18) to sleeve (17).

3) Install filter (29) to body H (10). 7) Install spring guide (15).
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 cylin-
der barrel. Take care not to mistake
the direction of the valve plate.
PC18MR-3 50-500 9
9) Install 2 pins (50) to body H (10). 4. Installation of body S (12) and body H (10)
1) Install 2 temporary mounting bolts M10 x
80 to 2 holes on the upper side and
tighten them gradually.
2) When the clearance between the mating
faces becomes 5 – 10 mm, install hexa-
gon 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):
10) Install packing (14) to face to be mated 51.0 – 64.7 Nm {5.2 – 6.6 kgm}
with body S (12).
a Be sure to replace packing (14) with
new one.
5. Installation of LS valve
Install LS valve (11) to body H (10).
a The spool may fall from the LS valve.
3 Tightening torque for LS valve (11):

Take care.
49.0 – 58.8 Nm {5 – 6 kgm}
50-500 10 PC18MR-3
6. Installation of adjustment unit

1) Fix set screw (8) and seal washer (9) with
hexagon nut (7) to projection (K) mea-
sured before disassembling.
a Replace seal washer (9) with new
one.
3 Hexagon nut (7):
19.6 – 20.6 Nm {2 – 2.1 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.
PC18MR-3 50-500 11
SEN04624-00 Disassembly and assembly of control valve assembly
Disassembly and assembly of control valve assembly 1
In this section, only precautions for assembling the control valve assembly are explained.
8-spool valve
50-500 12 PC18MR-3
Disassembly and assembly of control valve assembly SEN04624-00
a Work in a clean indoor place where there is no

dirt and dust.
a Clean the parts in clear solvent, and then dry
them with compressed air.
a Replace a part having burrs with new one.
a Coat the sliding surfaces of each part with en-
gine oil before installing.
a Degrease the female threads of the plugs and
screws with denatured alcohol, etc. and dry
them in advance. Do not apply pressure for 2
hours after tightening them.
2 Mating face of block:
Apply Sealend 242 or equivalent.
3 PA1 – PA8, PB1 – PB8 (M14 x 1.5):
29.4 – 39.2 Nm {3 – 4.0 kgm}
PC18MR-3 50-500 13
q Section B-B
a Take care of the installed direction of each spool.
a For 8 places of 07-1L on the right side and left side, apply the following.
a When tightening and loosening the bolts of 07-1L, be sure to keep the spool in the valve chamber.
2 07-1L: Apply a drop (about 0.02 g) of LOCTITE (No. 638) to threads.
3 07-1L: 6.9 – 9.8 Nm {0.7 – 1.0 kgm}
50-500 14 PC18MR-3
q Section C-C
3 15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
a After orifice (1) is installed, its head must not project from the mating face of the block.
PC18MR-3 50-500 15
q 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
sectional structure drawing.)
a All sections (07-1L): See the explanation of section B-B.
3 15-2L: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
50-500 16 PC18MR-3
q Sections F-F, G-G, and J-J

a All sections (07-1L): See the explanation of sec-
tion 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}
PC18MR-3 50-500 17
SEN04624-00 Removal and installation of hydraulic system and center swivel joint assembly
Removal and installation of

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

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

bly”.
7. Remove rubber cover (4) and disconnect

hoses (E), (F), (G), and (H).
a The hoses other than hose (H) have labels
on them.

5. Disconnect hoses (2) and (3) from the center

swivel joint.
q Hoses (2) are labeled (A), (C), (E), (G),
and (I) from the bottom.
q Hoses (3) are labeled (B), (D), (F), (H),
and (J) from the bottom.
a (A) – (J): Hoses are labeled. 8. Disconnect hoses (A), (B), (C), and (D) from
a Before disconnecting the hoses, prepare the control valve assembly.
plugs. a The hoses have labels on them.
a Prepare tags to record the destinations of a (A) – (H) of the hose labels are the name
the hoses. of the connecting ports of the center
swivel joint.
50-500 18 PC18MR-3
Removal and installation of hydraulic system and center swivel joint assembly SEN04624-00
9. Disconnect hose (T) from the hydraulic tank. Installation

removal.
[*1]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
59 – 74 Nm {6 – 7.6 kgm}

level again.
10. Disconnect hose (5).
q Bleeding air
11. Disconnect hose (H) and nipple (6) from center

swivel joint assembly (8).
12. Remove lever (7) from center swivel joint

assembly (8). [*1]
13. Remove center swivel joint assembly (8).
PC18MR-3 50-500 19
SEN04624-00 Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of 4. Remove dust seal (6) and 5 plugs (7) from
center swivel joint assembly 1 swivel shaft (5).
Special tools 5. Remove 4 plugs (8) from swivel shaft (5).

a There are 2 types of the plugs.
New/Remodel
6. Remove ring (10), O-ring (11), backup ring
Symbol
Necessity
Part No. Part name
(12), 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).
50-500 20 PC18MR-3
Disassembly and assembly of center swivel joint assembly SEN04624-00
Assembly
1. Install O-ring (11), backup ring (12), and 10
slipper seals (13) to rotor (9).
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.
2 Plug (7):
4.90 – 6.86 Nm {0.5 – 0.7 kgm}
2 Plug (8): 16.7 ± 2.9 Nm {1.7 ± 0.3 kgm}
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
slipper 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-3 50-500 21
SEN04624-00 Removal and installation of swing motor assembly
Removal and installation of swing Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Tilt up the floor frame. For details, see q Refilling with oil (Hydraulic tank)
“Removal and installation of radiator assem- a Add oil through the oil filler to the specified
bly”. level. Run the engine to circulate the oil
2. Disconnect hoses (1) – (5). level again.
5
a Before disconnecting the hoses, prepare Hydraulic oil: 15.2 l
plugs.
a Prepare tags to record the destinations of
the hoses. q Bleeding air
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
50-500 22 PC18MR-3
Disassembly and assembly of swing motor assembly SEN04624-00
Disassembly and assembly of swing motor assembly 1

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 re-
move 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 nec-
essary.
PC18MR-3 50-500 23
SEN04624-00 Disassembly and assembly of swing motor assembly
q Motor 9. Remove drive (10).

2. Grip the flange with the pinion gear down.
3. Remove the mounting bolts of valve housing

assembly (2).
q 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).
6. Remove valve plate (7). a Assemble only when necessary.
7. Remove valve drive (8).
8. Remove geroler (9).
50-500 24 PC18MR-3
14. Remove piston (17). 19. Remove snap ring (ø 45) (24), collar (25),
bearing (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 bear-
ing housing (21).
PC18MR-3 50-500 25
Assembly 2. Install X-ring (27) to bearing housing (21).

a Clean all the parts with cleaning oil. Take care
not to scratch or bruise them. Degrease the tap
holes, in particular.
a Replace the seals with new ones.
a Apply grease to the seals in advance.
q Assembly of brake assembly

1. Install bearing (26), collar (25), and snap ring
(ø 45) (24) to pinion gear (23).
a Install bearing (26) with the shield side
toward the pinion.
a Install collar (25) with the chamfered side
toward the snap ring.
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.
50-500 26 PC18MR-3
5. Install discs (20) to the bearing housing. 10. Install shaft face seal (16) to flange mounting
a Install plates (19) and discs (20) alter- (12).
nately so that last plate (19) will be on the
top. 11. Install bearing (15) and fix it with snap ring
(14).
12. Coat spring (13) with grease and stick it to

flange mounting (12).
2 Spring (13): Grease (G2-LI)
13. Install the O-ring to flange mounting (12).
6. Install the 2 O-rings (inside and outside) to ring

(18).
7. Install ring (18) to bearing housing (21).
14. Install flange mounting (12) to bearing housing

(21).
a Take care that the spring will not fall.
a When assembling, set the drain hole as
shown in the following illustration.
8. Install the O-ring to piston (17).
9. Install piston (17) to bearing housing (21).
PC18MR-3 50-500 27
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.
q 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
flange mounting (12). turned to the right by 15° from the posi-
tion where it is matched to the teeth of
17. Install drive (10). valve drive (8), the motor will revolve in
reverse, and that will be very danger-
18. Install geroler (9). ous.
a Match drain hole (D) to the flange mount-
ing.
19. Install valve drive (8).
20. Install the O-rings (2 types) to the grooves of

valve plate (7).
21. Install valve plate (7).

a Match the drain hole to the geroler (9).
50-500 28 PC18MR-3
23. Install spring (3) and pin (4) to hose (H) of 26. Install balancing plate (5) to valve housing
valve housing (2) in order. assembly (2), matching its cut part to pin (4).
24. Install the O-rings (2 types) to valve housing 27. Install valve housing assembly (2).
(2). a While inserting thin rod (3) such as a
screwdriver in port (B) of the valve hous-
ing (See illustration in 28) to hold balanc-
ing plate (5), install the valve housing.
a Match drain hole (DD) to the valve plate.
a Degrease the hexagon socket head bolts
in advance.
2 Hexagon socket head bolt:
LOCTITE #242
53 Nm {5.4 kgm}
a Tighten the bolts evenly in the diagonal
order.
25. Install inner face seal (28) and outer face seal
(29) to balancing plate (5).
28. Install the timer valve to the motor body.

15 Nm {1.5 kgm}
PC18MR-3 50-500 29
SEN04624-00 Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of a In this section, only the assembly procedure is

hydraulic cylinder assembly 1 explained.
Special tools Assembly

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

available
across flats: 41 t 1
mm)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 • Push tool (For
790-201-1721 bucket, boom 1
swing, and vari-
able gauge)
• Push tool (For
790-201-1731 1
arm and blade)
U 790-201-1500 Push tool KIT t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 2. Piston rod
• Plate (For bucket,
790-201-1530 boom swing, and 1 1) Press fit bushing (22) to piston rod (6).
variable gauge) 2) Press fit 2 dust seals (21).
790-201-1540 • Plate (For boom, 1
arm, and blade)
6 790-720-1000 Expander q 1
Ring piston ø 65
796-720-1740 (For blade) q 1
07281-00709 Clamp (For blade) q 1

Ring piston ø 60,
796-720-1630 55 (For boom, arm, q 1
and boom swing)
7 Ring piston ø 50
796-720-1620 (For bucket and q 1
variable gauge)
Clamp piston ø 50 -
60 (For boom, arm,
07281-00609 boom swing, q 1
bucket, and vari-
able gauge)
50-500 30 PC18MR-3
Disassembly and assembly of hydraulic cylinder assembly SEN04624-00
3. Cylinder head assembly a Boom cylinder.

1) Using tool U4, press fit bushing (20) to cyl-
inder head (14).
a Do not perform this step for boom cyl-
inder.
8) Install cylinder head assembly (11) to pis-

ton rod (6).
2) Using tool U5, press fit dust seal (18).
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
cylinder.
PC18MR-3 50-500 31
SEN04624-00 Disassembly and assembly of hydraulic cylinder assembly
4. Piston assembly 6) Install piston assembly (5) to piston rod

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

8) Using tool U3, install piston nut (4).
q Width across flats of piston nut
2) Set piston ring (9) to tool U6 and give 8 – Boom cylinder: 36 mm
10 turns to the handle to expand the pis- Arm cylinder: 41 mm
ton ring. Bucket cylinder: 32 mm
Boom swing cylinder: 32 mm
Blade cylinder: 36 mm
Variable gauge cylinder: 32 mm
2 Piston nut: Adhesive (LOCTITE
262 or equivalent)
3 Piston nut:
Boom cylinder:
422 ± 42.0 Nm {43 ± 4.3 kgm}
Arm cylinder:
618 ± 61.8 Nm {63 ± 6.3 kgm}
Bucket cylinder:
324 ± 32.5 Nm {33 ± 3.3 kgm}
Boom swing cylinder:
343 ± 34.0 Nm {35 ± 3.5 kgm}
3) Install piston ring (9) to piston (8). Blade cylinder:
4) Using tool U7, contract piston ring (9). 412 ± 41.0 Nm {42 ± 4.2 kgm}
5) Install wear ring (7). Variable gauge cylinder:
324 ± 32.5 Nm {33 ± 3.3 kgm}
50-500 32 PC18MR-3
Disassembly and assembly of hydraulic cylinder assembly SEN04624-00
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-3 50-500 33
SEN04624-00 Disassembly and assembly of hydraulic breaker assembly
Disassembly and assembly of hydraulic breaker assembly 1
50-500 34 PC18MR-3
Disassembly and assembly of hydraulic breaker assembly SEN04624-00
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-3 50-500 35
Special tools Disassembly of valve body assembly

1. Pull out control valve (13) from valve body
New/Remodel
(10).
Symbol
Necessity
Part No. Part name
2. Remove draw bolt (12).
Sketch
a Heat the draw bolt stud with a burner and
Q'ty
burn out the screw lock to remove.
1 796T-170-2420 Stand t 1 N Q
2 796T-170-2430 Shaft t 1 N Q Disassembly of cylinder assembly
3 796T-170-2440 Shaft t 1 N Q 1. Pull out inner tube (17) and piston (18) from
V 4 796T-170-2450 Shaft t 1 N Q the cylinder assembly.
5 796T-170-2460 Shaft t 1 N Q a Do not remove plug (14), spring (15) and
6 796-170-2160 Handle t 1 steel ball (16) from inner tube (17).
7 796-170-2170 Valve assembly t 1
2. Remove O-ring (19) from the cylinder assem-
bly.
Disassembly
a Work in a clean place free from dirt and dust. 3. Remove dust seal (24) and packing (23) from
a Erect the hydraulic breaker assembly on a stand cylinder assembly (21).
when disassembling it. a Stick a thin screwdriver or a needle into
a For each part, see the drawing on the previous the packing to remove.
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).
50-500 36 PC18MR-3
Disassembly of front end assembly Assembly

1. Chisel bushing a For each part, see the drawing on the previous
1) Set front end assembly (25) to tools V1 page.
and V2 and pull out bushings (31) and
(32) simultaneously, using the hydraulic Assembly of front end assembly
press. 1. Dust seal and bushing
a Hydraulic press capacity: 1) Using tool V4 and the hydraulic press, press
Min. 294 kN {30 ton} 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
chisel bushing (31) and inside of front
end assembly (25) and press fit slowly.
a Press fitting force: Min. 98 kN {10 ton}
2. Dust seal and bushing 2) Using tool V3 and the hydraulic press,
Push out dust seal (36) and bushing (37) with a press fit chisel bushing (32).
round bar 36 – 39 mm in diameter. a Apply lubricating oil to the outside of
chisel bushing (32) and inside of front
end assembly (25) and press fit slowly.
2 Lubricating oil: Engine oil (EO10-CD)
a Press fitting force: Min. 78 kN {8 ton}
PC18MR-3 50-500 37
Assembly of cylinder assembly Assembly of valve body

1. Install packing (23) and dust seal (24) to cylin- 1. Insert control valve (13) in valve body (10).
der assembly (21). a Check that the control valve is moved by
a Clean the packing and dust seal grooves. its weight.
2 Packing and dust seal grooves, packing
and dust seal: Engine oil (EO10-CD) 2. Install draw bolt (12).
a Using a screwdriver, the corners of which a Clean and degrease the threaded parts of
are rounded off, install the packing and valve body (10) and draw bolt (12).
dust seal in the directions shown in the fig- a Install the shorter threaded part of draw
ure, while preventing twist, etc. bolt (12).
a Take care not to damage the packing lip. 2 Draw bolt:
a Use a new packing and a new dust seal. Adhesive (THREEBOND 1303B)
3 Draw bolt: 150 ± 15 Nm {15 ± 1.5 kgm}
2. If plug (22) was removed, tighten it to the fol-
lowing torque. 3. If plug (11) was removed, tighten it to the fol-
3 Plug: 58.8 Nm {6 kgm} lowing torque.
3 Plug: 30 Nm {3 kgm}
3. Install O-ring (19) to the groove of cylinder
(21). Assembly of accumulator
1. Grip shell (6) in vise [1].
2. Fit diaphragm (5) to cover (4).

a Press around the diaphragm until its lip is
fitted perfectly to the groove of the cover.
2 Inside of shell (6) and outside of dia-
phragm (5): Engine oil (EO10-CD)
2 Threaded part of shell: Red lead
3. Using tool V6, tighten cover (4).

a Taking care of the threaded parts of the
shell and cover, tighten the cover slowly
until it becomes almost flush with the
shell.
4. Insert piston (18) in cylinder assembly (21). 3 Cover: 206 ± 9.8 Nm {21.0 ± 1.0 kgm}
2 Outside of piston:
Engine oil (EO10-CD)
5. Insert inner tube (17) in cylinder assembly

(21).
4. Tighten washer (3) and cap bolt (2) tempo-

rarily.
a Tighten these parts permanently after
charging the accumulator with gas.
5. Install backup ring (7) and O-ring (8) to accu-

mulator assembly (6).
6. Install cap (1) fitted with O-ring (35).
50-500 38 PC18MR-3
Assembly of breaker unit

1. Set front end assembly (25) on the stand and
insert cylinder assembly (21) in the front end
assembly.
a Set the cylinder assembly so that the
dowel pin (20) will be positioned as shown
in the following figure.
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
assembly to the valve body assembly.
2 O-ring (8): Engine oil (EO10-CD)
3 Mounting bolt: 98.1 Nm {10 kgm}
PC18MR-3 50-500 39
Charging accumulator with gas

1. Preparation for charging
1) Remove cap (1) from the top of accumula-
tor assembly (6).
2) Fit tool V7 to a screw provided on the
accumulator upper surface.
3) Connect the valve of nitrogen gas cylinder
(F) to tool V7 by gas supply rubber hose
(B).
4) Close escape valve (C) of tool V7.
2. Charging
1) Check that cap bolt (2) of the accumulator
is tightened. Turn the valve of nitrogen
gas cylinder (F) counterclockwise to open
the gas cylinder and check with pressure
gauge (D) that the nitrogen gas pressure
is higher than 5.9 MPa {60 kg/cm 2 }.
Immediately after checking, turn handle
(E) clockwise to close the gas cylinder.
2) Under this condition, check for gas leak-
age with pressure gauge (D).
3) While watching pressure gauge (D), turn
handle (E) of tool V7 counterclockwise
slowly, and the supply hole of the accumu-
lator opens and the pressure gauge indi-
cation lowers. Stop turning handle (E) at
this time.
4) While watching pressure gauge (D), turn
the valve of nitrogen gas cylinder (F)
counterclockwise to open. Open and
close the valve until the pressure gauge
indicates 5.4 MPa {55 kg/cm2}.
5) When the pressure gauge indicates the
above pressure, close the valve of nitro-
gen 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 dis-
charge the gas in the rubber hose into the
atmosphere.
9) After pressure gauge (D) indication low-
ers, remove tool V7.
10) Install the accumulator protection nut.
50-500 40 PC18MR-3
PC18MR-3 50-500 41
SEN04624-00

©2008 KOMATSU
All Rights Reserved
50-500 42
SEN04625-00
HYDRAULIC EXCAVATOR
PC18MR-3


600 Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC18MR-3 50-600 1
600 Work equipment
SEN04625-00 Removal and installation of work equipment assembly
Removal and installation of work 4. Remove cover (8).

equipment assembly 1
k Release the residual hydraulic pressure

from the hydraulic circuit. For details, see
“Releasing residual pressure from hydrau-
lic circuit”.
k Extract the boom cylinder and bucket cylin-
der to the stroke end and lower the work
equipment to the ground.
k Set the lock lever in the lock position.
Removal
“Removal and installation of radiator assem- 5. Sling boom cylinder (9) temporarily and
bly”. remove plates (10) and pin (11). [*1]
a Lower boom cylinder onto stand [1].
2. Disconnect 6 hoses (1) – (6).
a (3) and (5) are for the boom cylinder.
a The hoses are labeled.
6. Sling work equipment assembly (12) tempo-

rarily.
3. Disconnect connector (7).
50-600 2 PC18MR-3
600 Work equipment
Removal and installation of work equipment assembly SEN04625-00
7. Remove plate (13) and boom foot pin (14). [*2] Installation
removal.
[*1]
2 Pin and sliding surface on boom side:
Molybdenum disulfide lubricant (LM-P)
[*2]
8. Lift off work equipment assembly (12). 2 Pin and sliding surface on swing bracket
side: Molybdenum disulfide lubricant
4 Work equipment assembly: 150 kg
(LM-P)

level again.
q Bleeding air
PC18MR-3 50-600 3
SEN04625-00

©2008 KOMATSU
All Rights Reserved
50-600 4
SEN04626-00
HYDRAULIC EXCAVATOR
PC18MR-3


Removal and installation of canopy ................................................................................................................ 2
PC18MR-3 50-700 1
SEN04626-00 Removal and installation of canopy

canopy 1 q Carry out of installation in the reverse order to
removal.
Removal
bly”.

4 Roof: 17 kg
3. Lift off canopy pole (2). [*1]

4 Canopy pole: 50 kg
4 Canopy: 68 kg
50-700 2 PC18MR-3
Removal and installation of canopy SEN04626-00
PC18MR-3 50-700 3
SEN04626-00

©2008 KOMATSU
All Rights Reserved
50-700 4
SEN04627-00
HYDRAULIC EXCAVATOR
PC18MR-3


Removal and installation of KOMTRAX terminal ............................................................................................ 2
PC18MR-3 50-800 1
SEN04627-00 Removal and installation of KOMTRAX terminal

KOMTRAX terminal 1 q Carry out installation in the reverse order to
removal.
Removal
1. Turn the starting switch to the OFF position.
2. Remove the cover, garnish, etc. to expose

3. Remove the cab wiring harness from

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

and GPS antenna cable from KOMTRAX ter-
minal (1).
5. Remove all mounting bolts (2) and washers (3)

of the KOMTRAX terminal.
Reference: The mounting bolt size is M8.
6. Remove KOMTRAX terminal (1) from bracket.

a When handling the KOMTRAX terminal,
take care not to give an impact on it.
(Never hit it against another part or drop
it.)
50-800 2 PC18MR-3
Removal and installation of KOMTRAX terminal SEN04627-00
PC18MR-3 50-800 3
SEN04627-00

©2008 KOMATSU
All Rights Reserved
50-800 4
SEN04327-00
HYDRAULIC EXCAVATOR
PC18MR-3

90 Diagrams and drawings 1

100 Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
PC18MR-3 90-100 1
SEN04327-00
90-100 2 PC18MR-3
Hydraulic circuit diagram
Hydraulic circuit diagram PC18MR-3
PC18MR-3
SEN04327-00
PC18MR-3
90-100 3
SEN04327-00
PC18MR-3 90-100 5
SEN04327-00

©2008 KOMATSU
All Rights Reserved
90-100 6
SEN04328-01
HYDRAULIC EXCAVATOR
PC18MR-3

90 Diagrams and drawings 1

200 Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
Connector list and stereogram........................................................................................................................ 5
PC18MR-3 90-200 1
SEN04328-01
90-200 2 PC18MR-3
Electrical circuit diagram
Electrical circuit diagram PC18MR-3
SEN04328-01
PC18MR-3
90-200 3
Connector list and stereogram
Connector list and stereogram PC18MR-3
Connector Number Address of

Model Component name
No. of pins stereogram
A3 X 2 Rotary lamp for swing pressure switch —
(Revolution left) (If equipped)
A4 X 2 Rotary lamp for swing pressure switch —

(Revolution right) (If equipped)
A5 DT 2 Travel alarm for domestic (STD) —
A6 X 2 Travel pressure switch (STD) —
C1 AMP 18 KOMTRAX controller A-5
C2 AMP 12 KOMTRAX controller A-5
C3 — 2 Diode A-5
C4 Relay 5 Relay for KOMTRAX D-5
C5 X 1 Intermediate connector (For KOMTRAX) B-5
C6 X 1 Intermediate connector (For KOMTRAX) B-4
D2 — 2 Diode C-3
D3 — 2 Diode K-1
F1 VCH 6 Blade variable gauge change switch M-7
F2 DT 2 PPC lock switch (Left) M-8
F3 DT 2 Intermediate connector (Spare) K-9
F4 DT 2 Rotary lamp K-9
F5 YAZAKI 2 Horn switch J-9
F6 DT 2 PPC lock switch (Right) I-8
F7 AMP 20 Machine monitor I-9
F8 M 2 Buzzer I-9
F9 KES 4 Light switch M-8
F10 DT 2 Auto-accel switch J-9
F13 YAZAKI 4 Timer for engine stop solenoid B-5
F17 DT-T 3 Resistor H-8
FB1 — — Fuse box C-6
M1 YAZAKI 2 Horn H-1
M2 — 2 Fusible link (45A) M-7
M3 YAZAKI 1 Starting motor (ST terminal) M-7
M4 DT 3 Engine stop solenoid L-9
M5 YAZAKI 2 Fuel pump H-8
M6 DT 2 Engine coolant temperature sensor L-9
M7 SUMITOMO 3 Alternator (L, IG, P terminal) L-9
M8 — 3 Fuel level sensor M-5
M9 DT 2 PPC lock solenoid valve H-8
M10 DT 2 Travel speed acceleration solenoid valve H-8
Intermediate connector
M11 DT 2 (For variable gauge change solenoid) —
M12 X 4 Intermediate connector (Spare) I-1

M13 DT 2 Connector (If equipped) —
M14 — 2 Variable gauge change solenoid valve J-1
Additional outer power source socket (+)
P1 — 1 —
(EU STD)
Additional outer power source socket (–)
P2 — 1 —
(EU STD)
R1 Relay 5 Relay for engine start circuit C-6
R2 Relay 5 Relay for PPC lock solenoid C-5
R3 Relay 5 Relay for acceleration solenoid C-6
R4 YAZAKI 4 Engine safety relay D-6
R5 YAZAKI 4 Engine stop solenoid relay C-4
R6 Relay 5 Relay for drive (If equipped) —
T-F1 Terminal 1 Starting switch (B terminal) C-8
F-F2 Terminal 1 Starting switch (BR terminal) C-7
F-F3 Terminal 1 Starting switch (ACC terminal) B-8
F-F4 Terminal 1 Starting switch (C terminal) B-8
F-F5 Terminal 1 Starting switch (R1 terminal) C-8
F-F6 Terminal 1 Starting switch (R2 terminal) C-7
T-M1 Terminal 1 Battery M-6
T-M2 Terminal 1 Starting motor (B Terminal) M-7
T-M3 Terminal 1 Engine pressure switch L-9
T-M4 Terminal 1 Alternator (B terminal) I-8
T-M5 Terminal 1 Glow plug M-8
T-M6 Terminal 1 Revolving frame earth H-1
W1 DT 2 Intermediate connector (For work lamp) J-1
W2 DT 3 Work lamp E-6
W3 DT 3 Additional work lamp H-1
SEN04328-01
PC18MR-3
90-200 5
SEN04328-01
PC18MR-3 90-200 7
SEN04328-01

©2008 KOMATSU
All Rights Reserved
90-200 8

PC18MR3

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SEN04306-02

Machine model Serial number

00 Index and foreword 00

Composition of shop manual .......................................................................................................................... 2

Composition of shop manual 1

Section Title..................................................................................................................................... Form Number

00 Index and foreword .................................................................................................................... SEN04307-02

01 Specification ............................................................................................................................... SEN04310-00

10 Structure, function and maintenance standard........................................................................... SEN04312-00

20 Standard value table................................................................................................................... SEN04322-00

30 Testing and adjusting ................................................................................................................. SEN04323-00

50 Disassembly and assembly........................................................................................................ SEN04325-00

400 Undercarriage and frame ...................................................................................................SEN04623-00 Q

90 Diagrams and drawings..............................................................................................................SEN04326-01

200 Foreword and general information SEN04309-00

10 Structure, function and maintenance standard

430 Hydraulic system, Part 3 SEN04318-00

20 Standard value table

30 Testing and adjusting

H-30 Troubleshooting for hydraulic breaker .................................................................................................. 29

50 Disassembly and assembly

90 Diagrams and drawings

PC18MR-3 Hydraulic excavator

Machine model Serial number

00 Index and foreword 00

200 Foreword and general information

Safety notice (Rev. 2008/02)1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the