Komatsu PC18MR-3 Manual

HYDRAULIC
EXCAVATOR
TEN00549-00
PC18MR
-3
SERIAL NUMBERS
21114
and up
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
NOTICE
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
WARNING

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FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved
in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in
the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:
Pocket on inside of cover of toolbox under operator's seat
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FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous
condition is displayed inside a triangle and the method of avoiding
the hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1J(1))
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FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Leveling work
Ditching work
Loading work
Demolition work
See the section "WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR (PAGE 3-70)" for further
details.
DIRECTIONS OF MACHINE
(A)
(B)
(C)
(D)
Front
Rear
Left
Right
(E)
(F)
Operator's seat
Sprocket
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front and the sprocket (F) is at the rear of the machine.
PROTECTIVE STRUCTURE
This machine is ROPS compliant to ISO12117-2:2008 when a ROPS plate is installed - see "LOCATION OF
SAFETY LABELS (PAGE 2-4)" for location of ROPS plate.
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FOREWORD
PRODUCT INFORMATION
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
On the right front of the frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
This is fixed to the engine.
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FOREWORD
PRODUCT INFORMATION
EPA NAMEPLATE
This is stuck on the counterweight.
EPA: Environmental Protection Agency, U.S.A.
SERVICE METER LOCATION
On top of the machine monitor
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FOREWORD
PRODUCT INFORMATION
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 5
DIRECTIONS OF MACHINE 1- 5
PROTECTIVE STRUCTURE 1- 5
PRODUCT INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1- 6
EPA NAMEPLATE 1- 7
SERVICE METER LOCATION 1- 7
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 8
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 4
SAFETY LABELS 2- 5
GENERAL PRECAUTIONS 2- 10
SAFETY MACHINE OPERATION 2- 19
STARTING ENGINE 2- 19
OPERATION 2- 21
TRANSPORTATION 2- 27
BATTERY 2- 28
TOWING 2- 30
LIFTING OBJECTS WITH BUCKET 2- 31
SAFETY MAINTENANCE INFORMATION 2- 32
OPERATION 3- 1
MACHINE VIEW ILLUSTRATIONS 3- 2
OVERALL MACHINE VIEW 3- 2
CONTROLS AND GAUGES 3- 3
DETAILED CONTROLS AND GAUGES 3- 4
MONITORING SYSTEM 3- 4
SWITCHES 3- 10
CONTROL LEVERS AND PEDALS 3- 13
COVER WITH LOCK 3- 19
ENGINE REAR COVER 3- 20
COOLING COVER 3- 21
BATTERY COVER 3- 22
METHOD OF OPENING (TILTING) FLOOR 3- 23
AUXILIARY ELECTRIC POWER 3- 27
FUSE 3- 27
BLOCK FUSE 3- 28
OPERATION MANUAL STORAGE 3- 28
TOOL BOX 3- 29
HANDLING MACHINES EQUIPPED WITH KOMTRAX 3- 30
MACHINE OPERATIONS AND CONTROLS 3- 31
BEFORE STARTING ENGINE 3- 31
STARTING ENGINE 3- 44
AFTER STARTING ENGINE 3- 48
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FOREWORD
CONTENTS
STOPPING THE ENGINE 3- 51
MACHINE OPERATION 3- 52
STEERING THE MACHINE 3- 57
SWINGING 3- 59
WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 60
PROHIBITED OPERATIONS 3- 63
GENERAL OPERATION INFORMATION 3- 65
TRAVELING ON SLOPES 3- 67
ESCAPE FROM MUD 3- 69
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR 3- 70
BUCKET REPLACEMENT 3- 72
PARKING MACHINE 3- 73
MACHINE INSPECTION AFTER DAILY WORK 3- 74
LOCKING 3- 75
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY) 3- 76
TRANSPORTATION 3- 81
TRANSPORTATION PROCEDURE 3- 81
LOADING AND UNLOADING WITH TRAILER 3- 82
LIFTING MACHINE 3- 88
COLD WEATHER OPERATION 3- 91
COLD WEATHER OPERATION INFORMATION 3- 91
AFTER DAILY WORK COMPLETION 3- 93
AFTER COLD WEATHER SEASON 3- 93
LONG TERM STORAGE 3- 94
BEFORE STORAGE 3- 94
DURING STORAGE 3- 94
AFTER STORAGE 3- 94
TROUBLES AND ACTIONS 3- 95
RUNNING OUT OF FUEL 3- 95
PHENOMENA THAT ARE NOT FAILURES 3- 95
TOWING THE MACHINE 3- 96
SEVERE JOB CONDITION 3- 96
DISCHARGED BATTERY 3- 97
OTHER TROUBLE 3-101
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
ELECTRIC SYSTEM MAINTENANCE 4- 7
HANDLING HYDRAULIC SYSTEM 4- 8
WEAR PARTS 4- 9
WEAR PARTS LIST 4- 9
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10
TIGHTENING TORQUE SPECIFICATIONS 4- 12
TIGHTENING TORQUE LIST 4- 12
SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS LIST 4- 13
MAINTENANCE SCHEDULE 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 15
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FOREWORD
CONTENTS
MAINTENANCE PROCEDURE 4- 16
WHEN REQUIRED 4- 16
CHECK BEFORE STARTING 4- 38
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE 4- 38
EVERY 500 HOURS MAINTENANCE 4- 39
EVERY 1000 HOURS MAINTENANCE 4- 47
EVERY 1500 HOURS MAINTENANCE 4- 50
EVERY 2000 HOURS MAINTENANCE 4- 51
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION 6- 2
SAFETY FIRST 6- 2
ATTACHMENT INSTALLATION 6- 3
BUCKET WITH HOOK 6- 4
HOOK CONDITION 6- 4
PROHIBITED OPERATIONS 6- 4
MACHINE READY FOR ATTACHMENT 6- 5
LOCATIONS 6- 5
HYDRAULIC CIRCUIT 6- 8
ATTACHMENT OPERATIONS 6- 9
LONG TERM STORAGE 6- 10
SPECIFICATIONS 6- 10
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) 6- 11
CONTROL PATTERN CHANGE PROCEDURE 6- 11
MACHINE CONTROL PATTERNS 6- 12
ATTACHMENT GUIDE 6- 13
ATTACHMENT COMBINATIONS 6- 13
HANDLING ARM WITH BUILT-IN BREAKER 6- 14
REMOVING AND INSTALLING CHISEL 6- 14
PROCEDURE FOR BREAKER OPERATIONS 6- 17
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS 6- 18
INSTALLATION OF BUCKET 6- 19
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS 6- 21
STOWING CHISEL, DUMMY CHISEL 6- 21
CHECK BEFORE STARTING 6- 22
SPECIFICATIONS 6- 23
RECOMMENDED ATTACHMENT OPERATIONS 6- 24
HYDRAULIC BREAKER 6- 24
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 4
SAFETY LABELS 2- 5
SAFETY INFORMATION 2- 10
Safety Rules 2- 10
If Problems are Found 2- 10
Working Wear and Personal Protective Items 2- 10
Fire Extinguisher and First Aid Kit 2- 10
Safety Equipment 2- 11
Keep Machine Clean 2- 11
Keep Operator's Compartment Clean 2- 11
Leaving Operator's Seat with Lock 2- 11
Handrails and Steps 2- 12
Mounting and Dismounting 2- 12
No Persons on Attachments 2- 12
Burn Prevention 2- 13
Fire Prevention and Explosion Prevention 2- 13
Action if Fire Occurs 2- 14
Falling Objects, Flying Objects and Intruding Objects Prevention 2- 15
Cautions Related to ROPS (Rollover Protection System) 2- 14
Attachment Installation 2- 16
Attachment Combinations 2- 16
Unauthorized Modifications 2- 16
Safety at Jobsite 2- 16
Working on Loose Ground 2- 16
Distance to High Voltage Cables 2- 17
Ensure Good Visibility 2- 17
Ventilation for Enclosed Area 2- 17
Signalman's Signal and Signs 2- 18
Asbestos Dust Hazard Prevention 2- 18
SAFETY MACHINE OPERATION 2- 19
STARTING ENGINE 2- 19
Checks Before Starting Engine 2- 19
Safety Rules for Starting Engine 2- 20
Starting Engine in Cold Weather 2- 20
OPERATION 2- 21
Checks Before Operation 2- 21
Safety Rules for Changing Machine Directions 2- 21
Safety Rules for Traveling 2- 22
Traveling on Slopes 2- 23
Operations on Slopes 2- 24
Prohibited Operations 2- 24
Operations on Snow 2- 26
Parking Machine 2- 26
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SAFETY
SAFETY
TRANSPORTATION 2- 27
Loading and Unloading 2- 27
Shipping the Machine 2- 27
BATTERY 2- 28
Battery Hazard Prevention 2- 28
Starting Engine with Booster Cables 2- 29
TOWING 2- 30
Safety Rules for Towing 2- 30
LIFTING OBJECTS WITH BUCKET 2- 31
Safety Rules for Lifting Objects 2- 31
SAFETY MAINTENANCE INFORMATION 2- 32
Warning Tag 2- 32
Keep Work Place Clean and Tidy 2- 32
Appoint Leader when Working with Others 2- 32
Stop Engine Before Carrying Out Maintenance 2- 33
Cautions for Opening (Tilting) Floor 2- 34
Two Workers for Maintenance when Engine is Running 2- 35
Proper Tools 2- 35
Personnel 2- 36
Attachments 2- 36
Work Under the Machine 2- 36
Noise 2- 36
When Using Hammer 2- 36
Welding Works 2- 37
Removing Battery Terminals 2- 37
Safety First when Using High-pressure Grease to Adjust Track Tension 2- 37
Do not Disassemble Recoil Springs 2- 37
Safety Rules for High-pressure Oil 2- 37
Safety Handling High-pressure Hoses 2- 39
Waste Materials 2- 39
Compressed Air 2- 39
Periodic Replacement of Safety Critical Parts 2- 39
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
LOCATION OF SAFETY LABELS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Caution before operating or maintaining machine
(09651-03001)
(2) Caution for before operation (22L-98-22160)
(3) Caution for leaving operator's seat (09654-03001)
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SAFETY
SAFETY LABELS
SAFETY
SAFETY LABELS
(4) Caution for going close to electric cables (09801-03001)
(5) Caution for operating pattern (22J-98-1A631)
(6) Caution for high-temperature coolant (20M-98-83250)
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SAFETY
SAFETY LABELS
SAFETY
SAFETY LABELS
(7) Caution for high-temperature hydraulic oil (22L-98-22240)
(8) Caution for handling electric wires (09808-03000)
(9) Caution for check and adjust track tention (09657-03003)
(10) Caution when opening while engine is running (09667-03001)
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