Komatsu Hydraulic Excavator PC118MR Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC118MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC118MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

WEBM008700 - Hydraulic Excavator PC118MR-8 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 872 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

00 Index and foreword...3
  Table of contents...4
  Foreword and general information...12
    Safety notice...12
    How to read the shop manual...17
    Explanation of terms for maintenance standard...19
    Handling of hydraulic components...21
    Method of disconnecting and connecting push-pull type coupler...23
    Handling of electric equipment...26
    How to read electric wire code...36
    Precautions when performing work...39
    Standard tightening torque table...42
    List of abbreviation...46
    Conversion table...50
  Shop Manual...55
01 Specification...55
  Contents...56
  Specifications...57
    Specifications drawing...57
    Specifications...60
    Table of weight...63
    Table of fuel, coolant and lubricants...65
  Shop Manual...67
10 Structure and function...67
  Contents...68
  Engine and cooling system...70
    Engine mount...70
    PTO...71
    Cooling system...72
  Power train...74
    Power train...74
    Swing circle...75
    Swing machinery...76
  Undercarriage and frame...77
    Track frame...77
    Idler and recoil spring...78
    Carrier roller...79
    Track roller...80
    Track shoe...81
  Hydraulic system...82
    Hydraulic equipment layout drawing...82
    Valve control...83
    Hydraulic tank and filter...84
    Hydraulic pump...86
    Blade specification...86
    Control valve...98
    Outline...98
    11-spool valve...99
    CLSS...110
    Outline of CLSS...110
    Basic principle...111
    Function and operation by valve...114
    Hydraulic circuit diagram and name of valves...114
    1. Unload valve...116
    2. Introduction of LS pressure...119
    3. LS bypass plug...121
    4. Pressure compensation valve...122
    5. Surface area ratio of pressure compensation valve...123
    6. Right and left travel junction circuit...124
    7. Travel LS bypass circuit...126
    8. Boom regeneration circuit...128
    PPC valve...131
    Work equipment and swing PPC valve...131
    Travel PPC valve...137
    Blade and boom swing PPC valve...140
    Swing motor...142
    Safety valve with suction...144
    Operation of the modulating relief valve...145
    Operation of swing brake...146
    Actuation of hydraulic timer valve...147
    Travel motor...148
    Center swivel joint...150
    Solenoid valve...151
    Attachment oil flow adjuster EPC valve...152
    PPC accumulator...156
    For PPC circuit...156
    Anti-drop valve...157
  Work equipment...163
    Work equipment...163
    Dimensions of components...166
    1,850 mm arm...166
    2,000 mm arm...168
    2,300 mm arm...170
    Bucket...172
    Work equipment cylinder...174
    Boom cylinder...174
    2-piece boom cylinder...174
    Arm cylinder...174
    Bucket cylinder...175
    Boom swing cylinder...175
    Blade cylinder...175
  Cab and its attachments...178
    Air conditioner...178
    Air conditioner piping diagram...178
    Air conditioner unit...182
    Air conditioner controller...185
    Compressor...186
    Condenser...187
    Sensor...188
  Electrical system...189
    Electrical control system...189
    Machine control system diagram...189
    Engine control function...191
    Engine and pump mutual control function...193
    Auto-deceleration function...197
    Engine automatic warm-up function...199
    Swing control function...203
    Travel control function...205
    PPC lock function...207
    Oil flow adjuster function for attachment...208
    System components...210
    Monitor system...219
    Machine monitor...220
    Display...222
    Switches...226
    Operator mode function...230
    Service mode function...232
    KOMTRAX system...233
    Sensor...236
    Atmospheric pressure sensor...236
    Boost pressure and temperature sensor...236
    Coolant temperature sensor...237
    Crankshaft speed sensor...237
    Common rail pressure sensor...238
    Hydraulic oil temperature sensor...238
    Fuel level sensor...239
    Pump oil pressure sensor...240
    PPC oil pressure sensor...241
  Shop Manual...243
20 Standard value table...243
  Contents...244
  Standard value table...245
    Standard value table for engine...245
    Standard value table for chassis...246
30 Testing and adjusting...255
  Contents...256
  Testing and adjusting...257
    Testing engine speed...257
    Testing exhaust temperature...258
    Checking exhaust gas colour...259
    Adjusting valve clearance...260
    Testing compression pressure...262
    Testing blow-by pressure...264
    Testing engine oil pressure...265
    Handling fuel system parts...266
    Releasing residual pressure from fuel system...266
    Testing fuel pressure...267
    Testing fuel return rate and fuel leakage...268
    Bleeding air from fuel circuit...270
    Checking fuel circuit for leakage...272
    Testing and adjusting alternator belt tension...273
    Testing...273
    Adjusting...273
    Measuring the swing circle axial clearance...274
    Testing and adjusting track-shoe tension...275
    Checking and regulating pressure in the hydraulic circuits...276
    Testing and adjusting oil pressure in work equipment and travel circuits...277
    Testing and adjusting swing and blade circuit oil pressure...279
    Testing control circuit basic pressure...281
    Testing and adjusting oil pressure in pump PC control circuit...282
    Testing LS differential pressure and adjusting LS valve...284
    Testing solenoid valve output pressure...286
    Testing main pump flow rate...289
    Checking parts which cause hydraulic drift of work equipment...290
    Measuring travel deviation...292
    Adjusting the maximum speed of the travel motors...293
    Releasing residual pressure from hydraulic circuit...294
    Testing oil leakage...295
    Air bleeding from hydraulic circuits...298
    Order for operations...298
    Special functions of machine monitor...300
    Handling voltage circuit of engine controller...349
    Preparation work for troubleshooting of electrical system...350
    Procedure for testing diodes...355
    Pm Clinic service...356
40 Troubleshooting...361
  Contents...362
  Failure code table and fuse locations...366
    Failure code table...366
    Fuse locations...369
  General information on troubleshooting...371
    Points to remember when troubleshooting...371
    Sequence of events in troubleshooting...372
    Checks before troubleshooting...373
    Classification and procedures for troubleshooting...374
    Information in troubleshooting table...375
    Phenomena looking like troubles and troubleshooting Nos...377
    Connection table for connector pin numbers...380
    T- branch box and T- branch adapter table...416
  Troubleshooting by failure code...419
    Failure code [989L00] Engine controller lock caution 1...419
    Failure code [989M00] Engine controller lock caution 2...420
    Failure code [989N00] Engine controller lock caution 3...421
    Failure code [AB00KE] Charge voltage low...422
    Failure code [B@BAZG] Eng oil press. low...424
    Failure code [B@BCNS] Eng coolant overheat...425
    Failure code [B@HANS] Hyd. oil overheat...426
    Failure code [CA111] ECM critical internal failure...427
    Failure code [CA115] Eng. Ne and Bkup speed sensor error...430
    Failure code [CA122] Charge air press sensor high error...431
    Failure code [CA123] Charge air press sensor low error...433
    Failure code [CA131] Throttle sensor high error...434
    Failure code [CA132] Throttle sensor low error...436
    Failure code [CA144] Coolant temp. sensor high error...438
    Failure code [CA145] Coolant temp. sensor low error...440
    Failure code [CA153] Charge air temp. sensor high error...442
    Failure code [CA154] Charge air temp. sensor low error...444
    Failure code [CA155] Charge air temperature high speed derate...445
    Failure code [CA187] Sensor sup. 2 volt. low error...446
    Failure code [CA221] Ambient air press. sensor high error...448
    Failure code [CA222] Ambient air press. sensor low error...450
    Failure code [CA234] Eng. overspeed...451
    Failure code [CA238] Ne speed sensor sup. volt. error...452
    Failure code [CA271] IMV/PCV1 short error...454
    Failure code [CA272] IMV/PCV1 open error...455
    Failure code [CA322] Injector #1 (L #1) system open/short error...456
    Failure code [CA324] Injector #3 (L #3) system open/short error...458
    Failure code [CA331] Injector #2 (L #2) system open/short error...460
    Failure code [CA332] Injector #4 (L #4) system open/short error...462
    Failure code [CA342] Calibration code incompatibility...464
    Failure code [CA351] Inj. drive circuit error...465
    Failure code [CA352] Sensor sup. 1 volt. low error...468
    Failure code [CA386] Sensor sup. 1 volt. high error...470
    Failure code [CA435] Abnormality in engine oil pressure switch...472
    Failure code [CA441] Battery voltage low error...473
    Failure code [CA442] Battery voltage high error...474
    Failure code [CA449] Rail press. very high error...475
    Failure code [CA451] Rail press. sensor high error...476
    Failure code [CA488] Charge air temperature high torque derate...478
    Failure code [CA452] Rail press. sensor low error...479
    Failure code [CA553] Rail press. high error...480
    Failure code [CA559] Rail press. low error...481
    Failure code [CA689] Eng. Ne speed sensor error...484
    Failure code [CA731] Eng. Bkup speed sensor phase error...486
    Failure code [CA757] All persistent data lost error...487
    Failure code [CA778] Eng. Bkup speed sensor error...488
    Failure code [CA1633] KOMNET datalink timeout error...490
    Failure code [CA2185] Throttle sens. sup. volt. high error...492
    Failure code [CA2186] Throttle sens. sup. volt. low error...494
    Failure code [CA2249] Rail press. very low error...495
    Failure code [CA2311] Abnormality in IMV solenoid...496
    Failure code [D110KB] Battery relay drive short...498
    Failure code [D19JKZ] Personal code relay abnormality...500
    Failure code [D862KA] GPS antenna discon...502
    Failure code [DA22KK] Pump solenoid power low error...504
    Failure code [DA25KP] 5 V sensor 1 power abnormality...507
    Failure code [DA26KP] 5 V sensor 2 power abnormality...510
    Failure code [DA2RMC] CAN discon (Pump controller detected)...512
    Failure code [DAF8KB] Camera Power Supply Short Circuit...514
    Failure code [DAFGMC] GPS module error...516
    Failure code [DAFRMC] CAN discon (Monitor detected)...518
    Failure code [DFB1KZ] Service lever pot. 1 abnormality...520
    Failure code [DFB2KZ] Service lever pot. 2 abnormality...522
    Failure code [DFB3L8] Service lever1 potentio error...524
    Failure code [DFB4L8] Service lever2 potentio error...526
    Failure code [DFB5KZ] Service lever sPot. 1 abnormality...528
    Failure code [DFB6KZ] Service lever sPot. 2 abnormality...530
    Failure code [DGH2KB] Hydr oil sensor short...532
    Failure code [DHPAMA] Pump press sensor abnormality...534
    Failure code [DHS5KX] Travel PPC sensor abnormality...536
    Failure code [DHX1MA] Overload sensor abnormality...538
    Failure code [DV20KB] Travel alarm short circuit...539
    Failure code [DW43KA] Travel speed sol discon...540
    Failure code [DW43KB] Travel speed sol short...541
    Failure code [DW45KA] Swing brake sol discon...542
    Failure code [DW45KB] Swing brake sol short...544
    Failure code [DXA8KA] PC-EPC sol discon...546
    Failure code [DXA8KB] PC-EPC sol short...548
    Failure code [DXE7KA] Service current EPC2 open circuit...550
    Failure code [DXE7KB] Service current EPC2 short circuit...552
    Failure code [DXE8KA] Service current EPC3 open circuit...554
    Failure code [DXE8KB] Service current EPC3 short circuit...556
    Failure code [DXE9KA] Service current EPC4 open circuit...558
    Failure code [DXE9KB] Service current EPC4 short circuit...560
    Failure code [DXEAKA] Service current EPC1 open circuit...562
    Failure code [DXEAKB] Service current EPC1 short circuit...564
    Failure code [DY20KA] Wiper working abnormality...566
    Failure code [DY20MA] Wiper parking abnormality...568
    Failure code [DY2CKA] Washer drive open circuit...570
    Failure code [DY2CKB] Washer drive short circuit...572
    Failure code [DY2DKB] Wiper drive (fwd) short circuit...574
    Failure code [DY2EKB] Wiper drive (rev) short circuit...576
  Troubleshooting of electrical system...579
    Before carrying out troubleshooting of electrical system...579
    Information in troubleshooting table...581
    E-1 When starting switch is turned ON, machine monitor displays nothing...582
    E-2 Engine does not start (Engine does not turn)...585
    E-3 Preheater does not operate...588
    E-4 Automatic warm-up system does not operate (in cold season)...590
    E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked...591
    E-6 Precaution lights up while engine is running...594
    E-7 Emergency stop item lights up while engine is running...597
    E-8 Engine coolant temperature gauge does not indicate normally...598
    E-9 Hydraulic oil temperature gauge does not indicate normally...600
    E-10 Fuel level gauge does not indicate normally...603
    E-11 Contents of display by machine monitor are different from applicable machine...605
    E-12 Machine monitor does not display some items...606
    E-13 Function switch does not work...607
    E-14 Auto-decelerator does not operate normally...608
    E-15 Working mode does not change...609
    E-16 Travel speed does not change...610
    E-17 Alarm buzzer cannot be stopped...611
    E-18 Windshield wiper and window washer do not operate...612
    E-19 Swing holding brake does not operate normally...616
    E-20 Travel alarm does not sound or does not stop sounding...618
    E-21 Air conditioner does not operate normally (including air conditioner abnormality record)...619
    E-22 While starting switch is in OFF position, service meter is not displayed...632
    E-23 Machine monitor cannot be set in service mode...633
    E-24 Monitoring function does not display lever control signal normally...634
    E-25 KOMTRAX system does not operate normally...658
  Troubleshooting of hydraulic and mechanical system (H-mode)...659
    Information contained in troubleshooting table...659
    H-1 Speed or power of all work equipment, swing, and travel are low...660
    H-2 Engine speed sharply drops or engine stalls...661
    H-3 No work equipment, travel and swing move...662
    H-4 Abnormal noise is heard from around hydraulic pump...663
    H-5 Fine control performance or response of work equipment and travel is low...664
    H-6 Speed or power of boom is low...665
    H-7 Speed or power of arm is low...666
    H-8 Speed or power of bucket is low...667
    H-9 Speed or power of boom swing is low...668
    H-10 Speed or power of blade is low...669
    H-11 Work equipment does not move in its single operation...670
    H-12 Hydraulic drift of work equipment is large...671
    H-13 Time lag of work equipment is large...673
    H-14 Work equipment loaded more is slower during compound operation...674
    H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE...675
    H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel...676
    H-17 Machine deviates during travel...677
    H-18 Travel speed is low...678
    H-19 Machine cannot be steered easily or steering power is low...679
    H-20 Travel speed does not change or it is kept low or high...680
    H-21 Track does not move (only either side)...681
    H-22 Machine does not swing...682
    H-23 Swing acceleration, swing speed and swing power are low...683
    H-24 Excessive overrun when stopping swing...685
    H-25 When upper structure stops swinging, it makes large shock...686
    H-26 When upper structure stops swinging, it makes large sound...687
    H-27 Hydraulic drift of swing is large...688
    H-28 Flow rate in attachment circuit cannot be adjusted...689
  Troubleshooting of engine (S-mode)...690
    Method of using troubleshooting chart...690
    S-1 Starting performance is poor...694
    S-2 Engine does not start...695
    S-3 Engine does not pick up smoothly...698
    S-4 Engine stops during operations...699
    S-5 Engine does not rotate smoothly...700
    S-6 Engine lacks output (or lacks power)...701
    S-7 Exhaust smoke is black (incomplete combustion)...702
    S-8 Oil consumption is excessive (or exhaust smoke is blue)...703
    S-9 Oil becomes contaminated quickly...704
    S-10 Fuel consumption is excessive...705
    S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...706
    S-12 Oil pressure drops...707
    S-13 Oil level rises (Entry of coolant or fuel)...708
    S-14 Coolant temperature becomes too high (overheating)...709
    S-15 Abnormal noise is made...710
    S-16 Vibration is excessive...711
50 Disassembly and assembly...713
  Contents...714
    How to read this manual...716
    Coating materials list...718
  Engine and cooling system...721
    Removal and installation of fuel supply pump assembly...721
    Removal...721
    Installation...722
    Removal and installation of fuel injector assembly...723
    Removal...723
    Installation...724
    Removal and installation of front oil seal...725
    Special tools...725
    Removal...725
    Installation...726
    Removal and installation of rear oil seal...727
    Special tools...727
    Removal...727
    Installation...728
    Removal and installation of cylinder head assembly...730
    Removal...730
    Installation...734
    Removal and installation of radiator assembly...737
    Removal...737
    Installation...738
    Removal and installation of aftercooler assembly...739
    Removal...739
    Installation...740
    Removal and installation of work equipment oil cooler assembly...741
    Special tools...741
    Installation...742
    Removal and installation of engine and work equipment pump assembly...743
    Special tools...743
    Removal...743
    Installation...747
    Removal and installation of fuel tank assembly...748
    Removal...748
    Installation...750
  Power train...751
    Removal and installation of the final drive...751
    Removal...751
    Installation...751
    Removal and installation of swing motor...752
    Removal...752
    Installation...752
    Removal and installation of swing machinery...753
    Removal...753
    Installation...754
    Disassembly and assembly of swing machinery...755
    Special tools...755
    Disassembly...755
    Assembly...758
    Removal and installation of swing circle...764
    Removal...764
    Installation...764
  Undercarriage and frame...765
    Removal and installation of track roller...765
    Removal...765
    Installation...765
    Disassembly of idler assembly...766
    Removal and installation of idler and recoil spring assembly...767
    Removal...767
    Installation...767
    Disassembly of recoil spring...768
    Removal and installation of track shoes...769
    Removal...769
    Installation...769
    Removal and installation of sprocket assembly...770
    Removal...770
    Installation...770
    Removal and installation of carrier roller...771
    Removal...771
    Installation...771
    Removal and installation of revolving frame...772
    Removal...772
    Installation...773
    Removal and installation of counterweight assembly...775
    Removal...775
    Installation...776
    Removal and installation of additional counterweight assembly...777
    Removal...777
    Installation...778
  Hydraulic system...779
    Removal and installation of center swivel joint assembly...779
    Removal...779
    Installation...780
    Disassembly and assembly of center swivel joint assembly...781
    Special tools...781
    Disassembly...781
    Removal and installation of hydraulic tank assembly...783
    Special tools...783
    Removal...783
    Installation...785
    Removal and installation of hydraulic pump assembly...786
    Special tools...786
    Installation...788
    Removal and installation of control valve assembly...789
    Special tools...789
    Removal...789
    Installation...792
    Disassembly and assembly control valve...794
    Disassembly and assembly of work equipment PPC valve assembly...795
    Disassembly...795
    Assembly...795
    Disassembly and assembly of travel PPC valve assembly...797
    Special tools...797
    Assembly...797
    Removal and installation of boom swing cylinder assembly...799
    Removal...799
    Installation...800
    Removal and installation boom cylinder (version with 2-piece boom)...801
    Removal...801
    Installation...803
    Removal and installation of blade cylinder...804
    Removal...804
    Installation...804
    Disassembly and assembly of hydraulic cylinder assembly...805
    Special tools...805
    Disassembly...805
    Assembly...807
  Work equipment...811
    Removal and installation work equipment assembly (for 1-piece boom)...811
    Removal...811
    Installation...813
    Removal and installation work equipment assembly (2-piece boom)...814
    Removal...814
    Installation...815
    Removal and installation of boom swing bracket...816
    Removal...816
    Installation...818
  Cab and its attachments...819
    Removal and installation of operator cab assembly...819
    Removal...819
    Installation...823
    Removal and installation of operator's cab glass (Stuck glass)...824
    Special tools...825
    Removal...825
    Installation...825
    Removal and installation of front window assembly...834
    Removal...834
    Installation...834
    Removal and installation of floor frame assembly...835
    Removal...835
    Installation...840
  Electrical system...841
    Removal and installation of air compressor assembly...841
    Special tools...841
    Removal...841
    Installation...842
    Removal and installation of air conditioner condenser...843
    Removal...843
    Installation...844
    Removal and installation of air conditioner unit assembly...845
    Removal...845
    Installation...848
    Removal and installation of machine monitor assembly...850
    Installation...851
    Removal and installation of pump controller assembly...852
    Removal...852
    Installation...853
    Removal and installation of engine controller assembly...855
    Removal...855
    Installation...855
    Removal and installation of KOMTRAX terminal assembly...856
    Removal...856
    Installation...856
90 Diagrams and drawings...857
  Contents...858
  Hydraulic diagram...859
  Electrical diagram...861
    Electrical diagram (1/6)...861
    Electrical diagram (2/6)...863
    Electrical diagram (3/6)...865
    Electrical diagram (4/6)...867
    Electrical diagram (5/6)...869
    Electrical diagram (6/6)...871

Komatsu Hydraulic Excavator PC118MR Repair Service Manual