Komatsu Hydraulic Excavator PC118MR-8 Shop Manual WEBM008700 – PDF DOWNLOAD

Description

Komatsu Hydraulic Excavator PC118MR-8 Shop Manual WEBM008700 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC118MR-8 Shop Manual WEBM008700 – PDF DOWNLOAD

Language : English
Pages :872
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC118MR-8 Shop Manual WEBM008700 – PDF DOWNLOAD

SERIAL NUMBERS PC118MR-8 F00003 and up

1. General precautions

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC118MR-8 Shop Manual WEBM008700 – PDF DOWNLOAD

SERIAL NUMBERS PC118MR-8 F00003 and up

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
CLSS110
Outline of CLSS110
Basic principle111
Function and operation by valve114
Hydraulic circuit diagram and name of valves114
1 Unload valve116
2 Introduction of LS pressure119
3 LS bypass plug121
4 Pressure compensation valve122
5 Surface area ratio of pressure compensation valve123
6 Right and left travel junction circuit124
7 Travel LS bypass circuit126
8 Boom regeneration circuit128
PPC valve131
Work equipment and swing PPC valve131
Travel PPC valve137
Blade and boom swing PPC valve140
Swing motor142
Safety valve with suction144
Operation of the modulating relief valve145
Operation of swing brake146
Actuation of hydraulic timer valve147
Travel motor148
Center swivel joint150
Solenoid valve151
Attachment oil flow adjuster EPC valve152
PPC accumulator156
For PPC circuit156
Anti-drop valve157
Work equipment163
Work equipment163
Dimensions of components166
1,850 mm arm166
2,000 mm arm168
2,300 mm arm170
Bucket172
Work equipment cylinder174
Boom cylinder174
2-piece boom cylinder174
Arm cylinder174
Bucket cylinder175
Boom swing cylinder175
Blade cylinder175
Cab and its attachments178
Air conditioner178
Air conditioner piping diagram178
Air conditioner unit182
Air conditioner controller185
Compressor186
Condenser187
Sensor188
Electrical system189
Electrical control system189
Machine control system diagram189
Engine control function191
Engine and pump mutual control function193
Auto-deceleration function197
Engine automatic warm-up function199
Swing control function203
Travel control function205
PPC lock function207
Oil flow adjuster function for attachment208
System components210
Monitor system219
Machine monitor220
Display222
Switches226
Operator mode function230
Service mode function232
KOMTRAX system233
Sensor236
Atmospheric pressure sensor236
Boost pressure and temperature sensor236
Coolant temperature sensor237
Crankshaft speed sensor237
Common rail pressure sensor238
Hydraulic oil temperature sensor238
Fuel level sensor239
Pump oil pressure sensor240
PPC oil pressure sensor241
Shop Manual243
20 Standard value table243
Contents244
Standard value table245
Standard value table for engine245
Standard value table for chassis246
30 Testing and adjusting255
Contents256
Testing and adjusting257
Testing engine speed257
Testing exhaust temperature258
Checking exhaust gas colour259
Adjusting valve clearance260
Testing compression pressure262
Testing blow-by pressure264
Testing engine oil pressure265
Handling fuel system parts266
Releasing residual pressure from fuel system266
Testing fuel pressure267
Testing fuel return rate and fuel leakage268
Bleeding air from fuel circuit270
Checking fuel circuit for leakage272
Testing and adjusting alternator belt tension273
Testing273
Adjusting273
Measuring the swing circle axial clearance274
Testing and adjusting track-shoe tension275
Checking and regulating pressure in the hydraulic circuits276
Testing and adjusting oil pressure in work equipment and travel circuits277
Testing and adjusting swing and blade circuit oil pressure279
Testing control circuit basic pressure281
Testing and adjusting oil pressure in pump PC control circuit282
Testing LS differential pressure and adjusting LS valve284
Testing solenoid valve output pressure286
Testing main pump flow rate289
Checking parts which cause hydraulic drift of work equipment290
Measuring travel deviation292
Adjusting the maximum speed of the travel motors293
Releasing residual pressure from hydraulic circuit294
Testing oil leakage295
Air bleeding from hydraulic circuits298
Order for operations298
Special functions of machine monitor300
Handling voltage circuit of engine controller349
Preparation work for troubleshooting of electrical system350
Procedure for testing diodes355
Pm Clinic service356
40 Troubleshooting361
Contents362
Failure code table and fuse locations366
Failure code table366
Fuse locations369
General information on troubleshooting371
Points to remember when troubleshooting371
Sequence of events in troubleshooting372
Checks before troubleshooting373
Classification and procedures for troubleshooting374
Information in troubleshooting table375
Phenomena looking like troubles and troubleshooting Nos377
Connection table for connector pin numbers380
T- branch box and T- branch adapter table416
Troubleshooting by failure code419
Failure code [989L00] Engine controller lock caution 1419
Failure code [989M00] Engine controller lock caution 2420
Failure code [989N00] Engine controller lock caution 3421
Failure code [AB00KE] Charge voltage low422
Failure code [B@BAZG] Eng oil press low424
Failure code [B@BCNS] Eng coolant overheat425
Failure code [B@HANS] Hyd oil overheat426
Failure code [CA111] ECM critical internal failure427
Failure code [CA115] Eng Ne and Bkup speed sensor error430
Failure code [CA122] Charge air press sensor high error431
Failure code [CA123] Charge air press sensor low error433
Failure code [CA131] Throttle sensor high error434
Failure code [CA132] Throttle sensor low error436
Failure code [CA144] Coolant temp sensor high error438
Failure code [CA145] Coolant temp sensor low error440
Failure code [CA153] Charge air temp sensor high error442
Failure code [CA154] Charge air temp sensor low error444
Failure code [CA155] Charge air temperature high speed derate445
Failure code [CA187] Sensor sup 2 volt low error446
Failure code [CA221] Ambient air press sensor high error448
Failure code [CA222] Ambient air press sensor low error450
Failure code [CA234] Eng overspeed451
Failure code [CA238] Ne speed sensor sup volt error452
Failure code [CA271] IMV/PCV1 short error454
Failure code [CA272] IMV/PCV1 open error455
Failure code [CA322] Injector #1 (L #1) system open/short error456
Failure code [CA324] Injector #3 (L #3) system open/short error458
Failure code [CA331] Injector #2 (L #2) system open/short error460
Failure code [CA332] Injector #4 (L #4) system open/short error462
Failure code [CA342] Calibration code incompatibility464
Failure code [CA351] Inj drive circuit error465
Failure code [CA352] Sensor sup 1 volt low error468
Failure code [CA386] Sensor sup 1 volt high error470
Failure code [CA435] Abnormality in engine oil pressure switch472
Failure code [CA441] Battery voltage low error473
Failure code [CA442] Battery voltage high error474
Failure code [CA449] Rail press very high error475
Failure code [CA451] Rail press sensor high error476
Failure code [CA488] Charge air temperature high torque derate478
Failure code [CA452] Rail press sensor low error479
Failure code [CA553] Rail press high error480
Failure code [CA559] Rail press low error481
Failure code [CA689] Eng Ne speed sensor error484
Failure code [CA731] Eng Bkup speed sensor phase error486
Failure code [CA757] All persistent data lost error487
Failure code [CA778] Eng Bkup speed sensor error488
Failure code [CA1633] KOMNET datalink timeout error490
Failure code [CA2185] Throttle sens sup volt high error492
Failure code [CA2186] Throttle sens sup volt low error494
Failure code [CA2249] Rail press very low error495
Failure code [CA2311] Abnormality in IMV solenoid496
Failure code [D110KB] Battery relay drive short498
Failure code [D19JKZ] Personal code relay abnormality500
Failure code [D862KA] GPS antenna discon502
Failure code [DA22KK] Pump solenoid power low error504
Failure code [DA25KP] 5 V sensor 1 power abnormality507
Failure code [DA26KP] 5 V sensor 2 power abnormality510
Failure code [DA2RMC] CAN discon (Pump controller detected)512
Failure code [DAF8KB] Camera Power Supply Short Circuit514
Failure code [DAFGMC] GPS module error516
Failure code [DAFRMC] CAN discon (Monitor detected)518
Failure code [DFB1KZ] Service lever pot 1 abnormality520
Failure code [DFB2KZ] Service lever pot 2 abnormality522
Failure code [DFB3L8] Service lever1 potentio error524
Failure code [DFB4L8] Service lever2 potentio error526
Failure code [DFB5KZ] Service lever sPot 1 abnormality528
Failure code [DFB6KZ] Service lever sPot 2 abnormality530
Failure code [DGH2KB] Hydr oil sensor short532
Failure code [DHPAMA] Pump press sensor abnormality534
Failure code [DHS5KX] Travel PPC sensor abnormality536
Failure code [DHX1MA] Overload sensor abnormality538
Failure code [DV20KB] Travel alarm short circuit539
Failure code [DW43KA] Travel speed sol discon540
Failure code [DW43KB] Travel speed sol short541
Failure code [DW45KA] Swing brake sol discon542
Failure code [DW45KB] Swing brake sol short544
Failure code [DXA8KA] PC-EPC sol discon546
Failure code [DXA8KB] PC-EPC sol short548
Failure code [DXE7KA] Service current EPC2 open circuit550
Failure code [DXE7KB] Service current EPC2 short circuit552
Failure code [DXE8KA] Service current EPC3 open circuit554
Failure code [DXE8KB] Service current EPC3 short circuit556
Failure code [DXE9KA] Service current EPC4 open circuit558
Failure code [DXE9KB] Service current EPC4 short circuit560
Failure code [DXEAKA] Service current EPC1 open circuit562
Failure code [DXEAKB] Service current EPC1 short circuit564
Failure code [DY20KA] Wiper working abnormality566
Failure code [DY20MA] Wiper parking abnormality568
Failure code [DY2CKA] Washer drive open circuit570
Failure code [DY2CKB] Washer drive short circuit572
Failure code [DY2DKB] Wiper drive (fwd) short circuit574
Failure code [DY2EKB] Wiper drive (rev) short circuit576
Troubleshooting of electrical system579
Before carrying out troubleshooting of electrical system579
Information in troubleshooting table581
E-1 When starting switch is turned ON, machine monitor displays nothing582
E-2 Engine does not start (Engine does not turn)585
E-3 Preheater does not operate588
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 locked591
E-6 Precaution lights up while engine is running594
E-7 Emergency stop item lights up while engine is running597
E-8 Engine coolant temperature gauge does not indicate normally598
E-9 Hydraulic oil temperature gauge does not indicate normally600
E-10 Fuel level gauge does not indicate normally603
E-11 Contents of display by machine monitor are different from applicable machine605
E-12 Machine monitor does not display some items606
E-13 Function switch does not work607
E-14 Auto-decelerator does not operate normally608
E-15 Working mode does not change609
E-16 Travel speed does not change610
E-17 Alarm buzzer cannot be stopped611
E-18 Windshield wiper and window washer do not operate612
E-19 Swing holding brake does not operate normally616
E-20 Travel alarm does not sound or does not stop sounding618
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 displayed632
E-23 Machine monitor cannot be set in service mode633
E-24 Monitoring function does not display lever control signal normally634
E-25 KOMTRAX system does not operate normally658
Troubleshooting of hydraulic and mechanical system (H-mode)659
Information contained in troubleshooting table659
H-1 Speed or power of all work equipment, swing, and travel are low660
H-2 Engine speed sharply drops or engine stalls661
H-3 No work equipment, travel and swing move662
H-4 Abnormal noise is heard from around hydraulic pump663
H-5 Fine control performance or response of work equipment and travel is low664
H-6 Speed or power of boom is low665
H-7 Speed or power of arm is low666
H-8 Speed or power of bucket is low667
H-9 Speed or power of boom swing is low668
H-10 Speed or power of blade is low669
H-11 Work equipment does not move in its single operation670
H-12 Hydraulic drift of work equipment is large671
H-13 Time lag of work equipment is large673
H-14 Work equipment loaded more is slower during compound operation674
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE675
H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel676
H-17 Machine deviates during travel677
H-18 Travel speed is low678
H-19 Machine cannot be steered easily or steering power is low679
H-20 Travel speed does not change or it is kept low or high680
H-21 Track does not move (only either side)681
H-22 Machine does not swing682
H-23 Swing acceleration, swing speed and swing power are low683
H-24 Excessive overrun when stopping swing685
H-25 When upper structure stops swinging, it makes large shock686
H-26 When upper structure stops swinging, it makes large sound687
H-27 Hydraulic drift of swing is large688
H-28 Flow rate in attachment circuit cannot be adjusted689
Troubleshooting of engine (S-mode)690
Method of using troubleshooting chart690
S-1 Starting performance is poor694
S-2 Engine does not start695
S-3 Engine does not pick up smoothly698
S-4 Engine stops during operations699
S-5 Engine does not rotate smoothly700
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 quickly704
S-10 Fuel consumption is excessive705
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)706
S-12 Oil pressure drops707
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 made710
S-16 Vibration is excessive711
50 Disassembly and assembly713
Contents714
How to read this manual716
Coating materials list718
Engine and cooling system721
Removal and installation of fuel supply pump assembly721
Removal721
Installation722
Removal and installation of fuel injector assembly723
Removal723
Installation724
Removal and installation of front oil seal725
Special tools725
Removal725
Installation726
Removal and installation of rear oil seal727
Special tools727
Removal727
Installation728
Removal and installation of cylinder head assembly730
Removal730
Installation734
Removal and installation of radiator assembly737
Removal737
Installation738
Removal and installation of aftercooler assembly739
Removal739
Installation740
Removal and installation of work equipment oil cooler assembly741
Special tools741
Installation742
Removal and installation of engine and work equipment pump assembly743
Special tools743
Removal743
Installation747
Removal and installation of fuel tank assembly748
Removal748
Installation750
Power train751
Removal and installation of the final drive751
Removal751
Installation751
Removal and installation of swing motor752
Removal752
Installation752
Removal and installation of swing machinery753
Removal753
Installation754
Disassembly and assembly of swing machinery755
Special tools755
Disassembly755
Assembly758
Removal and installation of swing circle764
Removal764
Installation764
Undercarriage and frame765
Removal and installation of track roller765
Removal765
Installation765
Disassembly of idler assembly766
Removal and installation of idler and recoil spring assembly767
Removal767
Installation767
Disassembly of recoil spring768
Removal and installation of track shoes769
Removal769
Installation769
Removal and installation of sprocket assembly770
Removal770
Installation770
Removal and installation of carrier roller771
Removal771
Installation771
Removal and installation of revolving frame772
Removal772
Installation773
Removal and installation of counterweight assembly775
Removal775
Installation776
Removal and installation of additional counterweight assembly777
Removal777
Installation778
Hydraulic system779
Removal and installation of center swivel joint assembly779
Removal779
Installation780
Disassembly and assembly of center swivel joint assembly781
Special tools781
Disassembly781
Removal and installation of hydraulic tank assembly783
Special tools783
Removal783
Installation785
Removal and installation of hydraulic pump assembly786
Special tools786
Installation788
Removal and installation of control valve assembly789
Special tools789
Removal789
Installation792
Disassembly and assembly control valve794
Disassembly and assembly of work equipment PPC valve assembly795
Disassembly795
Assembly795
Disassembly and assembly of travel PPC valve assembly797
Special tools797
Assembly797
Removal and installation of boom swing cylinder assembly799
Removal799
Installation800
Removal and installation boom cylinder (version with 2-piece boom)801
Removal801
Installation803
Removal and installation of blade cylinder804
Removal804
Installation804
Disassembly and assembly of hydraulic cylinder assembly805
Special tools805
Disassembly805
Assembly807
Work equipment811
Removal and installation work equipment assembly (for 1-piece boom)811
Removal811
Installation813
Removal and installation work equipment assembly (2-piece boom)814
Removal814
Installation815
Removal and installation of boom swing bracket816
Removal816
Installation818
Cab and its attachments819
Removal and installation of operator cab assembly819
Removal819
Installation823
Removal and installation of operator’s cab glass (Stuck glass)824
Special tools825
Removal825
Installation825
Removal and installation of front window assembly834
Removal834
Installation834
Removal and installation of floor frame assembly835
Removal835
Installation840
Electrical system841
Removal and installation of air compressor assembly841
Special tools841
Removal841
Installation842
Removal and installation of air conditioner condenser843
Removal843
Installation844
Removal and installation of air conditioner unit assembly845
Removal845
Installation848
Removal and installation of machine monitor assembly850
Installation851
Removal and installation of pump controller assembly852
Removal852
Installation853
Removal and installation of engine controller assembly855
Removal855
Installation855
Removal and installation of KOMTRAX terminal assembly856
Removal856
Installation856
90 Diagrams and drawings857
Contents858
Hydraulic diagram859
Electrical diagram861
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

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24