Komatsu PW118MR-11 Hydraulic Excavator Shop Manual – Complete Workshop PDF

Description

Komatsu PW118MR-11 Shop Manual – Complete Workshop Reference

This is the complete Komatsu PW118MR-11 shop manual for the wheeled hydraulic excavator, covering serial numbers F30003 and up. At 2378 pages, it is the full dealer workshop reference – not a condensed owner’s guide. Every system on the machine is documented: engine, cooling, power train, undercarriage, hydraulics, electrical control, cab, and the urea SCR aftertreatment system.

File Details

• Manual type: Shop Manual (workshop service and repair)
• Brand: Komatsu
• Model: PW118MR-11
• Serial numbers: F30003 and up
• Engine: SAA4D95LE-7 (4-cycle, water-cooled, in-line, direct injection, variable geometry turbocharger, air-cooled aftercooler)
• Language: English
• Page count: 2378
• File format: PDF
• Document number: WENBM00160

Chapters Covered

• 00 Index and Foreword – safety notices, fire prevention, waste disposal, shop manual reading conventions, maintenance standard terms, fuel system handling, intake system parts handling, hydraulic equipment handling, push-pull coupler procedures, electrical equipment handling, wire code reading, standard tightening torque tables, abbreviations, conversion tables
• 01 Specification – overall dimensions, working range drawings, specifications, weight table, table of fuel, coolant and lubricants
• 10 Structure and Function – urea SCR system, DEF tank, DEF pump, DEF injector, DEF hoses, DEF tank heating valve, boot-up system, engine system, EGR system, EGR valve, EGR cooler, KCCV system, KCCV ventilator, CDR valve, exhaust throttle valve, KDOC, cooling system, power train overview, swing circle, swing machinery, front axle, transmission, hydraulic system layout, hydraulic tank, hydraulic pump, control valve, CLSS, work equipment system, swing motor, travel motor, PPC valves, brakes pump, swivel joint, solenoid valves, accumulators, holding valves, safety valves, hydraulic quick coupler, work equipment, electrical control system, engine control system, auto-deceleration system, engine automatic warm-up, overheat prevention, turbocharger protection, automatic idle stop, machine monitor system, KomVision controller and system, KOMTRAX system, pump controller, machine controller, engine controller, fuel control dial, cab mounts, ROPS cab, steering column
• 20 Standard Value Tables – standard service value table for engine and for machine
• 30 Testing and Adjusting – engine speed, exhaust gas color, exhaust throttle valve clearance, valve clearance, compression pressure, blowby pressure, engine oil pressure, fuel pressure, fuel return rate and leakage, air bleeding, fuel circuit leakage, cylinder cut-out mode, no-injection cranking, A/C compressor belt, cooling fan speed, injector compensation value writing, SCR related functions, DEF injector injection amount, DEF line heater relays, DEF pump heater relay, DEF tank heater valve, SCR denitration efficiency, DEF tank cleaning, swing circle bearing clearance, steering cylinder leakage, steering circuit pressure and relief, braking system pressure and leakage, brake disk wear, brake line bleeding, hydraulic circuit pressure regulation, work equipment and travel circuit pressure, swing circuit oil pressure, control circuit oil pressure, pump PC control oil pressure, pump LS control oil pressure, solenoid valve outlet pressure, PPC valve outlet pressure, PPC valve play, travel motor automatic displacement control, travel motor leakage, hydraulic drift isolation, oil leakage testing, steering cylinder leakage, air bleeding from circuit, slide door rail and roller servicing, mirror adjustment, machine monitor set and operate, KOMTRAX terminal start-up, KomVision camera angle and related items, headlight alignment, engine controller voltage circuit, battery disconnect switch, diode testing
• 40 Troubleshooting – general troubleshooting points, urea SCR system troubleshooting points, event sequence, pre-troubleshooting checks, walk-around check, fuel level and type, fuel prefilter, water separator, fuel filter replacement, oil levels for engine, PTO gear case, coolant, air cleaner, hydraulic tank and strainer, hydraulic oil filter, swing machinery case, transmission reduction gear, front and rear axle, air bleeding, electric equipment checks, connector handling, wiring harness testing, fault code tables, failure code troubleshooting by code, electrical system E-mode diagnostics, hydraulic and mechanical H-mode diagnostics, engine S-mode diagnostics
• 50 Disassembly and Assembly – supply pump, injectors, EGR valve, starter, aftercooler, fan clutch, engine front oil seal, fuel cooler, KDOC and SCR assembly, bellows pipe, KDOC, SCR, DEF tank, DEF tank sensor flange, DEF tank sensor, DEF tank strainer, KCCV assembly, DEF mixing tube, DEF injector, DEF pump, air cleaner, A/C condenser, swing motor, swing machinery, gear box, twin wheels, rear axle, front axle, axle locking cylinders, counterweight, travel motor, boom swing cylinder, work equipment PPC valve, outrigger/blade cylinder, hydraulic cylinder, brake pedal, work equipment assembly, boom swing bracket, blade and outriggers, cab assembly, cab door, cab glass, front window, air conditioner unit, operator’s seat, seat belt, engine controller, pump controller, machine monitor, KomVision controller, steering column switches, travel speed sensor, steering sensor, revolving frame swing position sensor, direction indicator, mass air flow sensor, KCCV crankcase pressure sensor, SCR temperature sensor, KomVision camera, KOMTRAX terminal
• 60 Maintenance Standard – engine mount, PTO, cooling system, swing circle, swing machinery, front axle, transmission, control valve, hydraulic tank, swing motor, self-reducing pressure valve, PPC valve, boom swing and 2-piece boom PPC valve, travel motor, solenoid valve, steering control solenoid valve, attachment flow adjustment EPC valves, travel speed and direction control solenoid valve, blade safety valve, holding valve, cab mount and tipping stopper, work equipment
• 80 Appendix – air conditioner components, refrigerant precautions, refrigeration cycle, air conditioner unit, dual pressure switch, air conditioner controller, compressor, condenser, receiver drier, sunlight sensor, outer temperature sensor, testing and troubleshooting procedures, wiring and connector pin arrangements, system diagram, input and output signals, parts and connector layout, air leakage testing, self-diagnosis, vent mode changeover, fresh/recirc changeover, sunlight sensor testing, dual pressure switch testing, relay testing, troubleshooting charts, failure code list
• 90 Diagrams and Drawings – symbols in electric circuit diagram, hydraulic circuit diagrams (1/2 and 2/2), electrical circuit diagrams (1/11 through 11/11)

What This Manual Gives a Technician

The PW118MR-11 shop manual is written as a complete workshop reference for Komatsu-trained service personnel and experienced independent technicians. It is organised the way a dealer shop actually works – specification first, then structure and function, then standard values, then testing and adjusting, then troubleshooting, then disassembly and assembly, and finally the maintenance standard limits. Each chapter supports the others: the structure and function chapter explains what a component does before the testing chapter tells you how to measure it, and the standard value tables give you the criteria to judge the result.

Because this machine uses a common rail engine with urea SCR aftertreatment, the manual goes deeper than most older excavator books. It documents the DEF tank, DEF pump, DEF injector, DEF hoses, DEF tank heating valve, SCR assembly, KDOC, ammonia sensor, NOx sensors, and the full inducement strategy that governs engine derate when the SCR system detects a fault. It also includes the dedicated SCR service tests that run from the machine monitor, including DEF pump pressure up, DEF injection quantity, denitration efficiency, and the heater relay tests.

Section Highlights

• Full hydraulic coverage – CLSS closed-centre load sensing, LS valve, PC valve, PC-EPC valve, LS-EPC valve, servo piston, control valve pressure compensation, unload valve, LS separation valve, boom regeneration circuit, travel LS bypass circuit, and the pressure compensation valve area ratio behaviour in combined operations.
• Complete electrical diagnostics – connector layouts in 17 sections, fuse locations, fuse box connection tables, connector contact identification, and electrical system E-mode symptom troubleshooting from E-1 through E-51.
• Hydraulic and mechanical H-mode diagnostics – symptom-driven diagnostics for slow or weak work equipment, hydraulic drift, slow travel, swing problems, low boom/arm/bucket speed, combined-operation faults, brake faults, and steering faults.
• Engine S-mode diagnostics – no-crank, no-start, misfire, poor startability, rough running, black smoke, oil consumption, coolant contamination, overheating, unusual noise, vibration, DEF overconsumption, and SCR regeneration problems.
• Component disassembly and assembly – step-by-step removal, disassembly, assembly, and installation for the supply pump, injectors, EGR valve, starter, aftercooler, fan clutch, front oil seal, fuel cooler, KDOC and SCR assembly, DEF system components, swing motor and machinery, front and rear axles, gear box, travel motor, hydraulic cylinders, cab and glass, air conditioner unit, and electronic controllers.
• Standard value tables – engine and machine standard values including rated horsepower, torque, capacities, pressures, flow rates, cylinder dimensions, travel speeds, swing times, hydraulic drift limits, and internal leakage limits.
• Air conditioner appendix – the full climate control section with refrigerant precautions, component layout, controller input/output signals, and self-diagnosis procedures.

Who This Manual Is For

This Komatsu PW118MR-11 shop manual is aimed at technicians who need to diagnose, service, repair, or overhaul the machine to the manufacturer’s procedure. It covers the wheeled excavator’s full systems, from the SAA4D95LE-7 common rail engine through the hydraulic pump and control valve, to the swing and travel circuits, the urea SCR aftertreatment, the electrical control network, and the cab and air conditioning. It is a working document, not a quick-reference chart – the kind of book you keep on the bench while doing a pump overhaul or a hydraulic drift diagnosis.

Why This Manual Matters

The PW118MR-11 is a complex machine. Its hydraulic system uses CLSS with LS and PC control, its engine uses common rail injection with EGR and VGT, and its aftertreatment uses DEF injection and SCR to meet emissions limits. Servicing any of these systems without the factory values is guesswork. The wrong relief pressure setting changes cycle times and stresses the pump. The wrong torque on an injector holder can let engine oil into the fuel return circuit. A misread SCR fault code leads to unnecessary parts replacement. This manual provides the correct specifications, adjustment values, tightening torques, clearances, and diagnostic paths so the job is done right the first time.

Delivery

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This is an instant PDF download. No shipping, no waiting. The file can be viewed on a laptop, tablet, or phone, and the pages you need can be printed for use in the workshop. Once purchased, the manual is yours to keep and refer to for every job on the PW118MR-11.