Komatsu PW118MR-8 Hydraulic Excavator Shop Manual WEBM008800 PDF

Description

Komatsu PW118MR-8 Hydraulic Excavator Shop Manual WEBM008800 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu PW118MR-8 Hydraulic Excavator Shop Manual WEBM008800 –  PDF DOWNLOAD

Language : English
Pages : 986
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PW118MR-8 Hydraulic Excavator Shop Manual WEBM008800 –  PDF DOWNLOAD

• SERIAL NUMBERS PW118MR-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 . 59
Table of weight 62
Table of fuel, coolant and lubricants 64
Shop Manual 65
10 Structure and function 65
Contents . 66
Engine and cooling system 68
Engine mount . 68
PTO 69
Cooling system . 70
Power train 72
Power train overview . 72
Front axle . 73
Differential . 73
Brakes . 74
Final reduction 75
Steering cylinder 76
Transmission . 77
Rear axle 79
Differential . 79
Final reduction 80
Steering cylinder 81
Brakes and parking brake cylinder 82
Steering system 84
Steering unit 88
Priority valve . 89
Swing circle . 90
Swing machinery 91
Hydraulic system . 92
Hydraulic tank and filter 92
Hydraulic pump . 94
Blade specification 94
Control valve 106
Outline 106
11-spool valve .107
CLSS .118
Outline of CLSS 118
Basic principle 119
Function and operation by valve 122
Hydraulic circuit diagram and name of valves .122
1. Unload valve 124
2. Introduction of LS pressure .127
3. LS bypass plug 129
4. Pressure compensation valve .130
5. Surface area ratio of pressure compensation valve .131
6. Right and left travel junction circuit 132
7. Travel LS bypass circuit 134
8. Boom regeneration circuit .136
PPC valve 139
Work equipment and swing PPC valve .139
Travel PPC valve .144
Blade, boom swing, 2-piece boom PPC valves .146
Brakes pump 150
Swing motor 151
Safety valve with suction 153
Operation of the modulating relief valve .154
Operation of swing brake .155
Actuation of hydraulic timer valve .156
Travel motor .157
Displacement automatic control high pressure related .160
Travel motor brake valves 161
Swivel joint .164
Solenoid valve .166
Attachment oil flow adjuster EPC valve .167
PPC accumulator 171
For PPC circuit 171
Holding valve 172
Work equipment .177
Work equipment .177
Dimensions of components .180
1,850 mm arm .180
2,000 mm arm .182
2,300 mm arm .184
Bucket .186
Work equipment cylinder 188
Boom cylinder 188
2-piece boom cylinder 188
Arm cylinder .188
Bucket cylinder 189
Boom swing cylinder 189
Blade/outrigger cylinder .189
Shop Manual 193
20 Standard value table 193
Contents .194
Standard value table .195
Standard value table for engine 195
Standard value table for chassis .196
30 Testing and adjusting .207
Contents .208
Testing and adjusting 209
Testing engine speed .209
Testing exhaust temperature 210
Checking exhaust gas colour 211
Adjusting valve clearance 212
Testing compression pressure .214
Testing blow-by pressure .216
Testing engine oil pressure 217
Handling fuel system parts .218
Releasing residual pressure from fuel system .218
Testing fuel pressure 219
Testing fuel return rate and fuel leakage 220
Bleeding air from fuel circuit .222
Checking fuel circuit for leakage 224
Testing and adjusting alternator belt tension 225
Testing 225
Adjusting 225
Measuring the swing circle axial clearance .226
Checking and regulating pressure in the hydraulic circuits .227
Testing and adjusting oil pressure in work equipment and travel circuits .228
Testing and adjusting swing and blade/outrigger circuit oil pressure .230
Testing control circuit basic pressure .232
Testing and adjusting oil pressure in pump PC control circuit 233
Testing LS differential pressure and adjusting LS valve 235
Testing solenoid valve output pressure .237
Testing main pump flow rate 240
Testing and adjusting steering circuit oil pressure 241
Testing the braking system pressure 243
Checking wear in the brake disks .246
Bleeding air from the brake lines 247
Adjusting the parking brake 248
Travel hydraulic equipment checking procedure 249
Testing and adjusting the automatic displacement control system in the travel motor 250
Checking for leakages in the travel motor 252
Checking and adjusting the speed of the travel propeller shaft .253
Adjustment of the speed sensor .255
Checking parts which cause hydraulic drift of work equipment .256
Testing oil leakage 258
Air bleeding from hydraulic circuits .260
Order for operations .260
Releasing residual pressure from the circuits 263
Checking leakages in the steering cylinders 264
Adjusting travel PPC valves clearance 265
Wheel types set up .266
Special functions of machine monitor .268
Handling voltage circuit of engine controller 316
Preparation work for troubleshooting of electrical system 317
Procedure for testing diodes .322
40 Troubleshooting .323
Contents .324
Failure code table and fuse locations 328
Failure code table .328
Failure code table of steering controller 331
Fuse locations .332
General information on troubleshooting .335
Points to remember when troubleshooting 335
Sequence of events in troubleshooting 336
Checks before troubleshooting 337
Classification and procedures for troubleshooting 338
Information in troubleshooting table .339
Phenomena looking like troubles and troubleshooting Nos 341
Connection table for connector pin numbers .344
T- branch box and T- branch adapter table 380
Troubleshooting by failure code 383
Failure code [6B2JMA] – Travel hydraulic abnormality .383
Failure code [2G00MA] – Brake oil pressure abnormality .384
Failure code [989L00] Engine controller lock caution 1 .385
Failure code [989M00] Engine controller lock caution 2 .386
Failure code [989N00] Engine controller lock caution 3 .387
Failure code [AB00KE] Charge voltage low .388
Failure code [B@BAZG] Eng oil press. low .390
Failure code [B@BCNS] Eng coolant overheat .391
Failure code [B@HANS] Hyd. oil overheat 392
Failure code [CA111] ECM critical internal failure .393
Failure code [CA115] Eng. Ne and Bkup speed sensor error .396
Failure code [CA122] Charge air press sensor high error 398
Failure code [CA123] Charge air press sensor low error .400
Failure code [CA131] Throttle sensor high error 402
Failure code [CA132] Throttle sensor low error .404
Failure code [CA144] Coolant temp. sensor high error .406
Failure code [CA145] Coolant temp. sensor low error 408
Failure code [CA153] Charge air temp. sensor high error 410
Failure code [CA154] Charge air temp. sensor low error .412
Failure code [CA155] – Charge air temperature high speed derate 413
Failure code [CA187] Sensor sup. 2 volt. low error .414
Failure code [CA221] Ambient air press. sensor high error 416
Failure code [CA222] Ambient air press. sensor low error .418
Failure code [CA227] Sensor sup. 2 volt. high error 419
Failure code [CA234] Eng. overspeed 420
Failure code [CA238] Ne speed sensor sup. volt. error 422
Failure code [CA271] IMV/PCV1 short error 424
Failure code [CA272] IMV/PCV1 open error .425
Failure code [CA322] Injector #1 (L #1) system open/short error 426
Failure code [CA324] Injector #3 (L #3) system open/short error 428
Failure code [CA331] Injector #2 (L #2) system open/short error 430
Failure code [CA332] Injector #4 (L #4) system open/short error 432
Failure code [CA342] – Calibration code incompatibility 434
Failure code [CA351] Inj. drive circuit error 435
Failure code [CA352] Sensor sup. 1 volt. low error .438
Failure code [CA386] Sensor sup. 1 volt. high error 440
Failure code [CA435] Abnormality in engine oil pressure switch .442
Failure code [CA441] Battery voltage low error .443
Failure code [CA442] Battery voltage high error 444
Failure code [CA449] Rail press. very high error .445
Failure code [CA451] Rail press. sensor high error .446
Failure code [CA452] Rail press. sensor low error 448
Failure code [CA488] – Charge air temperature high torque derate .449
Failure code [CA553] Rail press. high error 450
Failure code [CA559] Rail press. low error .451
Failure code [CA689] Eng. Ne speed sensor error 454
Failure code [CA731] Eng. Bkup speed sensor phase error 456
Failure code [CA757] All persistent data lost error 457
Failure code [CA778] Eng. Bkup speed sensor error 458
Failure code [CA1633] KOMNET datalink timeout error 460
Failure code [CA2185] Throttle sens. sup. volt. high error .462
Failure code [CA2186] Throttle sens. sup. volt. low error 464
Failure code [CA2249] Rail press. very low error .465
Failure code [CA2311] Abnormality in IMV solenoid 466
Failure code [D110KB] Battery relay drive short 468
Failure code [D19JKZ] Personal code relay abnormality 470
Failure code [D862KA] GPS antenna discon .472
Failure code [DA22KK] Pump solenoid power low error 474
Failure code [DA25KP] 5 V sensor 1 power abnormality .477
Failure code [DA26KP] 5 V sensor 2 power abnormality .480
Failure code [DA2RMC] CAN discon (Pump controller detected) 482
Failure code [DAF8KB] – Short circuit in camera power supply .484
Failure code [DAFGMC] GPS module error .486
Failure code [DAFRMC] CAN discon (Monitor detected) 488
Failure code [DDP4KX] – Disconnection in travel PPC pressure switch 490
Failure code [DDWCKZ] – Disconnection in direction control switches 492
Failure code [DLT4KA] – Disconnection in transmission speed sensor .494
Failure code [DFB1KZ] Service lever pot. 1 abnormality .496
Failure code [DFB2KZ] Service lever pot. 2 abnormality .498
Failure code [DFB3L8] Service lever1 potentio error 500
Failure code [DFB4L8] Service lever2 potentio error 502
Failure code [DFB5KZ] Service lever sPot. 1 abnormality 504
Failure code [DFB6KZ] Service lever sPot. 2 abnormality 506
Failure code [DGH2KB] Hydr oil sensor short 508
Failure code [DH10KS] – Abnormality in 24V sensor power source .509
Failure code [DHPAMA] Pump press sensor abnormality 510
Failure code [DHS5KX] Travel PPC sensor abnormality 512
Failure code [DHX1MA] Overload sensor abnormality 514
Failure code [DV20KB] Travel alarm ground short 515
Failure code [DW43MA] – Travel speed High abnormality 516
Failure code [DW43MA] – Travel speed Low abnormality .517
Failure code [DW45KA] Swing brake sol discon .518
Failure code [DW45KB] Swing brake sol short 520
Failure code [DW4AKB] – SUS lock Sol Short Circuit .522
Failure code [DW4AKA] – SUS lock Sol Open Circuit 524
Failure code [DW4CKB] – PPC lock relay Short circuit .526
Failure code [DW4CKA] – PPC lock relay Open Circuit 528
Failure code [DW9KKA] Travel Forward Solenoid Open Circuit .530
Failure code [DW9KKB] Travel forward speed sol short .532
Failure code [DW9LKA] Travel reverse Solenoid Open Circuit .534
Failure code [DW9LKB] Travel reverse solenoid short circuit 535
Failure code [DWB2KB] – Outrigger Sol. Short circuit right .536
Failure code [DWB2KA] – Outrigger Sol. Open Circuit Right 538
Failure code [DWB3KB] – Outrigger Sol. Short Circuit left 540
Failure code [DWB3KA] – Outrigger sol. Open Circuit left .542
Failure code [DWB4KB] – Outrigger blade sol. short circuit .544
Failure code [DWB4KA] – Outrigger blade sol. open circuit 546
Failure code [DXA8KA] PC-EPC sol discon 548
Failure code [DXA8KB] PC-EPC sol short .550
Failure code [DXE7KA] Service current EPC2 open circuit 552
Failure code [DXE7KB] Service current EPC2 short circuit .554
Failure code [DXE8KA] Service current EPC3 open circuit 556
Failure code [DXE8KB] Service current EPC3 short circuit .558
Failure code [DXE9KA] Service current EPC4 open circuit 560
Failure code [DXE9KB] Service current EPC4 short circuit .562
Failure code [DXEAKA] Service current EPC1 open circuit 564
Failure code [DXEAKB] Service current EPC1 short circuit .566
Failure code [DY20KA] Wiper working abnormality 568
Failure code [DY20MA] Wiper parking abnormality 570
Failure code [DY2CKA] Washer drive open circuit 572
Failure code [DY2CKB] Washer drive short circuit .574
Failure code [DY2DKB] Wiper drive (fwd) short circuit 576
Failure code [DY2EKB] Wiper drive (rev) short circuit 578
Troubleshooting by failure code steering controller 581
Failure code 0E3 Hydraulic gear valve sol short circuit 582
Failure code 0E4 Hydraulic gear valve sol disconnection 584
Failure code 0E5 Low speed gear valve sol short circuit 586
Failure code 0E6 Low speed gear valve sol disconnection 588
Failure code 0E7 High speed gear valve sol short circuit .590
Failure code 0E8 High speed gear valve sol disconnection .592
Failure code 0E9 High speed state short circuit 594
Failure code 1E0 High speed state disconnection 596
Failure code 1E1 Round valve sol short circuit .598
Failure code 1E2 Round valve sol disconnection .600
Failure code 1E3 Round valve sol short circuit .602
Failure code 1E4 Round valve sol disconnection .604
Failure code 1E5-1E7 2WS or LOCK valve sol short circuit .606
Failure code 1E6-1E8 2WS and LOCK valve sol disconnection 608
Failure code 1E9 4WS valve sol short circuit .610
Failure code 2E0 4WS valve sol disconnection .612
Failure code 2E1 Enable transm. state short circuit Gnd 614
Failure code 2E2 Hydr. gear state short circuit Gnd 616
Failure code 2E3 F-N-R Abnormality error .618
Failure code 2E5 Gear engaged open circuit .620
Failure code 2E6 Speed sensor open circuit .622
Failure code 2E7 High/low speed Abnormality error 624
Failure code 2E8 Solenoid power supply error .626
Failure code 2E9 Wiper intermittent open circuit .627
Failure code 3E0 Wiper continuos short circuit .628
Failure code 3E1 Wiper continuos open circuit 629
Failure code 3E2 Wiper intermittent short circuit 630
Failure code 3E3 Can Bus communication error .632
Troubleshooting of electrical system .635
Before carrying out troubleshooting of electrical system .635
Information in troubleshooting table .638
E-1 When starting switch is turned ON, machine monitor displays nothing 640
E-2 Engine does not start (Engine does not turn) .643
E-3 Preheater does not operate .646
E-4 Automatic warm-up system does not operate (in cold season) .648
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked 650
E-6 Precaution lights up while engine is running .652
E-7 Emergency stop item lights up while engine is running 655
E-8 Engine coolant temperature gauge does not indicate normally 656
E-9 Hydraulic oil temperature gauge does not indicate normally .658
E-10 Fuel level gauge does not indicate normally .661
E-11 Contents of display by machine monitor are different from applicable machine 663
E-12 Machine monitor does not display some items .664
E-13 Function switch does not work .665
E-14 Auto-decelerator does not operate normally 666
E-15 Working mode does not change 667
E-16 Alarm buzzer cannot be stopped 669
E-17 Windshield wiper and window washer do not operate .670
E-18 Swing holding brake does not operate normally .673
E-19 Travel alarm does not sound or does not stop sounding .674
E-20 Air conditioner does not operate normally (including air conditioner abnormality record) 675
E-21 While starting switch is in OFF position, service meter is not displayed 688
E-22 Machine monitor cannot be set in service mode .689
E-23 Monitoring function does not display lever control signal normally 690
E-24 KOMTRAX system does not operate normally 712
Troubleshooting of hydraulic and mechanical system (H-mode) 713
Information contained in troubleshooting table .713
H-1 Speed or power of all work equipment, swing, and travel are low 714
H-2 Engine speed sharply drops or engine stalls 715
H-3 No work equipment, travel and swing move .716
H-4 Abnormal noise is heard from around hydraulic pump .717
H-5 Fine control performance or response of work equipment and travel is low .718
H-6 Speed or power of boom is low 719
H-7 Speed or power of arm is low .720
H-8 Speed or power of bucket is low 721
H-9 Speed or power of boom swing is low 722
H-10 Speed or power of blade is low 723
H-11 Work equipment does not move in its single operation 724
H-12 Hydraulic drift of work equipment is large 725
H-13 Time lag of work equipment is large .727
H-14 Work equipment loaded more is slower during compound operation 728
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE .729
H-16 Travel speed does not change or it is kept low or high 730
H-17 Machine does not swing 731
H-18 Swing acceleration, swing speed and swing power are low .732
H-19 Excessive overrun when stopping swing .734
H-20 When upper structure stops swinging, it makes large shock .735
H-21 When upper structure stops swinging, it makes large sound .736
H-22 Hydraulic drift of swing is large .737
H-23 Flow rate in attachment circuit cannot be adjusted 738
Troubleshooting of engine (S-mode) .739
Method of using troubleshooting chart 739
S-1 Starting performance is poor .743
S-2 Engine does not start 744
S-3 Engine does not pick up smoothly .747
S-4 Engine stops during operations .748
S-5 Engine does not rotate smoothly 749
S-6 Engine lacks output (or lacks power) .750
S-7 Exhaust smoke is black (incomplete combustion) .751
S-8 Oil consumption is excessive (or exhaust smoke is blue) 752
S-9 Oil becomes contaminated quickly .753
S-10 Fuel consumption is excessive .754
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .755
S-12 Oil pressure drops 756
S-13 Oil level rises (Entry of coolant or fuel) 757
S-14 Coolant temperature becomes too high (overheating) 758
S-15 Abnormal noise is made 759
S-16 Vibration is excessive 760
50 Disassembly and assembly 761
Contents .762
How to read this manual 764
Coating materials list .766
Engine and cooling system 769
Removal and installation of fuel supply pump assembly 769
Removal 769
Installation .770
Removal and installation of fuel injector assembly .771
Removal 771
Installation .772
Removal and installation of front oil seal .773
Special tools 773
Removal 773
Installation .774
Removal and installation of rear oil seal 775
Special tools 775
Removal 775
Installation .776
Removal and installation of cylinder head assembly .778
Removal 778
Installation .782
Removal and installation of radiator assembly 785
Removal 785
Installation .786
Removal and installation of aftercooler assembly .787
Removal 787
Installation .788
Removal and installation of work equipment oil cooler assembly .789
Special tools 789
Installation .790
Removal and installation of engine and work equipment pump assembly 791
Special tools 791
Removal 791
Installation .795
Removal and installation of fuel tank assembly .796
Removal 796
Installation .798
Power train 799
Removal and installation of swing motor 799
Removal 799
Installation .799
Removal and installation of swing machinery 800
Removal 800
Installation .801
Disassembly and assembly of swing machinery 802
Special tools 802
Disassembly 802
Assembly .805
Removal and Installation of swing circle .811
Removal 811
Installation .811
Removal and installation of priority valve .812
Removal 812
Installation .812
Removal and installation of steering unit 813
Removal 813
Installation .814
Undercarriage and frame 815
Removal and installation of complete front axle 815
Removal 815
Installation .816
Removal and installation of complete rear axle .817
Removal 817
Installation .818
Disassembly and assembly of axles 819
Special tools 819
Disassembly 819
Assembly .835
Removal and installation of axle locking cylinders .860
Removal 860
Installation .860
Removal and installation of the transmission .861
Removal 861
Installation .862
Disassembly and assembly of the transmission .863
Disassembly 863
Assembly .868
Removal and installation of revolving frame 873
Removal 873
Installation .875
Removal and installation of counterweight assembly .876
Removal 876
Installation .878
Removal and installation of additional counterweight assembly 879
Removal 879
Installation .880
Hydraulic system .881
Removal and installation of travel motor .881
Removal 881
Installation .882
Disassembly and assembly of travel motor .883
Disassembly 883
Assembly .885
Removal and installation of center swivel joint assembly .889
Removal 889
Installation .890
Disassembly and assembly of center swivel joint assembly .891
Special tools 891
Disassembly 891
Assembly .891
Removal and installation of hydraulic tank assembly 892
Special tools 892
Removal 892
Installation .895
Removal and installation of hydraulic pump assembly 896
Special tools 896
Installation .898
Removal and installation of control valve assembly .899
Special tools 899
Removal 899
Installation .902
Disassembly and assembly control valve .904
Removal and installation of brake pump .905
Installation .906
Removal and installation of travel PPC valve .907
Removal 907
Installation .907
Disassembly and assembly of work equipment PPC valve assembly 908
Disassembly 908
Assembly .908
Removal and installation of boom swing cylinder assembly .910
Removal 910
Installation .911
Removal and installation of cylinder for outriggers or blade .913
Removal 913
Installation .914
Disassembly and assembly of hydraulic cylinder assembly 915
Special tools 915
Disassembly 915
Assembly .917
Work equipment .921
Removal and installation work equipment assembly .921
Removal 921
Installation .922
Removal and installation of boom swing bracket .923
Removal 923
Installation .925
Removal and installation blade and outriggers 926
Removal 926
Installation .926
Removal and installation blade and outriggers arms .927
Removal 927
Installation .927
Cab and its attachment .928
Removal and installation of operator cab assembly 928
Removal 928
Installation .932
Removal and installation of operator’s cab glass (Stuck glass) .933
Special tools 934
Removal 934
Installation .934
Removal and installation of front window assembly 943
Removal 943
Installation .943
Removal and installation of floor frame assembly .944
Removal 944
Installation .950
Electrical system 951
Removal and installation steering column assembly 951
Removal 951
Installation .951
Removal and installation of air compressor assembly 952
Special tools 952
Removal 952
Installation .953
Removal and installation of air conditioner condenser 954
Removal 954
Installation .955
Removal and installation of air conditioner unit assembly 956
Removal 956
Installation .959
Removal and installation of machine monitor assembly .961
Removal 961
Installation .962
Removal and installation of pump controller assembly .963
Removal 963
Installation .964
Removal and installation of engine controller assembly .966
Removal 966
Installation .966
Removal and installation of KOMTRAX terminal assembly 967
Removal 967
Installation .967
90 Diagrams and drawings .969
Contents .970
Hydraulic diagram 971
Hydraulic diagram (1/2) 971
Hydraulic diagram (2/2) 973
Electrical diagram .975
Electrical diagram (1/6) .975
Electrical diagram (2/6) .977
Electrical diagram (3/6) .979
Electrical diagram (4/6) .981
Electrical diagram (5/6) .983
Electrical diagram (6/6) .985

DESCRIPTION:

Komatsu PW118MR-8 Hydraulic Excavator Shop Manual WEBM008800 –  PDF DOWNLOAD

• SERIAL NUMBERS PW118MR-8 F00003 and up

G.B 26/12/24