Komatsu PC118MR-8 Hydraulic Excavator Workshop Repair Service Manual PDF - MKMTSPC118MR.zip

A full workshop service repair manual featuring Electrical Wiring Diagrams for the Komatsu PC118MR Hydraulic Excavator, containing every technical detail needed to service, troubleshoot, fix, and overhaul the machine the way professional technicians do.

Inside the Komatsu Hydraulic Excavator PC118MR workshop service repair manual you will find:

* 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