Komatsu Excavator PC118MR-8 service & repair manual

Description Komatsu Excavator PC118MR-8 service & repair manual

Komatsu Hydraulic Excavator PC118MR-8 pdf workshop service & repair manual

Serial number F00003 and up

Technical data, specifications, testing, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of hydraulic components
Method of disconnecting and connecting push-pull type coupler
Handling of electric equipment
How to read electric wire code
Precautions when performing work
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specifications drawing
Table of weight
Table of fuel, coolant and lubricants

Structure and function
Engine and cooling system
Engine mount
PTO
Cooling system
Power train
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler and recoil spring
Carrier roller
Track roller
Track shoe
Hydraulic system
Hydraulic equipment layout drawing
Valve control
Hydraulic tank and filter
Hydraulic pump
Control valve
CLSS
Function and operation by valve
1. Unload valve
2. Introduction of LS pressure
3. LS bypass plug
4. Pressure compensation valve
5. Surface area ratio of pressure compensation valve
6. Right and left travel junction circuit
7. Travel LS bypass circuit
8. Boom regeneration circuit
PPC valve
Work equipment and swing PPC valve
Travel PPC valve
Blade and boom swing PPC valve
Swing motor
Safety valve with suction
Operation of the modulating relief valve
Operation of swing brake
Actuation of hydraulic timer valve
Travel motor
Center swivel joint
Solenoid valve
Attachment oil flow adjuster EPC valve
PPC accumulator
For PPC circuit
Anti-drop valve
Work equipment
Dimensions of components
1,850 mm arm
2,000 mm arm
2,300 mm arm
Bucket
Work equipment cylinder
Boom cylinder
2-piece boom cylinder
Arm cylinder
Bucket cylinder
Boom swing cylinder
Blade cylinder
Cab and its attachments
Air conditioner
Air conditioner piping diagram
Air conditioner unit
Air conditioner controller
Compressor
Condenser
Sensor
Electrical system
Electrical control system
Machine control system diagram
Engine control function
Engine and pump mutual control function
Auto-deceleration function
Engine automatic warm-up function
Swing control function
Travel control function
PPC lock function
Oil flow adjuster function for attachment
System components
Monitor system
Machine monitor
Display
Switches
KOMTRAX system
Sensor
Atmospheric pressure sensor
Boost pressure and temperature sensor
Coolant temperature sensor 
Crankshaft speed sensor
Common rail pressure sensor
Hydraulic oil temperature sensor
Fuel level sensor
Pump oil pressure sensor
PPC oil pressure sensor

Standard value table
Standard value table for engine
Standard value table for chassis

Testing and adjusting
Testing engine speed
Testing exhaust temperature
Checking exhaust gas colour
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return rate and fuel leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Testing and adjusting alternator belt tension
Measuring the swing circle axial clearance
Testing and adjusting track-shoe tension
Checking and regulating pressure in the hydraulic circuits
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting swing and blade circuit oil pressure
Testing control circuit basic pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing LS differential pressure and adjusting LS valve
Testing solenoid valve output pressure
Testing main pump flow rate
Checking parts which cause hydraulic drift of work equipment
Measuring travel deviation
Adjusting the maximum speed of the travel motors
Releasing residual pressure from hydraulic circuit
Testing oil leakage
Air bleeding from hydraulic circuits
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service

Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Information in troubleshooting table
Phenomena looking like troubles and troubleshooting Nos
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code
Troubleshooting of electrical system
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
How to read this manual
Coating materials list
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of front oil seal
Removal and installation of rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of work equipment oil cooler assembly
Removal and installation of engine and work equipment pump assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of the final drive
Removal and installation of swing motor
Removal and installation of swing machinery
Disassembly and assembly of swing machinery
Removal and installation of swing circle
Undercarriage and frame
Removal and installation of track roller
Disassembly of idler assembly
Removal and installation of idler and recoil spring assembly
Disassembly of recoil spring
Removal and installation of track shoes
Removal and installation of sprocket assembly
Removal and installation of carrier roller
Removal and installation of revolving frame
Removal and installation of counterweight assembly
Removal and installation of additional counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Removal and installation of control valve assembly
Disassembly and assembly control valve
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Removal and installation of boom swing cylinder assembly (for 1-piece boom)
Removal and installation boom cylinder (version with 2-piece boom)
Removal and installation of blade cylinder
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation work equipment assembly (for 1-piece boom)
Removal and installation work equipment assembly (2-piece boom)
Removal and installation of boom swing bracket
Cab and its attachments
Removal and installation of operator cab assembly
Removal and installation of operator's cab glass (Stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Electrical system
Removal and installation of air compressor assembly
Removal and installation of air conditioner condenser
Removal and installation of air conditioner unit assembly
Removal and installation of machine monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
Removal and installation of KOMTRAX terminal assembly

Diagrams and drawings
Hydraulic diagram
Electrical diagram

Engine SAA4D95LE-5 workshop service manual