Komatsu Wheeled Excavator PW118MR-11 service & repair manual

Description Komatsu Wheeled Excavator PW118MR-11 service & repair manual

Komatsu Wheeled Hydraulic Excavator PW118MR-11 pdf workshop service & repair manual

Serial number F30003 and up

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

SERVICE MANUAL CONTENT:
INDEX AND FOREWORD
FOREWORD, SAFETY AND GENERAL INFORMATION
IMPORTANT SAFETY NOTICE
FIRE PREVENTION
DISPOSE OF WASTE MATERIALS
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES
HANDLING OF INTAKE SYSTEM PARTS
HANDLING OF HYDRAULIC EQUIPMENT
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER
HANDLING OF ELECTRICAL EQUIPMENT
HOW TO READ ELECTRIC WIRE CODE
PRECAUTIONS WHEN PERFORMING OPERATION
PRACTICAL USE OF KOMTRAX
STANDARD TIGHTENING TORQUE TABLE
ABBREVIATION
CONVERSION TABLE

SPECIFICATION
OVERALL DIMENSIONS
WORKING RANGE DRAWINGS
WEIGHT TABLE
TABLE OF FUEL, COOLANT, AND LUBRICANTS

STRUCTURE AND FUNCTION
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
DEF TANK
DEF PUMP
DEF INJECTOR
DEF HOSE
DEF TANK HEATING VALVE
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
EGR SYSTEM
EGR VALVE
EGR COOLER
KCCV SYSTEM
KCCV VENTILATOR
CDR VALVE
EXHAUST THROTTLE VALVE
KDOC
COOLING SYSTEM
POWER TRAIN
POWER TRAIN OVERVIEW
SWING CIRCLE
SWING MACHINERY
UNDERCARRIAGE AND FRAME
FRONT AXLE
TRANSMISSION
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
HYDRAULIC TANK
HYDRAULIC PUMP
CONTROL VALVE
CLSS
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
UNDERCARRIAGE PART
VALVE CONTROL
SELF-REDUCING PRESSURE VALVE
SWING MOTOR
TRAVEL MOTOR
WORK EQUIPMENT AND SWING PPC VALVE
BOOM SWING AND 2-PIECE BOOM PPC VALVE
TRAVEL PPC VALVE
BRAKES PUMP
SWIVEL JOINT
SOLENOID VALVE
STEERING CONTROL SOLENOID VALVE GROUP
1-ATTACHMENT FLOW ADJUSTMENT EPC VALVE
2-ATTACHMENT FLOW ADJUSTMENT EPC VALVE
TRAVEL SPEED AND DIRECTION CONTROL SOLENOID VALVE
BOOM/OUTRIGGER SCHEMATIC
UNDERCARRIAGE ATTACHMENT SCHEMATIC
ACCUMULATOR
HOLDING VALVE
2-PIECE BOOM SAFETY VALVE
BLADE/OUTRIGGERS SAFETY VALVE
BOOM SWING SAFETY VALVE
HYDRAULIC QUICK COUPLER
WORK EQUIPMENT
WORK EQUIPMENT SHIM
ELECTRICAL SYSTEM
ELECTRICAL CONTROL SYSTEM
ENGINE CONTROL SYSTEM
FUNCTION OF ENGINE CONTROL SYSTEM
AUTO-DECELERATION SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM
OVERHEAT PREVENTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM
AUTOMATIC IDLE STOP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
CONTROL SYSTEM
MACHINE MONITOR SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
KomVision CONTROLLER
STRUCTURE OF KomVision CONTROLLER
KomVision SYSTEM
KomVision CAMERA
KOMTRAX SYSTEM
PUMP CONTROLLER
MACHINE CONTROLLER
ENGINE CONTROLLER
FUEL CONTROL DIAL
CAB AND ITS ATTACHMENTS
CAB MOUNT AND CAB TIPPING STOPPER
ROPS CAB
STEERING COLUMN

STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR MACHINE

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST EXHAUST GAS COLOR
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
TEST COOLING FAN SPEED
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
TEST INJECTION AMOUNT FROM DEF INJECTOR
TEST DEF LINE HEATER RELAY
TEST DEF PUMP HEATER RELAY
TEST DEF TANK HEATER VALVE
TEST DENITRATION EFFICIENCY OF SCR
CLEAN DEF TANK
POWER TRAIN
TESTING SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
CHECKING LEAKAGES IN THE STEERING CYLINDERS
TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE
TESTING STEERING CIRCUIT RELIEF PRESSURE
TESTING THE BRAKING SYSTEM PRESSURE
TESTING THE BRAKE SYSTEM LEAKAGE
CHECKING WEAR IN THE BRAKE DISKS
BLEEDING AIR FROM THE BRAKE LINES
HYDRAULIC SYSTEM
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS
TESTING AND ADJUSTING SWING CIRCUIT OIL PRESSURE
TESTING OIL PRESSURE OF CONTROL CIRCUIT
INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL PRESSURE
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TESTING OUTLET PRESSURE OF SOLENOID VALVE
TESTING PPC VALVE OUTLET PRESSURE
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE
TESTING AND ADJUSTING THE AUTOMATIC DISPLACEMENT CONTROL OF TRAVEL MOTOR
CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR
ADJUSTMENT OF THE SPEED SENSOR
ISOLATING THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TESTING OIL LEAKAGE
CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR
CHECKING LEAKAGES IN THE STEERING CYLINDERS
BLEEDING AIR FROM CIRCUIT
CAB AND ITS ATTACHMENTS
TESTING, CLEANING AND LUBRICATING SLIDE DOOR RAIL AND ROLLER
ADJUSTING MIRRORS
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
METHOD FOR STARTING UP KOMTRAX TERMINAL
ADJUST KomVision CAMERA ANGLE
ADJUST KomVision RELATED ITEMS
ADJUSTING HEADLIGHT LAMP ALIGNMENT FOR STREET CIRCULATION
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING BATTERY DISCONNECT SWITCH
TESTING DIODES

TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
WALK-AROUND CHECK
CHECK OF FUEL LEVEL AND TYPE
CHECK FUEL PREFILTER
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL
METHOD FOR CHECKING OIL LEVEL IN PTO GEAR CASE, ADDING OIL
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT
METHOD FOR CHECKING AIR CLEANER
METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT
METHOD FOR CHANGING AIR CLEANER ELEMENT
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER
METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT
METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE, ADDING OIL
METHOD FOR CHECKING THE OIL LEVELS IN THE TRANSMISSION REDUCTION GEAR
METHOD FOR CHECKING THE FRONT AXLE OIL LEVEL
METHOD FOR CHECKING THE REAR AXLE OIL LEVEL
BLEED AIR FROM FUEL SYSTEM
BLEED AIR FROM HYDRAULIC SYSTEM
METHOD FOR CHECKING ELECTRIC EQUIPMENT
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
PREPARATION FOR TROUBLESHOOTING OF MACHINE CONTROLLER
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTOR LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
FUSE LOCATION TABLE
CONNECTION TABLE OF FUSE BOX
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL EGR VALVE ASSEMBLY
REMOVE AND INSTALL STARTER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVAL AND INSTALL OF FAN CLUTCH ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVAL AND INSTALL KDOC AND SCR ASSEMBLY
REMOVAL AND INSTALL BELLOWS PIPE ASSEMBLY
REMOVAL AND INSTALL KDOC ASSEMBLY
REMOVAL AND INSTALL SCR ASSEMBLY
REMOVE AND INSTALL DEF TANK
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY
REMOVE AND INSTALL DEF TANK SENSOR
REMOVE AND INSTALL DEF TANK STRAINER
REMOVAL AND INSTALL KCCV ASSEMBLY
REMOVAL AND INSTALL DEF MIXING TUBE
REMOVAL AND INSTALL DEF INJECTOR
REMOVE AND INSTALL DEF PUMP
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL SWING MOTOR
REMOVE AND INSTALL SWING MACHINERY ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF GEAR BOX
UNDERCARRIAGE AND FRAME
REMOVAL AND INSTALLATION OF TWIN-TYPE WHEELS
DISASSEMBLY AND ASSEMBLY OF REAR AXLE
REMOVAL AND INSTALL GEAR BOX
DISASSEMBLY AND ASSEMBLY OF GEAR BOX
REMOVAL AND INSTALL FRONT AXLE
DISASSEMBLY AND ASSEMBLY OF FRONT AXLE
REMOVAL AND INSTALL AXLE LOCKING CYLINDERS
REMOVAL AND INSTALL OF COUNTERWEIGHT
HYDRAULIC SYSTEM
REMOVAL AND INSTALL TRAVEL MOTOR
REMOVAL AND INSTALL BOOM SWING CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
REMOVAL AND INSTALL CYLINDER FOR OUTRIGGERS OR BLADE
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
REMOVAL AND INSTALL BRAKE PEDAL ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALL WORK EQUIPMENT ASSEMBLY
REMOVAL AND INSTALL BOOM SWING BRACKET
REMOVAL AND INSTALL BLADE AND OUTRIGGERS
REMOVAL AND INSTALL BLADE AND OUTRIGGERS ARMS
CAB AND ITS ATTACHMENTS
REMOVAL AND INSTALL OPERATORS CAB ASSEMBLY
REMOVAL AND INSTALL OPERATORS CAB DOOR
REMOVAL AND INSTALL OPERATORS CAB GLASS (ADHERED GLASS)
REMOVAL AND INSTALL FRONT WINDOW ASSEMBLY
REMOVAL AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVAL AND INSTALL OPERATORS SEAT
REMOVAL AND INSTALL SEAT BELT
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALL PUMP CONTROLLER ASSEMBLY
REMOVAL AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY
REMOVAL AND INSTALL STEERING COLUMN SWITCHES
REMOVAL AND INSTALL TRAVEL SPEED SENSOR
REMOVAL AND INSTALL STEERING SENSOR
REMOVAL AND INSTALL REVOLVING FRAME SWING POSITION SENSOR
REMOVAL AND INSTALL DIRECTION INDICATOR, HEAD LIGHT DIPPER BEAM CONTROL GROUP
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR
REMOVE AND INSTALL SCR TEMPERATURE SENSOR
REMOVE AND INSTALL KomVision CAMERA
REMOVAL AND INSTALL KOMTRAX TERMINAL ASSEMBLY

MAINTENANCE STANDARD
ENGINE MOUNT
PTO
ENGINE AND COOLING SYSTEM
COOLING SYSTEM
POWER TRAIN SYSTEM
SWING CIRCLE
SWING MACHINERY
UNDERCARRIAGE AND FRAME
FRONT AXLE
TRANSMISSION
HYDRAULIC SYSTEM
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
1-ATTACHMENT FLOW ADJUSTMENT EPC VALVE
2-ATTACHMENT FLOW ADJUSTMENT EPC VALVE
TRAVEL SPEED AND DIRECTION CONTROL SOLENOID VALVE
BLADE SAFETY VALVE
HOLDING VALVE
CAB AND ITS ATTACHMENTS
CAB MOUNT AND CAB TIPPING STOPPER
WORK EQUIPMENT

APPENDIX
AIR CONDITIONER COMPONENTS
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
AIR CONDITIONER UNIT
DUAL PRESSURE SWITCH
AIR CONDITIONER CONTROLLER
COMPRESSOR
CONDENSER
RECEIVER DRIER
SUNLIGHT SENSOR
OUTER TEMPERATURE SENSOR (OUTSIDE AIR TEMPERATURE SENSOR)
PROCEDURE FOR TESTING AND TROUBLESHOOTING
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS
SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF THE AIR CONDITIONER CONTROLLER
AIR CONDITIONER UNIT
PARTS AND CONNECTORS LAYOUT
TESTING AIR LEAKAGE (DUCT)
TESTING WITH SELF-DIAGNOSIS FUNCTION
TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
TESTING SUNLIGHT SENSOR
TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TESTING RELAYS
TROUBLESHOOTING CHART
INFORMATION IN TROUBLESHOOTING TABLE
FAILURE CODE LIST RELATED TO AIR CONDITIONER
FAILURE CODE [879AKA] A/C RECIRC AIR TEMP SENS OPEN CIRCUIT
FAILURE CODE [879AKB] A/C RECIRC AIR TEMP SENS SHORT
FAILURE CODE [879BKA] A/C FRESH AIR TEMP SENS OPEN CIRCUIT
FAILURE CODE [879BKB] A/C FRESH AIR TEMP SENS SHORT CIRCUIT
FAILURE CODE [879CKA] VENTILATING SENSOR OPEN CIRCUIT
FAILURE CODE [879CKB] VENTILATING SENSOR SHORT CIRCUIT
FAILURE CODE [879DKZ] SUNLIGHT SENSOR OPEN OR SHORT CIRCUIT
FAILURE CODE [879EMC] VENTILATION DAMPER MALFUNCTION
FAILURE CODE [879FMC] AIR MIX DAMPER MALFUNCTION
FAILURE CODE [879GKX] REFRIGERANT PRESS INPUT SIG OUT OF RANGE
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
TROUBLESHOOTING WITH GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING REFRIGERANT PIPING
HANDLING OF COMPRESSOR OIL

DIAGRAMS AND DRAWINGS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS IN ELECTRIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

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