Komatsu Hydraulic Excavator PW98MR-8 Shop Manual WEBM008901 PDF

Description

Komatsu Hydraulic Excavator PW98MR-8 Shop Manual WEBM008901 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PW98MR-8 Shop Manual WEBM008901  – PDF DOWNLOAD

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

IMAGES PREVIEW OF THE MANUAL: 

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PW98MR-8 Shop Manual WEBM008901  – PDF DOWNLOAD

• SERIAL NUMBERS PW98MR-8 F80003 and up

00 Index and foreword . 3
Table of contents . 4
Foreword and general information 14
Safety notice . 14
How to read the shop manual . 19
Explanation of terms for maintenance standard . 21
Handling of hydraulic components 23
Method of disconnecting and connecting push-pull type coupler . 25
Handling of electric equipment 28
How to read electric wire code 38
Precautions when performing work 41
Standard tightening torque table 44
List of abbreviation 48
Conversion table 52
Shop Manual . 57
01 Specification 57
Contents 58
Specifications 59
Specifications drawing 59
Specifications 61
Table of weight . 64
Table of fuel, coolant and lubricants . 66
Shop Manual . 67
10 Structure and function . 67
Contents 68
Engine mount 70
Engine mount 70
PTO . 71
PTO . 71
Cooling system 72
Cooling system 72
Power train . 74
Power train overview 74
Front axle 76
Transmission 82
Rear axle . 84
Axle locking cylinder . 96
Solenoid valve group 97
Priority valve 98
Steering unit . 99
Swing circle 100
Swing machinery .102
Hydraulic system 104
Hydraulic tank and filter .104
Hydraulic system 106
Hydraulic pump 106
Control valve .118
CLSS 130
Function and operation by valve .134
PPC valve .151
Brakes pump .160
Swing motor .161
Travel motor 171
Swivel joint 178
Solenoid valve 180
PPC accumulator .190
Anti-drop valve .192
Work equipment 198
Work equipment 198
Dimensions of components 202
Work equipment cylinder .210
Shop Manual .215
20 Standard value table .215
Contents 216
Standard value table 217
Standard value table for engine .217
Standard value table for chassis 218
30 Testing and adjusting 229
Contents 230
Testing and adjusting .231
Testing engine speed 231
Testing exhaust temperature .232
Checking exhaust gas color 233
Adjusting valve clearance .234
Testing compression pressure 236
Testing blow-by pressure 238
Testing engine oil pressure .239
Handling fuel system parts 240
Releasing residual pressure from fuel system 240
Testing fuel pressure .241
Testing fuel return rate and fuel leakage .242
Bleeding air from fuel circuit 245
Checking fuel circuit for leakage .247
Testing and adjusting alternator belt tension .248
Checking and adjusting air conditioner compressor belt tension 250
Measuring the swing circle axial clearance 251
Checking and regulating pressure in the hydraulic circuits 252
Testing and adjusting oil pressure in work equipment and travel circuits 254
Testing and adjusting swing and attachment 2 circuit oil pressure .256
Testing control circuit basic pressure 258
Testing and adjusting oil pressure in pump PC control circuit .259
Testing LS differential pressure and adjusting LS valve .261
Testing solenoid valve output pressure 263
Testing main pump flow rate .266
Testing and adjusting steering circuit oil pressure .267
Testing the braking system pressure .269
Checking wear in the brake disks 272
Bleeding air from the brake lines .273
Adjusting the parking brake .274
Travel hydraulic equipment checking procedure .275
Testing and adjusting the automatic displacement control system in the travel motor .276
Checking for leakages in the travel motor .278
Checking and adjusting the speed of the travel propeller shaft 279
Adjustment of the speed sensor 281
Checking parts which cause hydraulic drift of work equipment 282
Air bleeding from hydraulic circuits 284
Releasing residual pressure from the circuits .287
Checking leakages in the steering cylinders .288
Adjusting travel PPC valves clearance .289
Wheel types set up 290
Special functions of machine monitor 291
Handling voltage circuit of engine controller .339
Preparation work for troubleshooting of electrical system .340
Procedure for testing diodes 345
40 Troubleshooting 347
Contents 348
Failure code table and fuse locations .353
Failure code table 353
Failure code table of steering controller .356
Fuse locations 357
General information on troubleshooting 360
Points to remember when troubleshooting .360
Sequence of events in troubleshooting .361
Checks before troubleshooting .362
Classification and procedures for troubleshooting .363
Information in troubleshooting table 364
Phenomena looking like troubles and troubleshooting Nos .366
Connection table for connector pin numbers 369
T- branch box and T- branch adapter table .405
Troubleshooting by failure code .409
Failure code [6B2JMA] – Travel hydraulic abnormality 409
Failure code [2G00MA] – Brake oil pressure abnormality 410
Failure code [989L00] Engine controller lock caution 1 411
Failure code [989M00] Engine controller lock caution 2 412
Failure code [989N00] Engine controller lock caution 3 413
Failure code [AB00KE] Charge voltage low 414
Failure code [B@BAZG] Eng oil press. low 416
Failure code [B@BCNS] Eng coolant overheat 417
Failure code [B@HANS] Hyd. oil overheat .418
Failure code [CA111] ECM critical internal failure 419
Failure code [CA115] Eng. Ne and Bkup speed sensor error 422
Failure code [CA122] Charge air press sensor high error .424
Failure code [CA123] Charge air press sensor low error 426
Failure code [CA131] Throttle sensor high error .428
Failure code [CA132] Throttle sensor low error 430
Failure code [CA144] Coolant temp. sensor high error 432
Failure code [CA145] Coolant temp. sensor low error .434
Failure code [CA153] Charge air temp. sensor high error .436
Failure code [CA154] Charge air temp. sensor low error 438
Failure code [CA155] Charge air temperature high speed derate .439
Failure code [CA187] Sensor sup. 2 volt. low error 440
Failure code [CA221] Ambient air press. sensor high error .442
Failure code [CA222] Ambient air press. sensor low error 444
Failure code [CA227] Sensor sup. 2 volt. high error .445
Failure code [CA234] Eng. overspeed .446
Failure code [CA238] Ne speed sensor sup. volt. error .448
Failure code [CA271] IMV/PCV1 short error .450
Failure code [CA272] IMV/PCV1 open error 451
Failure code [CA322] Injector #1 (L #1) system open/short error .452
Failure code [CA324] Injector #3 (L #3) system open/short error .454
Failure code [CA331] Injector #2 (L #2) system open/short error .456
Failure code [CA332] Injector #4 (L #4) system open/short error .458
Failure code [CA342] Calibration code incompatibility .460
Failure code [CA351] Inj. drive circuit error .461
Failure code [CA352] Sensor sup. 1 volt. low error 464
Failure code [CA386] Sensor sup. 1 volt. high error .466
Failure code [CA435] Abnormality in engine oil pressure switch 468
Failure code [CA441] Battery voltage low error 469
Failure code [CA442] Battery voltage high error .470
Failure code [CA449] Rail press. very high error 471
Failure code [CA451] Rail press. sensor high error 472
Failure code [CA452] Rail press. sensor low error .474
Failure code [CA488] Charge air temperature high torque derate 475
Failure code [CA553] Rail press. high error .476
Failure code [CA559] Rail press. low error 477
Failure code [CA689] Eng. Ne speed sensor error .480
Failure code [CA731] Eng. Bkup speed sensor phase error .482
Failure code [CA757] All persistent data lost error .483
Failure code [CA778] Eng. Bkup speed sensor error .484
Failure code [CA1633] KOMNET datalink timeout error .486
Failure code [CA2185] Throttle sens. sup. volt. high error 488
Failure code [CA2186] Throttle sens. sup. volt. low error .490
Failure code [CA2249] Rail press. very low error 491
Failure code [CA2311] Abnormality in IMV solenoid .492
Failure code [D110KB] Battery relay drive short .494
Failure code [D19JKZ] Personal code relay abnormality .496
Failure code [D862KA] GPS antenna discon 498
Failure code [DA22KK] Pump solenoid power low error .500
Failure code [DA25KP] 5 V sensor 1 power abnormality 503
Failure code [DA26KP] 5 V sensor 2 power abnormality 506
Failure code [DA2RMC] CAN discon (Pump controller detected) .508
Failure code [DAF8KB] Short circuit in camera power supply 510
Failure code [DAFGMC] GPS module error 512
Failure code [DAFRMC] CAN discon (Monitor detected) .514
Failure code [DDP4KX] Disconnection in travel PPC pressure switch .516
Failure code [DDWCKZ] Disconnection in direction control switches .518
Failure code [DLT4KA] Disconnection in transmission speed sensor 520
Failure code [DFB1KZ] Service lever pot. 1 abnormality 522
Failure code [DFB2KZ] Service lever pot. 2 abnormality 524
Failure code [DFB3L8] Service lever1 potentio error .526
Failure code [DFB4L8] Service lever2 potentio error .528
Failure code [DFB5KZ] Service lever sPot. 1 abnormality .530
Failure code [DFB6KZ] Service lever sPot. 2 abnormality .532
Failure code [DGH2KB] Hydr oil sensor short .534
Failure code [DH10KS] Abnormality in 24V sensor power source 535
Failure code [DHPAMA] Pump press sensor abnormality .536
Failure code [DHS5KX] Travel PPC sensor abnormality .538
Failure code [DHX1MA] Overload sensor abnormality .540
Failure code [DV20KB] Travel alarm ground short .541
Failure code [DW43MA] Travel speed High abnormality .542
Failure code [DW43MA] Travel speed Low abnormality 543
Failure code [DW45KA] Swing brake sol discon 544
Failure code [DW45KB] Swing brake sol short .546
Failure code [DW4AKB] SUS lock Sol Short Circuit 548
Failure code [DW4AKA] SUS lock Sol Open Circuit .550
Failure code [DW4CKB] PPC lock relay Short circuit 552
Failure code [DW4CKA] PPC lock relay Open Circuit .554
Failure code [DW9KKA] Travel Forward Solenoid Open Circuit 556
Failure code [DW9KKB] Travel forward speed sol short 558
Failure code [DW9LKA] Travel reverse Solenoid Open Circuit 560
Failure code [DW9LKB] Travel reverse solenoid short circuit .561
Failure code [DWB2KB] Outrigger Sol. Short circuit right 562
Failure code [DWB2KA] Outrigger Sol. Open Circuit Right .564
Failure code [DWB3KB] Outrigger Sol. Short Circuit left .566
Failure code [DWB3KA] Outrigger sol. Open Circuit left 568
Failure code [DWB4KB] Outrigger blade sol. short circuit 570
Failure code [DWB4KA] Outrigger blade sol. open circuit .572
Failure code [DXA8KA] PC-EPC sol discon .574
Failure code [DXA8KB] PC-EPC sol short 576
Failure code [DXE7KA] Service current EPC2 open circuit .578
Failure code [DXE7KB] Service current EPC2 short circuit 580
Failure code [DXE8KA] Service current EPC3 open circuit .582
Failure code [DXE8KB] Service current EPC3 short circuit 584
Failure code [DXE9KA] Service current EPC4 open circuit .586
Failure code [DXE9KB] Service current EPC4 short circuit 588
Failure code [DXEAKA] Service current EPC1 open circuit .590
Failure code [DXEAKB] Service current EPC1 short circuit 592
Failure code [DY20KA] Wiper working abnormality .594
Failure code [DY20MA] Wiper parking abnormality .596
Failure code [DY2CKA] Washer drive open circuit .598
Failure code [DY2CKB] Washer drive short circuit 600
Failure code [DY2DKB] Wiper drive (fwd) short circuit .602
Failure code [DY2EKB] Wiper drive (rev) short circuit .604
Troubleshooting by failure code steering controller .607
Failure code 0E3 Hydraulic gear valve sol short circuit .608
Failure code 0E4 Hydraulic gear valve sol disconnection .610
Failure code 0E5 Low speed gear valve sol short circuit .612
Failure code 0E6 Low speed gear valve sol disconnection .614
Failure code 0E7 High speed gear valve sol short circuit 616
Failure code 0E8 High speed gear valve sol disconnection 618
Failure code 0E9 High speed state short circuit .620
Failure code 1E0 High speed state disconnection .622
Failure code 1E1 Round valve sol short circuit 624
Failure code 1E2 Round valve sol disconnection 626
Failure code 1E3 Round valve sol short circuit 628
Failure code 1E4 Round valve sol disconnection 630
Failure code 1E5-1E7 2WS or LOCK valve sol short circuit 632
Failure code 1E6-1E8 2WS and LOCK valve sol disconnection .634
Failure code 1E9 4WS valve sol short circuit 636
Failure code 2E0 4WS valve sol disconnection 638
Failure code 2E1 Enable transm. state short circuit Gnd .640
Failure code 2E2 Hydr. gear state short circuit Gnd .642
Failure code 2E3 F-N-R Abnormality error 644
Failure code 2E5 Gear engaged open circuit 646
Failure code 2E6 Speed sensor open circuit 648
Failure code 2E7 High/low speed Abnormality error .650
Failure code 2E8 Solenoid power supply error 652
Failure code 2E9 Wiper intermittent open circuit 653
Failure code 3E0 Wiper continuos short circuit 654
Failure code 3E1 Wiper continuos open circuit .655
Failure code 3E2 Wiper intermittent short circuit .656
Failure code 3E3 Can Bus communication error 658
Troubleshooting of electrical system 661
Before carrying out troubleshooting of electrical system 661
Information in troubleshooting table 664
E-1 When starting switch is turned ON, machine monitor displays nothing .666
E-2 Engine does not start (Engine does not turn) 669
E-3 Preheater does not operate 672
E-4 Automatic warm-up system does not operate (in cold season) 674
E-5 All work equipment and swing do not move or cannot be locked 676
E-6 Precaution lights up while engine is running 678
E-7 Emergency stop item lights up while engine is running .681
E-8 Engine coolant temperature gauge does not indicate normally .682
E-9 Hydraulic oil temperature gauge does not indicate normally 684
E-10 Fuel level gauge does not indicate normally 687
E-11 Contents of display by machine monitor are different from applicable machine .689
E-12 Machine monitor does not display some items 690
E-13 Function switch does not work 691
E-14 Auto-decelerator does not operate normally .692
E-15 Working mode does not change .693
E-16 Alarm buzzer cannot be stopped .695
E-17 Windshield wiper and window washer do not operate 696
E-18 Swing holding brake does not operate normally 699
E-19 Travel alarm does not sound or does not stop sounding 700
E-20 Air conditioner does not operate normally (including air conditioner abnormality record) .701
E-21 While starting switch is in OFF position, service meter is not displayed .714
E-22 Machine monitor cannot be set in service mode 715
E-23 Monitoring function does not display lever control signal normally .716
E-24 KOMTRAX system does not operate normally .738
Troubleshooting of hydraulic and mechanical system (H-mode) .739
Information contained in troubleshooting table 739
H-1 Speed or power of all work equipment, swing, and travel are low .740
H-2 Engine speed sharply drops or engine stalls .741
H-3 No work equipment, travel and swing move 742
H-4 Abnormal noise is heard from around hydraulic pump 743
H-5 Fine control performance or response of work equipment and travel is low 744
H-6 Speed or power of boom is low .745
H-7 Speed or power of arm is low 746
H-8 Speed or power of bucket is low .747
H-9 Speed or power of boom swing is low .748
H-10 Speed or power of blade is low .749
H-11 Work equipment does not move in its single operation .750
H-12 Hydraulic drift of work equipment is large .751
H-13 Time lag of work equipment is large 753
H-14 Work equipment loaded more is slower during compound operation .754
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE 755
H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel .756
H-17 Machine deviates during travel .757
H-18 Travel speed is low 758
H-19 Machine cannot be steered easily or steering power is low 759
H-20 Travel speed does not change or it is kept low or high .760
H-21 Track does not move (only either side) .761
H-22 Machine does not swing .762
H-23 Swing acceleration, swing speed and swing power are low 763
H-24 Excessive overrun when stopping swing 765
H-25 When upper structure stops swinging, it makes large shock 766
H-26 When upper structure stops swinging, it makes large sound 767
H-27 Hydraulic drift of swing is large 768
H-28 Flow rate in attachment circuit cannot be adjusted .769
Troubleshooting of engine (S-mode) 770
Method of using troubleshooting chart .770
S-1 Starting performance is poor 774
S-2 Engine does not start .775
S-3 Engine does not pick up smoothly 778
S-4 Engine stops during operations 779
S-5 Engine does not rotate smoothly .780
S-6 Engine lacks output (or lacks power) 781
S-7 Exhaust smoke is black (incomplete combustion) 782
S-8 Oil consumption is excessive (or exhaust smoke is blue) .783
S-9 Oil becomes contaminated quickly 784
S-10 Fuel consumption is excessive 785
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 786
S-12 Oil pressure drops .787
S-13 Oil level rises (Entry of coolant or fuel) .788
S-14 Coolant temperature becomes too high (overheating) .789
S-15 Abnormal noise is made .790
S-16 Vibration is excessive .791
50 Disassembly and assembly .793
Contents 794
How to read this manual .796
Coating materials list 798
Engine and cooling system .801
Removal and installation of fuel supply pump assembly .801
Removal and installation of fuel injector assembly 805
Removal and installation of engine front seal .808
Removal and installation of engine rear seal 809
Removal and installation of cylinder head assembly 811
Removal and installation of radiator assembly .821
Removal and installation of aftercooler assembly 824
Removal and installation of fuel tank assembly 826
Removal and installation of hydraulic oil cooler assembly .828
Removal and installation of engine hood assembly 831
Power train .832
Removal and installation of swing motor and swing machinery assembly 832
Disassembly and assembly of swing machinery .834
Removal and installation of swing circle assembly .843
Undercarriage and frame .844
Removal and installation front axle .844
Removal and installation of rear axle .846
Disassembly and assembly of axles .848
Removal and installation of axle locking cylinders 889
Removal and installation of transmission 890
Disassembly and assembly of the transmission 891
Removal and installation of counterweight assembly 901
Hydraulic system 905
Removal and installation of travel motor 905
Removal and installation of hydraulic tank assembly .907
Disassembly and assembly of control valve assembly 910
Disassembly and assembly of work equipment PPC valve assembly .912
Removal and installation of boom swing cylinder assembly 914
Disassembly and assembly of hydraulic cylinder assembly .917
Disassembly and assembly of hydraulic cylinder assembly .921
Removal and installation of boom cylinder .926
Removal and installation of 2-piece boom cylinder .928
Removal and installation swivel joint .930
Work equipment 932
Removal and installation work equipment assembly 932
Removal and installation blade and outriggers .934
Removal and installation blade and outrigger arms .935
Removal and installation of boom swing bracket 936
Removal and installation of upper equipment .939
Cab and its attachment 941
Removal and installation of operator cab assembly .941
Removal and installation of operator’s cab glass (Stuck glass) 947
Removal and installation of front window assembly .957
Electrical system .958
Removal and installation of air conditioner compressor assembly .958
Removal and Installation of air conditioner condenser assembly 959
Removal and installation of air conditioner unit assembly .960
Removal and installation of machine monitor assembly 964
Removal and installation of pump controller assembly 965
Removal and installation of engine controller assembly 967
Removal and installation of KOMTRAX terminal assembly .969
Removal and installation of transmission – reverser, direction indicator and headlight dipper beam control group 970
90 Diagrams and drawings 971
Contents 972
Hydraulic diagram .973
Electrical diagram 0
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 Hydraulic Excavator PW98MR-8 Shop Manual WEBM008901  – PDF DOWNLOAD

• SERIAL NUMBERS PW98MR-8 F80003 and up

1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding
for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting
and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling
each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section
explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of re manufacturing and repairing engine and replacing parts.

G.B 25/12/24