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Komatsu PW148-10 Shop Manual VENBM60002 – PDF DOWNLOAD
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Description
Komatsu PW148-10 Shop Manual VENBM60002 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PW148-10 Shop Manual VENBM60002 – PDF DOWNLOAD
Language : English
Pages : 1313
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Komatsu PW148-10 Shop Manual VENBM60002 – PDF DOWNLOAD
VENBM60002 PW148-10.................................................................................................. 1 FOREWORD............................................................................................................. 5 Safety........................................................................................................... 5 Important safety notice...................................................................................... 5 General precautions.......................................................................................... 5 Preparations for work........................................................................................ 5 Precautions during work...................................................................................... 6 General.......................................................................................................... 7 General...................................................................................................... 7 Structure and function....................................................................................... 7 Testing, adjusting and troubleshooting....................................................................... 7 Disassembly and assembly..................................................................................... 7 Maintenance standard......................................................................................... 7 How to read the shop manual...................................................................................... 8 Volumes...................................................................................................... 8 Distribution and updating................................................................................ 8 Filing method................................................................................................ 8 Revised edition mark......................................................................................... 8 Revisions.................................................................................................... 8 Symbols...................................................................................................... 8 Hoisting instructions............................................................................................ 9 Hoisting..................................................................................................... 9 Wire Ropes............................................................................................... 9 Coating materials................................................................................................ 10 Standard tightening torque....................................................................................... 12 Standard tightening torque of bolts and nuts................................................................. 12 Tightening torque of hose nuts............................................................................... 13 Tightening torque of split flange bolts...................................................................... 13 Tightening torques for hoses (taper seal type and face seal type)............................................ 13 Tightening torque for 107 engine series (bolts and nuts)..................................................... 14 Tightening torque for 107 engine series (eye joints)......................................................... 14 Tightening torque for 107 engine series (tapered screws)..................................................... 14 Electric wire code............................................................................................... 15 Classification by thickness.................................................................................. 15 Classification by color and code............................................................................. 15 Conversion tables................................................................................................ 16 Method of using the conversion table......................................................................... 16 Units............................................................................................................ 22 GENERAL.............................................................................................................. 37 Specification dimension drawings................................................................................. 38 Dimensions................................................................................................... 38 Working ranges................................................................................................... 40 Working range: 1-piece boom.................................................................................. 40 Working range: 2-piece boom.................................................................................. 41 Weight table..................................................................................................... 45 1-piece boom................................................................................................. 46 2-piece boom................................................................................................. 47 Fuel, coolant and lubricants..................................................................................... 48 STRUCTURE AND FUNCTION............................................................................................... 49 Engine related parts............................................................................................. 52 Variable Flow Turbocharger................................................................................... 54 EGR system piping drawing.................................................................................... 57 EGR system circuit diagram................................................................................... 58 EGR valve.................................................................................................... 59 EGR cooler................................................................................................... 61 KCCV layout drawing.......................................................................................... 62 KCCV ventilator.............................................................................................. 64 KDOC muffler................................................................................................. 66 Cooling system............................................................................................... 68 Power train...................................................................................................... 70 Swing circle................................................................................................. 72 Specifications........................................................................................... 72 Swing machinery & motor.......................................................................................... 73 Specification................................................................................................ 74 Operation of swing lock...................................................................................... 75 Relief valve portion......................................................................................... 76 Operation................................................................................................ 76 Undercarriage.................................................................................................... 78 Transmission..................................................................................................... 80 Specifications............................................................................................... 80 Function..................................................................................................... 82 Hydraulic quick coupler.......................................................................................... 83 Schematic.................................................................................................... 83 Operation.................................................................................................... 84 Hydraulic quick coupler solenoid valve....................................................................... 84 Specification................................................................................................ 84 Quick coupler error logic.................................................................................... 85 Travel motor..................................................................................................... 86 Function..................................................................................................... 87 Operation of travel motor.................................................................................... 88 Clutch control circuit........................................................................................... 90 Function..................................................................................................... 91 Axle............................................................................................................. 92 Outline...................................................................................................... 92 Suspension lock cylinder......................................................................................... 96 Specifications............................................................................................... 96 Structure and function....................................................................................... 96 Circuit...................................................................................................... 97 Axle oscillation............................................................................................. 97 Braking system................................................................................................... 98 Structure and function....................................................................................... 99 Gear pump........................................................................................................ 100 Specifications............................................................................................... 100 Function..................................................................................................... 100 Priority valve................................................................................................... 102 Specification................................................................................................ 102 Function..................................................................................................... 102 Power brake valve................................................................................................ 104 Specifications............................................................................................... 105 Function..................................................................................................... 105 Accumulator for brake valve...................................................................................... 106 Specifications............................................................................................... 106 Structure and function....................................................................................... 106 Steering system.................................................................................................. 107 Structure and function....................................................................................... 107 Steering column.................................................................................................. 108 Orbitrol valve................................................................................................... 109 Specifications............................................................................................... 109 Structure and function....................................................................................... 109 Hydraulic equipment layout drawings.............................................................................. 110 Hydraulic circuit diagram........................................................................................ 112 Hydraulic tank................................................................................................... 113 Specifications............................................................................................... 113 Hydraulic pump................................................................................................... 114 Function..................................................................................................... 116 Structure.................................................................................................... 116 Operation.................................................................................................... 117 LS valve..................................................................................................... 119 PC valve..................................................................................................... 120 Function................................................................................................. 121 Operation................................................................................................ 122 1. LS valve.............................................................................................. 122 2. PC valve.............................................................................................. 126 LS(PC)-EPC valve............................................................................................. 133 Function................................................................................................. 134 Operation................................................................................................ 134 Pilot pressure control (PPC) system.............................................................................. 136 Function..................................................................................................... 137 Operation.................................................................................................... 137 Control valve.................................................................................................... 138 Outline...................................................................................................... 138 CLSS............................................................................................................. 153 Outline of CLSS.............................................................................................. 153 Features................................................................................................. 153 Structure................................................................................................ 153 Basic Principle.............................................................................................. 154 Operation for each function and valve........................................................................ 156 Hydraulic circuit diagram and name of valves............................................................. 156 1. Unload valve.............................................................................................. 158 Function................................................................................................. 158 Operation................................................................................................ 158 Operation................................................................................................ 159 Operation................................................................................................ 160 2. Introduction of LS pressure............................................................................... 161 Work equipment valve..................................................................................... 161 Function................................................................................................. 161 Operation................................................................................................ 161 3. LS bypass plug............................................................................................ 162 Outline.................................................................................................. 162 Operation................................................................................................ 162 4. Pressure compensation valve............................................................................... 163 Function................................................................................................. 163 Operation................................................................................................ 164 5. Area ratio of pressure compensation valve................................................................. 165 Function................................................................................................. 165 6. Boom regeneration circuit................................................................................. 166 Function................................................................................................. 166 Operation................................................................................................ 166 Function................................................................................................. 167 Operation................................................................................................ 167 7. Arm regeneration circuit.................................................................................. 168 Function................................................................................................. 168 Operation................................................................................................ 168 Function................................................................................................. 169 Operation................................................................................................ 169 8. Swing bleeding valve...................................................................................... 170 Function................................................................................................. 170 Operation (In fine control operation).................................................................... 171 9. LS select valve........................................................................................... 172 Function................................................................................................. 172 Operation................................................................................................ 172 Centre swivel joint.............................................................................................. 173 Travel PPC pedal................................................................................................. 174 Work equipment – Swing PPC valve................................................................................. 176 Operation.................................................................................................... 178 Solenoid valve block with integrated ATT - EPC................................................................... 180 ON / OFF Solenoid valves (3 way valve)....................................................................... 182 Operation................................................................................................ 182 ON / OFF Solenoid valves (4 way valve)................................................................... 184 Operation................................................................................................ 184 Hi/ Lo Solenoid valve (4 way valve)...................................................................... 186 Attachment PPC valve......................................................................................... 188 Function................................................................................................. 189 Operation................................................................................................ 189 Undercarriage solenoid valve block........................................................................... 191 Boom/Outrigger schematic..................................................................................... 192 Undercarriage attachment schematic........................................................................... 193 Proportional attachment control.............................................................................. 194 Proportional attachment schematic............................................................................ 195 Boom safety valve................................................................................................ 196 Operation.................................................................................................... 197 Hydraulic cylinder............................................................................................... 198 Boom cylinder................................................................................................ 198 Arm cylinder................................................................................................. 198 Bucket cylinder.............................................................................................. 198 Adjust cylinder.............................................................................................. 199 Outrigger cylinder........................................................................................... 200 Function................................................................................................. 201 Dozer cylinder............................................................................................... 202 Function................................................................................................. 203 Work equipment................................................................................................... 204 Work equipment............................................................................................... 205 1. Dimension of arm.......................................................................................... 206 2. Dimension of bucket....................................................................................... 208 Air conditioner.................................................................................................. 210 Air conditioner piping....................................................................................... 210 Electrical wiring diagram........................................................................................ 211 Electrical system................................................................................................ 212 Engine control............................................................................................... 212 1. Operation of System................................................................................... 212 2. Component............................................................................................. 213 Engine controller................................................................................................ 214 Pump controller.................................................................................................. 218 Electrical control system........................................................................................ 221 Machine control system diagram................................................................................... 222 1. Engine and pump control function.......................................................................... 223 Function..................................................................................................... 224 Function..................................................................................................... 228 Function..................................................................................................... 230 Function..................................................................................................... 232 Operation.................................................................................................... 233 Function..................................................................................................... 234 Function..................................................................................................... 238 Function..................................................................................................... 240 Function..................................................................................................... 244 Specifications............................................................................................... 245 Function..................................................................................................... 245 Function..................................................................................................... 246 Operation.................................................................................................... 246 Machine monitor system........................................................................................... 250 Monitor panel................................................................................................ 252 Monitor display.............................................................................................. 256 Monitor items and display.................................................................................... 258 Caution monitor.............................................................................................. 260 Pilot monitor................................................................................................ 263 Monitor switches............................................................................................. 265 Declaration of switch function on keypad................................................................. 266 Guidance icon and function switch........................................................................ 268 Operator mode function................................................................................... 271 Service mode function.................................................................................... 272 KOMTRAX system................................................................................................... 273 KOMTRAX terminal............................................................................................. 274 Overload warning device.......................................................................................... 276 Outline...................................................................................................... 276 Function................................................................................................. 276 Structure................................................................................................ 276 Sensor........................................................................................................... 277 Ambient pressure sensor...................................................................................... 278 Charge (boost) pressure and temperature sensor............................................................... 279 Coolant temperature sensor................................................................................... 280 Ne (crankshaft) speed sensor................................................................................. 280 Bkup (camshaft) speed sensor................................................................................. 281 Common rail pressure sensor.................................................................................. 281 Exhaust manifold pressure sensor............................................................................. 282 EGR orifice temperature sensor............................................................................... 282 Variable flow turbocharger motor (with built-in position sensor)............................................. 283 EGR valve (with built-in position sensor).................................................................... 284 Mass air flow and temperature sensor......................................................................... 285 Crankcase pressure sensor.................................................................................... 285 Engine oil level sensor...................................................................................... 286 Fuel level sensor............................................................................................ 287 WIF (Water-In-Fuel detection) sensor......................................................................... 288 Coolant level sensor......................................................................................... 289 Hydraulic oil temperature sensor......................................................................... 290 Air cleaner clogging sensor.................................................................................. 290 Overload Caution sensor...................................................................................... 291 Swing proximity sensor....................................................................................... 292 Travel PPC sensor............................................................................................ 292 PPC pressure sensor.......................................................................................... 292 Park brake pressure sensor................................................................................... 293 Brake accumulator low pressure sensor.................................................................... 293 Brake stop light sensor.................................................................................. 293 PPC levers....................................................................................................... 294 LH PPC lever................................................................................................. 294 RH PPC lever................................................................................................. 295 1st attachment circuit hydraulic performance (main valve bypassed)............................................... 296 Travel system.................................................................................................... 297 Travel circuit............................................................................................... 297 Travel Motor Performance................................................................................. 298 Auto-grease pump............................................................................................. 300 Overview................................................................................................. 301 Display and control unit................................................................................. 301 LED-display.............................................................................................. 302 Push buttons............................................................................................. 302 Three-digit LED display.................................................................................. 303 Check central lubrication system, fill up grease......................................................... 304 Lubrication diagrams............................................................................................. 305 Auto-grease pump with one-piece boom......................................................................... 305 Auto-grease pump with two-piece boom......................................................................... 306 Two point system one-piece boom.............................................................................. 307 Two point system two-piece boom.............................................................................. 308 Standard value table for engine related parts.................................................................... 310 Standard value table for chassis related parts................................................................... 311 Flow control characteristic of PC valve (STD)................................................................ 324 PM clinic service................................................................................................ 325 Check sheet.................................................................................................. 326 STANDARD VALUE TABLE................................................................................................. 309 TESTING AND ADJUSTING................................................................................................ 333 Measuring engine speed........................................................................................... 334 Measuring intake air pressure (boost pressure)................................................................... 335 Checking exhaust gas colour...................................................................................... 337 Measuring and adjusting valve clearance.......................................................................... 339 Testing...................................................................................................... 339 Adjusting.................................................................................................... 340 Testing compression pressure..................................................................................... 341 Testing...................................................................................................... 341 Measuring blow-by pressure....................................................................................... 345 Measuring engine oil pressure.................................................................................... 346 Handling fuel system parts....................................................................................... 347 Releasing residual pressure from fuel system..................................................................... 348 Measuring fuel pressure.......................................................................................... 349 Measuring fuel delivery, return and leakage...................................................................... 353 Bleeding air from fuel circuit................................................................................... 358 Checking fuel circuit for leakage............................................................................ 360 Checking and adjusting air conditioner compressor belt tension................................................... 361 Checking..................................................................................................... 361 Adjusting.................................................................................................... 361 Replacing the fan belt........................................................................................... 362 Measurement of clearance in swing circle bearing................................................................. 363 Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel.... 364 Measurement.................................................................................................. 364 Adjustment................................................................................................... 365 Inspection and adjustment of control circuit oil pressure........................................................ 367 Measurement.................................................................................................. 367 Procedure for pressure reducing adjustment................................................................... 368 Inspection and adjustment of pump PC (valve inlet) control oil pressure.......................................... 369 Measurement.................................................................................................. 369 Adjustment................................................................................................... 371 Inspection and adjustment of pump LS differential pressure....................................................... 372 Measurement.................................................................................................. 372 Adjustment................................................................................................... 374 Measurement of solenoid valve output pressure.................................................................... 375 Checking Proportional Control PPC Circuit.................................................................... 377 Adjustment of work equipment and swing PPC valve................................................................. 378 Measuring and adjusting quick coupler control valve output pressure.............................................. 379 Testing travel motor relief pressure............................................................................. 380 Measuring travel motor relief pressure....................................................................... 380 Testing propshaft speed.......................................................................................... 381 Measuring rotating speed of propshaft........................................................................ 381 Testing transmission clutch control circuit...................................................................... 382 Description.................................................................................................. 382 Inspection of locations of hydraulic drift of work equipment..................................................... 384 Release of remaining pressure in hydraulic circuit............................................................... 386 Measurement of oil leakage....................................................................................... 387 Air bleeding of various parts.................................................................................... 390 Inspection procedures for diode.................................................................................. 393 Special function of monitor panel................................................................................ 394 Changing the lubrication interval times.......................................................................... 461 TROUBLESHOOTING...................................................................................................... 463 Troubleshooting.................................................................................................. 463 General information on troubleshooting........................................................................... 464 Troubleshooting points....................................................................................... 464 Sequence of events in troubleshooting........................................................................ 465 1. Points to remember when handling electric equipment................................................... 468 2. Points to remember when troubleshooting electric circuits............................................. 474 3. Points to remember when handling hydraulic equipment.................................................. 475 Checks before troubleshooting................................................................................ 477 How to read electric wire code............................................................................... 478 Connector location chart and circuit diagram by system........................................................... 482 Connector table.............................................................................................. 483 Connection table for connector pin numbers....................................................................... 496 T-boxes and T-adapters table................................................................................. 532 Before carrying out troubleshooting when failure code is displayed............................................... 542 Information contained in troubleshooting table................................................................... 544 Troubleshooting by failure code (Display of code)................................................................ 546 Failure code [879AKA] – A/C inner sensor open circuit............................................................ 546 Failure code [879AKB] – A/C inner sensor short circuit........................................................... 546 Failure code [879CKA] – Ventilating sensor open circuit.......................................................... 546 Failure code [879CKB] – Ventilating sensor short circuit......................................................... 547 Failure code [879DKZ] – Sunlight sensor open or short circuit.................................................... 547 Failure code [879EMC] – Ventilation damper abnormality........................................................... 547 Failure code [879FMC] – Air mix damper abnormality............................................................... 547 Failure code [879GKX] – Refrigerant abnormality.................................................................. 547 Failure code [2G00MA] – Brake oil pressure abnormality........................................................... 548 Failure code [6B2JMA] – Travel hydraulic abnormality............................................................. 550 Failure code [989L00] – Engine controller lock caution 1......................................................... 551 Failure code [989M00] – Engine controller lock caution 2......................................................... 552 Failure code [989N00] – Engine controller lock caution 3......................................................... 553 Failure code [AA10NX] – Air cleaner clogging..................................................................... 554 Failure code [AB00KE] – Charge voltage low....................................................................... 556 Failure code [B@BAZG] – Engine oil pressure low.................................................................. 558 Failure code [B@BAZK] – Engine oil level low..................................................................... 559 Circuit diagram related to engine oil level.................................................................. 559 Failure code [B@BCNS] – Engine coolant overheat.................................................................. 560 Failure code [B@BCZK] – Engine coolant level low................................................................. 561 Circuit diagram related to radiator coolant level switch..................................................... 561 Failure code [B@HANS] – Hydraulic oil overheat................................................................... 562 Failure code [CA111] – EMC critical internal failure............................................................. 562 Failure code [CA115] – Engine neutral and backup speed sensor error.............................................. 563 Failure code [CA122] – Charge air press sensor high error........................................................ 564 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 565 Failure code [CA123] – Charge air press sensor low error......................................................... 566 Failure code [CA131] – Throttle sensor high error................................................................ 568 Circuit diagram related to fuel control dial................................................................. 569 Failure code [CA132] – Throttle sensor low error................................................................. 570 Circuit diagram related to fuel control dial................................................................. 571 Failure code [CA144] – Coolant temperature sensor high error..................................................... 572 Failure code [CA145] – Coolant temp sensor low error............................................................. 574 Circuit diagram related to coolant temperature sensor........................................................ 575 Failure code [CA153] – Charge air temperature sensor high error.................................................. 576 Failure code [CA154] – Charge air temperature sensor low error................................................... 578 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 579 Failure code [CA187] – Sensor supply 2 voltage low error......................................................... 580 Failure code [CA221] – Ambient press sensor high error........................................................... 582 Circuit diagram related to ambient pressure sensor........................................................... 583 Failure code [CA222] – Ambient press sensor low error............................................................ 584 Circuit diagram related to ambient pressure sensor........................................................... 585 Failure code [CA227] – Sensor supply 2 volt high error........................................................... 586 Failure code [CA234] – Engine overspeed.......................................................................... 587 Failure code [CA238] – NE speed sensor supply voltage error...................................................... 588 Failure code [CA239] – Ne speed sens supply volt high error...................................................... 590 Circuit diagram related to Ne speed sensor................................................................... 591 Failure code [CA271] – IMV/PCV1 short circuit error.............................................................. 592 Failure code [CA272] – IMV/PCV1 open error....................................................................... 594 Failure code [CA295] – Ambient press sens in range error......................................................... 595 Failure code [CA322] – Injector #1 (L#1) open/short circuit error................................................ 596 Circuit diagram related to no. 1 injector.................................................................... 597 Failure code [CA324] – Injector #3 (L#3) open/short circuit Error................................................ 598 Circuit diagram related to no. 3 injector.................................................................... 599 Failure code [CA331] – Injector #2 (L#2) open/short circuit error................................................ 600 Circuit diagram related to no. 2 injector.................................................................... 601 Failure code [CA332] – Injector #4 (L#4) open/short circuit error................................................ 602 Circuit diagram related to no. 4 injector.................................................................... 603 Failure code [CA343] – ECM critical internal failure............................................................. 604 Failure code [CA351] – Injectors drive circuit error............................................................. 605 Failure code [CA352] – Sensor 1 supply voltage low error......................................................... 606 Failure code [CA356] – Mass air flow sensor high error........................................................... 608 Failure code [CA357] – Mass air flow sensor low error............................................................ 610 Failure code [CA386] – Sensor 1 supply voltage high error........................................................ 612 Failure code [CA428] – Water-in-fuel sensor high error........................................................... 614 Failure code [CA429] – Water-in-fuel sensor low error............................................................ 616 Failure code [CA435] – Engine oil pressure switch error.......................................................... 618 Failure code [CA441] – Battery voltage low error................................................................. 620 Failure code [CA442] – Battery voltage high error................................................................ 622 Failure code [CA449] – Common rail pressure very high error...................................................... 624 Failure code [CA451] – Rail pressure sensor high error........................................................... 626 Failure code [CA452] – Rail pressure sensor low error............................................................ 628 Failure code [CA466] – KVGT motor driver position error.......................................................... 630 Failure code [CA488] – Charge air temperature high torque derate................................................. 632 Failure code [CA515] – Rail press sens sup volt high error....................................................... 634 Failure code [CA516] – Rail press sens sup volt low error........................................................ 636 Failure code [CA553] – Common rail pressure high error........................................................... 638 Failure code [CA555] – Crankcase press high error 1.............................................................. 639 Failure code [CA556] – Crankcase press high error 2.............................................................. 640 Failure code [CA559] – Rail pressure low error................................................................... 642 Failure code [CA689] – Engine ne speed sensor error.............................................................. 644 Failure code [CA691] – Intake air temp sens high error........................................................... 646 Failure code [CA692] – Intake air temp sens low error............................................................ 648 Failure code [CA697] – ECM int temp sensor high error............................................................ 650 Failure code [CA698] – ECM int temp sensor low error............................................................. 651 Failure code [CA731] – Engine Bkup speed sensor phase error...................................................... 652 Failure code [CA778] – Engine Bkup speed sensor error............................................................ 654 Failure code [CA1117] – Persistent data lost error............................................................... 658 Failure code [CA1695] – Sensor 5 supply volt high error.......................................................... 660 Failure code [CA1696] – Sensor 5 supply volt low error........................................................... 661 Failure code [CA1843] – Crankcase press sens high error.......................................................... 662 Failure code [CA1844] – Crankcase press sens low error........................................................... 664 Failure code [CA1896] – EGR valve stuck error.................................................................... 666 Failure code [CA1942] – Crankcase press sens in range error...................................................... 668 Failure code [CA1961] – EGR motor driver IC over temp error...................................................... 669 Failure code [CA2185] – Throt sensor sup volt high error......................................................... 670 Circuit diagram related to throttle sensor................................................................... 671 Failure code [CA2186] – Throt sensor sup volt low error.......................................................... 672 Failure code [CA2249] – Rail pressure very low error............................................................. 674 Failure code [CA2272] – EGR valve pos sens low error............................................................. 676 Failure code [CA2311] – IMV solenoid error....................................................................... 678 Failure code [CA2349] – EGR valve solenoid open error............................................................ 680 Failure code [CA2353] – EGR valve solenoid short error........................................................... 682 Failure code [CA2357] – EGR valve servo error.................................................................... 684 Failure code [CA2373] – Exhaust manifold press sens high error................................................... 686 Failure code [CA2374] – Exhaust manifold press sens low error.................................................... 688 Failure code [CA2375] – EGR orifice temp sens high error......................................................... 690 Failure code [CA2376] – EGR orifice temp sens low error.......................................................... 692 Failure code [CA2554] – Exh manifold press sens in range error................................................... 694 Failure code [CA2555] – Grid heater relay volt low error......................................................... 696 Failure code [CA2556] – Grid heater relay volt high error........................................................ 698 Failure code [CA2961] – EGR orifice temperature high error 1..................................................... 700 Failure code [CA2973] – Chg air press sensor in range error...................................................... 701 Failure code [CA3419] – Mass air flow sensor sup volt high error................................................. 702 Failure code [CA3421] – Mass air flow sensor sup volt low error.................................................. 704 Failure code [CA3724] – EGR/KVGT motor driver power low error.................................................... 706 Failure code [CA3741] – Rail press valve trip error.............................................................. 708 Failure code [CA3918] – KVGT stuck error......................................................................... 709 Failure code [CA3919] – KVGT motor driver IC over temp error..................................................... 710 Failure code [CA3921] – KVGT servo error 2....................................................................... 711 Failure code [CA3922] – KVGT motor driver open error............................................................. 712 Failure code [CA3923] – KVGT motor driver short error............................................................ 714 Failure code [D110KB] – Battery relay output voltage............................................................. 716 Failure code [D161KA] – Backup alarm relay open circuit.......................................................... 718 Failure code [D161KB] – Backup alarm relay short circuit......................................................... 720 Failure code [D19JKZ] – Personal code relay abnormality.......................................................... 722 Failure code [D19QKB] – Refuel pump relay short circuit.......................................................... 724 Failure code [D1EMKA] – Parking brake relay open circuit......................................................... 726 Failure code [D1EMKB] – Parking brake relay short circuit........................................................ 728 Failure code [D811MC] – KOMTRAX error............................................................................ 730 Failure code [D862KA] – GPS antenna open circuit................................................................. 731 Failure code [D8ALKA] – System operating lamp disconnection (KOMTRAX)............................................ 732 Failure code [D8ALKB] – System operating lamp short circuit (KOMTRAX)............................................ 734 Failure code [D8AQKR] – CAN2 discon (KOMTRAX).................................................................... 736 Failure code [DA20MC] – Pump controller.......................................................................... 737 Failure code [DA22KK] – Pump solenoid power low error............................................................ 738 Failure code [DA25KP] – 5V sensor 1 power abnormality............................................................ 740 Failure code [DA26KP] – 5V sensor 2 power abnormality............................................................ 742 Failure code [DA29KQ] – Model selection abnormality.............................................................. 744 Failure code [DA2LKA] – System operating lamp disconnection (pump con)........................................... 746 Failure code [DA2LKB] – System operating lamp short circuit (pump con)........................................... 748 Failure code [DA2QKR] – CAN2 discon (pump con)................................................................... 750 Failure code [DA2RKR] – CAN1 discon (pump con)................................................................... 752 Failure code [DAB0KT] – Internal flash memory error.............................................................. 753 Failure code [DAC3KB] – Cruise control system power supply short circuit......................................... 754 Failure code [DAF0MB] – Monitor ROM abnormality.................................................................. 756 Failure code [DAF0MC] – Monitor error............................................................................ 757 Failure code [DAF8KB] – Camera power supply short circuit........................................................ 758 Failure code [DAF9KQ] – Model selection abnormality.............................................................. 760 Failure code [DAFGMC] – GPS module operation error............................................................... 761 Failure code [DAFLKA] – Operating lamp open circuit (monitor).................................................... 762 Failure code [DAFLKB] – System operating lamp short circuit (monitor)............................................ 764 Failure code [DAFQKR] – CAN2 discon (monitor).................................................................... 766 Failure code [DAZ9KQ] – A/C model selection abnormality.......................................................... 767 Failure code [DAZQKR] – CAN2 discon (AC)......................................................................... 768 Failure code [DB2QKR] – CAN2 discon (engine con)................................................................. 772 Failure code [DB2RKR] – CAN1 discon (engine con)................................................................. 776 Failure code [DDK8KA] – SUSLock forced sw open circuit........................................................... 780 Failure code [DDK8KB] – SUSLock forced sw short circuit.......................................................... 782 Failure code [DDP4KX] – Disconnection in travel PPC pressure switch.............................................. 784 Failure code [DDP6L5] – Service brake press sw abnormality....................................................... 786 Failure code [DDQ1KA] – SUSLock mode selection sw open circuit................................................... 788 Failure code [DDQ1KB] – SUSLock mode selection sw short circuit.................................................. 790 Failure code [DDWCKZ] – Direction switch abnormality............................................................. 792 Failure code [DFB1KZ] – Service lever potentio 1 abnormality..................................................... 794 Failure code [DFB2KZ] – Service lever potentio 2 abnormality..................................................... 796 Failure code [DFB3L8] – Service lever 1 potentio error........................................................... 798 Failure code [DFB4L8] – Service lever 2 potentio error........................................................... 799 Failure code [DFB5KZ] – Service lever sub potentio 1 abnormality................................................. 800 Failure code [DFB6KZ] – Service lever sub potentio 2 abnormality................................................. 802 Failure code [DGH2KB] – Hydraulic oil temperature sensor short circuit........................................... 804 Failure code [DH10KP] – 24V sensor power abnormality............................................................. 806 Failure code [DHA4KA] – Air cleaner clog sensor open circuit..................................................... 808 Failure code [DHH2MA] – Return line filter press sensor abnormally............................................... 810 Failure code [DHPAMA] – F pump press sensor abnormality.......................................................... 812 Failure code [DHS5KX] – Abnormality in travel PPC sensor......................................................... 814 Failure code [DHU1KA] – Brake accumulator press sensor open circuit.............................................. 816 Failure code [DHU1KY] – Brake accumulator press sensor hot short circuit......................................... 818 Failure code [DHUCKA] – Parking brake press sensor open circuit.................................................. 820 Failure code [DHUCKY] – Parking brake press sensor short circuit................................................. 822 Failure code [DHUGKA] – Service brake press sensor open circuit.................................................. 824 Failure code [DHUGKY] – Service brake press sensor short circuit................................................. 826 Failure code [DHX1MA] – Overload sensor abnormality (analog)..................................................... 828 Failure code [DLT4KA] – Disconnection in transmission speed sensor............................................... 830 Failure code [DR21KX] – Camera 2 picture rev. drive abnormality.................................................. 832 Failure code [DR31KX] – Camera 3 picture rev. drive abnormality.................................................. 834 Failure code [DW27KA] – Disconnection in transmission clutch solenoid............................................ 836 Failure code [DW27KB] – Short circuit in transmission clutch solenoid............................................ 838 Failure code [DW27KY] – T/M clutch sol hot short circuit......................................................... 840 Failure code [DW4AKA] – Disconnection in suspension lock solenoid................................................ 842 Failure code [DW4AKB] – Short circuit in suspension lock solenoid................................................ 844 Failure code [DW4AKY] – SUSLock sol hot short circuit............................................................ 846 Failure code [DW4CKA] – Disconnection in PPC lock solenoid....................................................... 848 Failure code [DW4CKB] – PPC lock sol. short circuit.............................................................. 850 Failure code [DW4MKA] – Disconnection in creep solenoid.......................................................... 852 Failure code [DW4MKB] – Short circuit in creep solenoid.......................................................... 853 Failure code [DW44KA] – Disconnection in travel F/R solenoid..................................................... 854 Failure code [DW44KB] – Short circuit in travel F/R solenoid..................................................... 856 Failure code [DW44KY] – Travel F/R sol hot short circuit......................................................... 858 Failure code [DW45KA] – Disconnection in swing holding brake solenoid............................................ 860 Failure code [DW45KB] – Swing holding brake solenoid short circuit............................................... 862 Failure code [DW91KA] – Disconnection in travel neutral solenoid................................................. 864 Failure code [DW91KB] – Short circuit in travel neutral solenoid................................................. 866 Failure code [DWB1KA] – Disconnection in outrigger operation solenoid............................................ 868 Failure code [DWB1KB] – Short circuit in outrigger operation solenoid............................................ 870 Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid.................................................. 872 Failure code [DWB2KB] – Short circuit in 1st outrigger solenoid.................................................. 874 Failure code [DWB3KA] – Disconnection in 2nd outrigger solenoid.................................................. 876 Failure code [DWB3KB] – Short circuit in 2nd outrigger solenoid.................................................. 878 Failure code [DWB4KA] – Disconnection in 3rd outrigger solenoid.................................................. 880 Failure code [DWB4KB] – Short circuit in 3rd outrigger solenoid.................................................. 882 Failure code [DWB5KA] – Disconnection in 4th outrigger solenoid.................................................. 884 Failure code [DWB5KB] – Short circuit in 4th outrigger solenoid.................................................. 886 Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid................................................. 888 Failure code [DWK0KB] – Short circuit in 2-stage relief solenoid................................................. 889 Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid.......................................... 890 Failure code [DWK2KB] – Short circuit in 2-stage back pressure solenoid.......................................... 891 Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system.............................................. 892 Failure code [DXA8KB] – Short circuit in PC-EPC (F) solenoid..................................................... 894 Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system.................................................. 896 Failure code [DXE0KB] – Short circuit in LS-EPC solenoid......................................................... 897 Failure code [DXE7KA] – Service current EPC2 solenoid disconnection (right hand)................................. 898 Failure code [DXE7KB] – Service current EPC solenoid short (right hand).......................................... 900 Failure code [DXE8KA] – Service current EPC solenoid disconnection (left hand)................................... 902 Failure code [DXE8KB] – Service current EPC3 solenoid short (left hand).......................................... 904 Failure code [DXE9KA] – Service current EPC solenoid disconnection (right hand).................................. 906 Failure code [DXE9KB] – Service current EPC solenoid short (right hand).......................................... 908 Failure code [DXEAKA] – Service Current EPC1 open circuit (left hand)............................................ 910 Failure code [DXEAKB] – Service current EPC1 solenoid short (left hand).......................................... 912 Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit.......................................... 914 Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit......................................... 915 Failure code [DY20KA] – Wiper working abnormality................................................................ 916 Failure code [DY20MA] – Wiper parking abnormality................................................................ 918 Failure code [DY2CKA] – Window washer drive system disconnection................................................. 920 Failure code [DY2CKB] – Washer drive short circuit............................................................... 922 Failure code [DY2DKB] – Wiper drive (fwd) short circuit.......................................................... 924 Failure code [DY2EKB] – Wiper drive (rev) short circuit.......................................................... 926 Troubleshooting of central lubrication system (CLS).............................................................. 929 Trouble...................................................................................................... 929 Troubleshooting during grease pump operation................................................................. 931 Pump element................................................................................................. 932 Check power supply........................................................................................... 933 Changing the control unit.................................................................................... 933 Troubleshooting – grease system faults....................................................................... 934 Venting of the system........................................................................................ 935 TROUBLESHOOTING...................................................................................................... 537 Troubleshooting when failure code is indicated................................................................... 537 How to read this manual.......................................................................................... 940 Removal and installation of assemblies....................................................................... 940 Special tools............................................................................................ 940 Removal of parts......................................................................................... 940 Installation of parts.................................................................................... 940 Sketches of special tools................................................................................ 940 DISASSEMBLY AND ASSEMBLY............................................................................................. 937 Coating material lists........................................................................................... 941 Special tools list............................................................................................... 944 Sketches of special tools........................................................................................ 946 List of tools.................................................................................................... 947 Precautions when performing operation............................................................................ 948 Removal and installation of fuel supply pump assembly............................................................ 950 Special tools................................................................................................ 950 Removal...................................................................................................... 950 Installation................................................................................................. 952 Removal and installation of fuel injector assembly............................................................... 956 Special tools................................................................................................ 956 Removal...................................................................................................... 956 Installation................................................................................................. 959 Removal and installation of cylinder head assembly............................................................... 963 Special tools................................................................................................ 963 Removal...................................................................................................... 963 Installation................................................................................................. 970 Removal and installation of radiator assembly.................................................................... 981 Removal...................................................................................................... 981 Installation................................................................................................. 982 Removal and installation of hydraulic oil cooler assembly........................................................ 983 Special tools................................................................................................ 983 Removal...................................................................................................... 983 Installation................................................................................................. 985 Removal and installation of aftercooler assembly................................................................. 986 Removal...................................................................................................... 986 Installation................................................................................................. 987 Removal and installation of KDOC assembly........................................................................ 988 Removal...................................................................................................... 988 Installation................................................................................................. 989 Removal and installation of KCCV assembly........................................................................ 990 Removal...................................................................................................... 990 Installation................................................................................................. 990 Removal and installation of air cleaner assembly................................................................. 991 Removal...................................................................................................... 991 Installation................................................................................................. 992 Removal and installation of engine and main pump assembly........................................................ 993 Special tools................................................................................................ 993 Removal...................................................................................................... 993 Installation.................................................................................................1000 Removal and installation of front oil seal.......................................................................1002 Special tools................................................................................................1002 Removal......................................................................................................1002 Installation.................................................................................................1004 Removal and installation of rear oil seal........................................................................1007 Special tools................................................................................................1007 Removal......................................................................................................1007 Installation.................................................................................................1007 Removal and installation of engine hood assembly.................................................................1010 Removal......................................................................................................1010 Installation.................................................................................................1010 Removal and installation of travel motor.........................................................................1011 Removal......................................................................................................1011 Installation.................................................................................................1011 Disassembly and assembly of travel motor assembly................................................................1012 Disassembly..................................................................................................1012 Assembly.....................................................................................................1014 Removal and installation of swing motor and swing machinery......................................................1016 Removal......................................................................................................1016 Installation.................................................................................................1017 Removal of swing motor assembly..................................................................................1018 Removal......................................................................................................1018 Installation.................................................................................................1019 Disassembly and assembly of swing motor and swing machinery......................................................1020 Disassembly..................................................................................................1020 Assembly.....................................................................................................1022 Removal and installation of front axle assembly..................................................................1026 Removal......................................................................................................1026 Installation.................................................................................................1027 Disassembly and assembly of front axle...........................................................................1028 Disassembly of steering cylinder.............................................................................1028 Assembly of steering cylinder................................................................................1030 Disassembly of epicyclic reduction gear and brake............................................................1034 Assembly of epicylic reduction gear and brake................................................................1038 Disassembly of joint box.....................................................................................1044 Assembly of joint box........................................................................................1048 Disassembly of beam trumpet and differential unit............................................................1053 Assembly of beam trumpet and differential unit...............................................................1056 Disassembly of pinion group..................................................................................1062 Assembly of pinion group.....................................................................................1064 Toe-in adjustment............................................................................................1070 Steering angle adjustment....................................................................................1071 Removal and installation of rear axle and transmission...........................................................1072 Removal......................................................................................................1072 Installation.................................................................................................1073 Disassembly and assembly of rear axle assembly...................................................................1074 Special tools................................................................................................1074 Removal of epicyclic reduction gear and brake................................................................1074 Installation of epicylic reduction gear and brake............................................................1078 Disassembly of beam trumpet and differential unit............................................................1085 Installation of beam trumpet and differential unit...........................................................1089 Disassembly of pinion group..................................................................................1095 Installation of pinion group.................................................................................1098 796-H70-0180Disassembly and assembly of transmission.............................................................1104 Special tools................................................................................................1104 Removal of travel motor and flange...........................................................................1104 Installation of travel motor.................................................................................1106 Removal of transmission box..................................................................................1108 Installation of transmission box.............................................................................1116 Removal and installation of propshaft assembly...................................................................1127 Removal......................................................................................................1127 Installation.................................................................................................1127 Removal and installation of wheel................................................................................1128 Removal......................................................................................................1128 Installation.................................................................................................1128 Removal and installation of suspension lock cylinder assembly....................................................1129 Removal......................................................................................................1129 Installation.................................................................................................1129 Disassembly and assembly of suspension lock cylinders............................................................1130 Change Rod Seal..............................................................................................1130 Removal and installation of outrigger assembly...................................................................1131 Removal......................................................................................................1131 Installation.................................................................................................1131 Disassembly and assembly of outriggers...........................................................................1132 Disassembly..................................................................................................1132 Assembly.....................................................................................................1132 Removal and installation of dozer blade assembly.................................................................1133 Removal......................................................................................................1133 Installation.................................................................................................1133 Disassembly and assembly of dozer blade..........................................................................1134 Disassembly..................................................................................................1134 Assembly.....................................................................................................1134 Removal and installation of swing circle assembly................................................................1135 Removal......................................................................................................1135 Installation.................................................................................................1135 Removal and installation of revolving frame assembly.............................................................1136 Removal......................................................................................................1136 Installation.................................................................................................1138 Removal and installation of centre swivel joint..................................................................1139 Removal......................................................................................................1139 Installation.................................................................................................1141 Disassembly and assembly of centre swivel joint assembly.........................................................1142 Special tools................................................................................................1142 Disassembly..................................................................................................1142 Assembly.....................................................................................................1143 Removal and installation of fuel tank assembly...................................................................1144 Removal......................................................................................................1144 Installation.................................................................................................1145 Removal and installation of hydraulic tank assembly..............................................................1146 Removal......................................................................................................1146 Installation.................................................................................................1147 Removal and installation of control valve assembly...............................................................1148 Removal......................................................................................................1148 Installation.................................................................................................1151 Removal and installation of LS separation valve assembly.........................................................1152 Removal......................................................................................................1152 Installation.................................................................................................1152 Removal and installation of pressure compensation valve assembly.................................................1153 Removal......................................................................................................1153 Installation.................................................................................................1153 Removal and installation of main relief valve assembly...........................................................1154 Removal......................................................................................................1154 Installation.................................................................................................1154 Removal and installation of LS control EPC valve.................................................................1155 Removal......................................................................................................1155 Installation.................................................................................................1155 Removal and installation of PC EPC valve assembly................................................................1156 Removal......................................................................................................1156 Installation.................................................................................................1156 Removal and installation of PPC valve block assembly.............................................................1157 Removal......................................................................................................1157 Installation.................................................................................................1157 Removal and installation of oil seal in hydraulic pump input shaft...............................................1158 Special tools................................................................................................1158 Removal......................................................................................................1158 Installation.................................................................................................1158 Disassembly and assembly of work equipment PPC valve.............................................................1159 Assembly.....................................................................................................1159 Disassembly and assembly of hydraulic cylinder...................................................................1160 Special tools................................................................................................1160 Disassembly..............................................................................................1160 Assembly.................................................................................................1162 Removal and installation of monoboom work equipment..............................................................1166 Special tools................................................................................................1166 Removal......................................................................................................1166 Installation.................................................................................................1167 Removal and installation of 2 piece boom work equipment..........................................................1168 Special tools................................................................................................1168 Removal......................................................................................................1168 Installation.................................................................................................1169 Removal and installation of air conditioner unit.................................................................1170 Special tools................................................................................................1170 Removal......................................................................................................1170 Installation.................................................................................................1173 Removal and installation of counterweight........................................................................1174 Removal......................................................................................................1174 Installation.................................................................................................1175 Removal and installation of operator cab assembly................................................................1176 Removal......................................................................................................1176 Installation.................................................................................................1177 Removal and installation of monitor assembly.....................................................................1178 Removal......................................................................................................1178 Installation.................................................................................................1178 Removal and installation of pump controller assembly.............................................................1179 Removal......................................................................................................1179 Installation.................................................................................................1179 Removal and installation of engine controller assembly...........................................................1180 Removal......................................................................................................1180 Installation.................................................................................................1181 Removal and Installation of KOMTRAX terminal.....................................................................1182 Removal......................................................................................................1182 Installation.................................................................................................1182 Appendix.............................................................................................................1185 Table of contents................................................................................................1185 Air conditioner components.......................................................................................1186 Precautions for refrigerant..................................................................................1186 Air conditioner component....................................................................................1187 Configuration and function of refrigeration cycle............................................................1190 Outline of refrigeration cycle...............................................................................1191 Air conditioner unit.........................................................................................1193 Function.....................................................................................................1194 Functions of major components................................................................................1195 Servomotor...................................................................................................1196 Expansion valve..............................................................................................1197 Dual pressure switch.........................................................................................1199 Function.....................................................................................................1199 Air conditioner controller...................................................................................1200 Compressor...................................................................................................1201 Function.....................................................................................................1201 Air conditioner condenser....................................................................................1202 Function.....................................................................................................1202 Sunlight sensor..............................................................................................1204 Function.....................................................................................................1204 Procedure for testing and troubleshooting....................................................................1205 Circuit diagram and arrangement of connector pins............................................................1207 System diagram...............................................................................................1209 Input and output signals of the air conditioner controller...................................................1210 Function.....................................................................................................1211 Parts and connectors layout..................................................................................1212 Details......................................................................................................1213 Testing with self-diagnosis function.........................................................................1216 Testing outline..............................................................................................1216 How to open the electrical system abnormality record screen in service mode of the machine monitor...........1217 Testing vent (mode) changeover...............................................................................1219 Testing......................................................................................................1219 Testing FRESH/RECIRC air changeover..........................................................................1221 Testing......................................................................................................1221 Testing sunlight sensor......................................................................................1222 Testing......................................................................................................1222 Testing (dual) pressure switch for refrigerant...............................................................1223 Testing......................................................................................................1223 Testing relays...............................................................................................1224 Testing......................................................................................................1224 Troubleshooting chart 1......................................................................................1225 Troubleshooting chart 2......................................................................................1226 Information in troubleshooting table.........................................................................1229 Information in troubleshooting table.........................................................................1229 Failure code list related to air conditioner.................................................................1230 Failure code [879AKA] A/C Inner Sensor Open Circuit..........................................................1231 Failure code [879AKB] A/C Inner Sensor Short Circuit.........................................................1232 Failure code [879CKA] Ventilating Sensor Open Circuit........................................................1233 Failure code [879CKB] Ventilating Sensor Short Circuit.......................................................1234 Failure code [879DKZ] Sunlight sensor Open or Short Circuit..................................................1235 Circuit diagram related to sunlight sensor...................................................................1236 Failure code [879EMC] Ventilation Damper Abnormality.........................................................1237 Failure code [879FMC] Air Mix Damper Abnormality.............................................................1238 Failure code [879GKX] Refrigerant Abnormality................................................................1239 Troubleshooting for power supply system (Air conditioner does not operate)...................................1241 Circuit diagram related to blower motor system...............................................................1250 Troubleshooting with gauge pressure..........................................................................1251 Connection of service tool...................................................................................1254 Precautions for disconnecting and connecting air conditioner piping..........................................1256 Handling of compressor oil...................................................................................1258 Desiccant replacement........................................................................................1260 Tool control system..............................................................................................1263 System overview..............................................................................................1263 Operation....................................................................................................1263 System delivery condition....................................................................................1264 Adjusting and testing........................................................................................1265 Required equipment.......................................................................................1265 Software installation....................................................................................1266 Initial program start....................................................................................1268 Connect to tool control monitor/controller...............................................................1269 Analog inputs setup and calibration......................................................................1272 Tool parameters..........................................................................................1275 1st attachment pressure control..........................................................................1276 2nd attachment pressure control..........................................................................1277 1st attachment proportional switch flow control..........................................................1278 2nd attachment proportional switch flow control..........................................................1280 Additional software functionality........................................................................1282 Troubleshooting of tool control system.......................................................................1284 Software errors..........................................................................................1284 System error codes (displayed on the tool control monitor)...............................................1284 Tool control current [%] reference value table (1/2).........................................................1286 Tool control current [%] reference value table (2/2).........................................................1288 OTHER................................................................................................................1291 Hydraulic circuit diagram (1/3)..................................................................................1293 Hydraulic circuit diagram (2/3)..................................................................................1294 Hydraulic circuit diagram (3/3)..................................................................................1295 Circuit diagram (cabin 1/5)......................................................................................1296 Circuit diagram (cabin 2/5)......................................................................................1297 Circuit diagram (cabin 3/5)......................................................................................1298 Circuit diagram (cabin 4/5)......................................................................................1299 Circuit diagram (cabin 5/5)......................................................................................1300 Circuit diagram (machine 1/5))...................................................................................1301 Circuit diagram (machine 2/5))...................................................................................1302 Circuit diagram (machine 3/5))...................................................................................1303 Circuit diagram (machine 4/5))...................................................................................1304 Circuit diagram (machine 5/5))...................................................................................1305 Connector diagram 1/8............................................................................................1306 Connector table for revolving frame harness..................................................................1306 Connector diagram 2/8............................................................................................1307 Connector table for operator‘s cab wiring harness (Part 1/2).................................................1307 Connector diagram 3/8............................................................................................1308 Connector table for operators cab wiring harness (Part 2/2)..................................................1308 Connector diagram (4/8)..........................................................................................1309 Connector table various wiring harness (Part 1/3)............................................................1309 Connector diagram (5/8)..........................................................................................1310 Connector table various wiring harness (Part 2/3)............................................................1310 Connector diagram (6/8)..........................................................................................1311 Connector table various wiring harness (Part 3/3)............................................................1311 Connector diagram (7/8)..........................................................................................1312 Connector table optionally wiring harness....................................................................1312 Connector diagram (8/8)..........................................................................................1313
DESCRIPTION:
Komatsu PW148-10 Shop Manual VENBM60002 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
General
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
Testing, adjusting and troubleshooting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
Maintenance standard
This section gives the judgement standards when inspecting disassembled parts.
S.S 28/12/24
