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KOMATSU PW98MR-11E0 WHEELED EXCAVATOR SHOP MANUAL WENBM00290 – PDF DOWNLOAD
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KOMATSU PW98MR-11E0 WHEELED EXCAVATOR SHOP MANUAL WENBM00290 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW98MR-11E0 WHEELED EXCAVATOR SHOP MANUAL WENBM00290 – PDF DOWNLOAD
Language : English
Pages : 2386
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PW98MR-11E0 WHEELED EXCAVATOR SHOP MANUAL WENBM00290 – PDF DOWNLOAD
00 Index and Foreword.................................................................................. 3 Index.............................................................................................. 4 Foreword, Safety, Basic Information................................................................ 18 How to Read the Shop Manual.................................................................... 18 Safety Notice for Operation.................................................................... 20 Precautions to Prevent Fire.................................................................... 28 Procedures If Fire Occurs...................................................................... 30 Precautions When You Discard Waste Materials................................................... 31 Precautions When You Handle Hydraulic Equipment................................................ 32 Precautions When You Disconnect and Connect Pipings............................................ 35 Precautions When You Handle Electrical Equipment............................................... 42 Precautions When You Handle Fuel System Equipment.............................................. 44 Precautions When You Handle Intake System Equipment............................................ 45 Practical Use of KOMTRAX....................................................................... 46 Disconnect and Connect Push-Pull Type Coupler.................................................. 47 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................ 47 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................ 48 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................ 49 Precautions for Disconnection and Connection of Connectors..................................... 51 Disconnect and Connect Deutsch Connector....................................................... 55 How to Disconnect and Connect Slide Lock Type Connector........................................ 56 Disconnect and Connect Connector with Lock to Pull............................................. 58 Disconnect and Connect Connector with Lock to Push............................................. 59 Disconnect and Connect Connector with Housing to Rotate........................................ 61 How to Read the Codes for Electric Cable....................................................... 62 Explanation of Terms for Maintenance Standard.................................................. 66 Standard Tightening Torque Table............................................................... 69 Conversion Table............................................................................... 76 Abbreviation List.............................................................................. 81 01 Specification....................................................................................... 87 Table of Contents.................................................................................. 88 Specifications..................................................................................... 89 Specification Drawing.......................................................................... 89 Specification Drawing: PW98MR-11E0......................................................... 89 Working Range Drawings......................................................................... 90 Working Range Drawings: PW98MR-11E0........................................................ 90 Specifications................................................................................. 92 Specifications: PW98MR-11E0................................................................ 92 Weight Table................................................................................... 97 Weight Table: PW98MR-11E0.................................................................. 97 Fuel, Coolant, Lubricants (For European Union)................................................. 99 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................. 99 10 Structure and Function.............................................................................. 101 Table of Contents.................................................................................. 102 Boot-up System..................................................................................... 105 Layout Drawing of Boot-up System............................................................... 105 System Operating Lamp System................................................................... 106 System Diagram of System Operating Lamp.................................................... 106 Function of System Operating Lamp.......................................................... 106 Battery Disconnect Switch...................................................................... 107 Function of Battery Disconnect Switch...................................................... 107 Engine System...................................................................................... 108 Layout Drawing of Engine System................................................................ 108 Engine Control System.......................................................................... 110 System Diagram of Engine Control........................................................... 110 Function of Engine Control System.......................................................... 111 Auto-Deceleration System....................................................................... 114 System Diagram of Auto-Deceleration System................................................. 114 Function of Auto-Deceleration System....................................................... 115 Operation of Auto-Deceleration System...................................................... 115 Engine Automatic Warm-up System................................................................ 116 System Diagram of Engine Automatic Warm-up System.......................................... 116 Function of Engine Automatic Warm-up System................................................ 117 Overheat Prevention System..................................................................... 118 Function of Overheat Prevention System..................................................... 118 Turbocharger Protection System................................................................. 119 Function of Turbocharger Protection System................................................. 119 Automatic Idle Stop System..................................................................... 120 System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller).... 120 Function of Automatic Idle Stop System..................................................... 120 Component Parts of Engine System............................................................... 123 PTO........................................................................................ 123 Turbocharger............................................................................... 123 EGR System................................................................................. 126 EGR Valve.................................................................................. 129 EGR Cooler................................................................................. 131 High Efficiency Breather System............................................................ 132 High Efficiency Breather................................................................... 133 Exhaust Throttle Valve..................................................................... 135 KDPF....................................................................................... 136 Cooling System..................................................................................... 140 Layout Drawing of Cooling System............................................................... 140 Specifications of Cooling System........................................................... 141 Control System..................................................................................... 142 Layout Drawing of Control System............................................................... 142 Machine Monitor System......................................................................... 144 System Diagram of Machine Monitor System................................................... 144 Function of Machine Monitor System......................................................... 144 KOMTRAX System................................................................................. 146 System Diagram of KOMTRAX System........................................................... 146 Function of KOMTRAX System................................................................. 146 Component Parts of Control System.............................................................. 147 Machine Monitor............................................................................ 147 Gateway Function Controller................................................................ 163 Communication Terminal..................................................................... 166 Machine Controller......................................................................... 168 Pump Controller............................................................................ 172 Resistor for PC-EPC Valve.................................................................. 176 CAN Terminating Resistor................................................................... 176 Engine Controller.......................................................................... 178 Fuel Control Dial.......................................................................... 184 Hydraulic System................................................................................... 186 Layout Drawing of Hydraulic System............................................................. 186 CLSS........................................................................................... 189 Structure of CLSS.......................................................................... 189 Function of CLSS........................................................................... 190 Engine and Pump Combined Control System........................................................ 192 Engine and Pump Combined Control System Diagram............................................ 192 Function of Engine and Pump Combined Control System........................................ 193 Component Parts of Hydraulic System............................................................ 197 Hydraulic Tank............................................................................. 198 Main Pump.................................................................................. 200 Control Valve.............................................................................. 211 Work Equipment System.............................................................................. 233 Layout Drawing of Work Equipment System........................................................ 233 PPC Lock System................................................................................ 235 System Diagram of PPC Lock................................................................. 235 Function of PPC Lock System................................................................ 235 Work Equipment Automatic Lock System........................................................... 236 System Diagram of Lock Lever Automatic Lock System......................................... 236 Function of Work Equipment Automatic Lock System........................................... 236 Operation of Lock Lever Automatic Lock System.............................................. 237 Overload Caution System........................................................................ 238 Overload Caution System Diagram............................................................ 238 Function of Overload Caution System........................................................ 239 Attachment Oil Flow Adjuster System............................................................ 240 Attachment Oil Flow Adjuster System Diagram................................................ 240 Function of Attachment Oil Flow Adjuster System............................................ 240 Component Parts of Work Equipment System....................................................... 242 Work Equipment and Swing PPC Valve......................................................... 242 Blade PPC Valve............................................................................ 247 2-Piece Boom PPC Valve..................................................................... 249 5-Spool Solenoid Valve..................................................................... 251 4-Spool Solenoid Valve..................................................................... 252 Travel and Attachment Solenoid Valve....................................................... 253 Attachment and Boom Swing Flow Adjustment EPC Valve........................................ 254 Boom Anti-drop Valve....................................................................... 255 Arm Anti-Drop Valve........................................................................ 259 Boom Swing Safety Valve.................................................................... 265 Pilot Circuit Accumulator.................................................................. 266 Attachment Circuit Accumulator (For Low Pressure Circuit).................................. 267 Swing System....................................................................................... 268 Layout Drawing of Swing System................................................................. 268 Swing Control System Diagram................................................................... 270 Function of Swing Control System........................................................... 270 Component Parts of Swing System................................................................ 272 Swing Motor................................................................................ 272 Swing Machinery............................................................................ 281 Swing Circle............................................................................... 283 Power Train System................................................................................. 285 Layout Drawing of Power Train System........................................................... 285 Component Parts of Power Train System.......................................................... 287 Front Axle................................................................................. 287 Rear Axle.................................................................................. 292 Travel Motor................................................................................... 302 Braking System................................................................................. 305 Steering System................................................................................ 307 Description................................................................................ 307 Operation.................................................................................. 308 Axle Locking Cylinder.......................................................................... 311 Steering Unit.................................................................................. 313 Work Equipment..................................................................................... 315 Structure of Work Equipment.................................................................... 315 Work Equipment Clearance Adjustment Shim....................................................... 316 Function of Work Equipment Clearance Adjustment Shim....................................... 316 Bucket Clearance Adjustment Shim............................................................... 317 Function of Bucket Clearance Adjustment Shim............................................... 317 CAB Related Parts.................................................................................. 318 ROPS CAB....................................................................................... 318 Structure of ROPS CAB...................................................................... 318 Function of ROPS CAB....................................................................... 318 CAB Mount...................................................................................... 319 Structure of CAB Mount..................................................................... 319 Function of CAB Mount...................................................................... 320 20 Standard Value Table................................................................................ 321 Table of Contents.................................................................................. 322 Standard Value Table for Engine.................................................................... 323 Standard Value Table for Engine: PW98MR-11E0................................................... 323 Standard Value Table for Machine................................................................... 326 Standard Value Table for Machine: PW98MR-11E0.................................................. 326 Machine Posture and Procedures to Measure Performance.......................................... 338 30 Testing and Adjusting............................................................................... 343 Table of Contents.................................................................................. 344 Related Information on Testing and Adjusting....................................................... 347 Sketch of Tools for Testing and Adjusting...................................................... 347 Engine and Cooling System.......................................................................... 349 Examine Engine Speed........................................................................... 349 How to Examine Engine High Idle Speed...................................................... 349 How to Examine Engine Low Idle Speed....................................................... 349 How to Examine Engine Speed at Pump Relief................................................. 350 How to Examine Engine Speed with Auto-Deceleration......................................... 350 Examine Exhaust Gas Color...................................................................... 352 How to Examine Exhaust Gas Color with the Handy Smoke Checker.............................. 352 How to Examine Exhaust Gas Color with Smoke Meter.......................................... 353 Examine and Adjust Valve Clearance............................................................. 355 How to Examine Valve Clearance............................................................. 355 How to Adjust Valve Clearance.............................................................. 356 Examine Compression Pressure................................................................... 357 How to Examine Compression Pressure........................................................ 357 Examine Blowby Pressure........................................................................ 360 How to Examine Blowby Pressure............................................................. 360 Examine Engine Oil Pressure.................................................................... 362 How to Examine Engine Oil Pressure......................................................... 362 Visual Check Inside of EGR Valve............................................................... 364 Clean Inside of EGR Valve...................................................................... 366 Examine Fuel Pressure.......................................................................... 369 How to Examine Fuel Pressure............................................................... 369 Examine Fuel Return Rate and Leakage........................................................... 371 How to Examine Leakage from Pressure Limiter............................................... 372 How to Examine Injector Return Rate........................................................ 374 Bleed Air from Fuel System..................................................................... 376 How to Bleed Air from Fuel System.......................................................... 377 Examine Fuel Circuit for Leakage............................................................... 378 How to Examine Fuel System for Leakage at Engine Stop...................................... 378 How to Examine Fuel System for Leakage at Engine Low Idle.................................. 378 How to Examine Fuel System for Leakage at Engine High Idle................................. 379 How to Examine Fuel System for Leakage at Rated Engine Speed............................... 379 Handle Cylinder Cut-out Mode Operation......................................................... 380 Handle No-Injection Cranking Operation......................................................... 381 Examine Fan Belt............................................................................... 382 How to Examine Fan Belt.................................................................... 382 Examine Automatic Tensioner.................................................................... 383 How to Examine Automatic Tensioner......................................................... 383 Write Injector Compensation Value to Engine Controller......................................... 385 Swing System....................................................................................... 391 How to Examine Swing Circle Bearing Clearance.................................................. 391 Power Train........................................................................................ 393 Examine Oil Leakage from Steering Cylinder..................................................... 393 Examine Pressure in Steering Circuit........................................................... 394 How Examine Steering Pressure on Machine Monitor........................................... 394 How to Examine Steering Pressure with Testing Tool......................................... 395 Examine Brake Circuit Pressure................................................................. 396 How to Examine Brake Pressure.............................................................. 396 How to Examine Accumulator Recharge Pressure............................................... 397 How to Examine Accumulator Pre-charge Pressure with Testing Tool........................... 398 Examine Oil Leakage from Brake System.......................................................... 401 How to Examine Hydraulic Leakage of Brake Circuit.......................................... 401 Identification of the Defective Axle....................................................... 401 Identification of the Defective Brake Group................................................ 402 Examine Brake Disc Wear Volume................................................................. 403 How to Bleed Air from Brake Circuit............................................................ 404 Hydraulic System................................................................................... 405 Release Remained Pressure in Hydraulic Circuit................................................. 405 How to Release Remained Pressure from Hydraulic Tank....................................... 405 How to Release Remained Pressure from Work Equipment....................................... 405 How to Release Remained Pressure from Hydraulic Cylinder Circuit........................... 406 How to Release Remained Pressure from Swing Motor Circuit.................................. 409 How to Release Remained Pressure from Travel Motor Circuit................................. 410 How to Release Remained Pressure from Swing Cylinder Circuit............................... 410 How to Release Remained Pressure from Blade/Outrigger Cylinder............................. 410 Examine and Adjust Oil Pressure in Work Equipment and Travel Circuits.......................... 412 How to Examine Unload Valve Pressure....................................................... 412 How to Adjust Unload Valve Pressure........................................................ 413 How to Examine Work Equipment and Travel Relief Pressure................................... 414 How to Adjust Work Equipment and Travel Relief Pressure.................................... 416 Examine and Adjust Oil Pressure in Swing Circuit............................................... 417 How to Examine Swing Relief Pressure....................................................... 417 How to Adjust Swing Relief Pressure........................................................ 419 Examine Oil Pressure of Control Circuit........................................................ 420 How to Examine Oil Pressure of Control Circuit............................................. 420 Examine and Adjust Oil Pressure in Pump PC Control Circuit..................................... 422 How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)...................... 422 How to Examine Source Pressure of PC-EPC Valve............................................. 424 How to Adjust Oil Pressure in Pump PC Control Circuit...................................... 425 Examine and Adjust Oil Pressure in Pump LS Control Circuit..................................... 427 How to Examine LS Differential Pressure with Machine Monitor............................... 427 How to Examine LS Differential Pressure with Testing Tool.................................. 429 How to Adjust LS Valve..................................................................... 431 Examine Outlet Pressure in PPC Valve........................................................... 433 How to Examine Outlet Pressure in PPC Valve................................................ 433 Adjust Play of Work Equipment and PPC Valves................................................... 436 Examine Travel Hydraulic Equipment............................................................. 437 Examine and Adjust Automatic Displacement Control of Travel Motor.............................. 438 How to Work Before Examine Automatic Displacement Control of Travel Motor.................. 438 How to Examine Automatic Displacement Control of Travel Motor.............................. 439 How to Adjust Automatic Displacement Control of Travel Motor............................... 439 How to Work After Examine Automatic Displacement Control of Travel Motor................... 439 Examine and Adjust Speed of Travel Propeller Shaft............................................. 440 How to Work Before Examine Speed of Travel Propeller Shaft................................. 440 How to Examine Speed of Travel Propeller Shaft............................................. 440 How to Adjust Speed of Travel Propeller Shaft.............................................. 440 Adjust Speed Sensor............................................................................ 442 Examine Parts Which Cause Hydraulic Drift of Work Equipment.................................... 443 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder...... 443 How to Examine Parts Which Cause Hydraulic Drift of Arm Cylinder........................... 443 How to Examine Parts Which Cause Hydraulic Drift of PPC Valve.............................. 444 Examine Oil Leakage............................................................................ 445 How to Examine Oil Leakage from Boom Cylinder.............................................. 445 How to Examine Oil Leakage from Arm Cylinder............................................... 445 How to Examine Oil Leakage from Bucket Cylinder............................................ 445 How to Examine Oil Leakage from Boom Swing Cylinder........................................ 446 How to Examine Oil Leakage from Swing Motor................................................ 446 How to Examine Oil Leakage from Travel Motor............................................... 447 Bleed Air from Hydraulic Circuit............................................................... 449 How to Bleed Air from Main Pump............................................................ 450 How to Bleed Air from Cylinder............................................................. 451 How to Bleed Air from LS Circuit........................................................... 451 How to Bleed Air from Swing PPC Circuit.................................................... 452 How to Bleed Air from Swing Motor.......................................................... 453 How to Bleed Air from Travel Motor......................................................... 453 How to Examine Hydraulic Oil Level......................................................... 454 CAB Related Parts.................................................................................. 457 Adjust Mirrors................................................................................. 457 How to Adjust Left Front Mirror (A) and (A1)............................................... 457 How to Adjust Right Front Mirror (B)....................................................... 458 Electrical System.................................................................................. 459 Set and Operate Machine Monitor................................................................ 459 Operator Mode.............................................................................. 463 Service Mode............................................................................... 467 Start Up KOMTRAX System........................................................................ 536 Adjust rearview camera angle................................................................... 543 Adjust Right View Camera Angle................................................................. 546 Handle Voltage Circuit of Engine Controller.................................................... 548 Handle Battery Disconnect Switch............................................................... 549 Pm Clinic.......................................................................................... 550 Pm Clinic Service.............................................................................. 550 Pm Clinic Check Sheet: PW98MR-11E0......................................................... 552 40 Troubleshooting..................................................................................... 561 Table of Contents.................................................................................. 562 Related Information to Troubleshooting............................................................. 571 General Troubleshooting Points................................................................. 571 Troubleshooting Points for Aftertreatment System............................................... 572 Sequence of Events in Troubleshooting.......................................................... 580 Checks Before Troubleshooting.................................................................. 582 Inspection Procedure Before Troubleshooting.................................................... 584 Walk-Around Check.......................................................................... 584 Test in Accordance with Testing Procedure...................................................... 586 Examine Fuel Level and Type................................................................ 586 Examine Fuel Prefilter..................................................................... 587 Examine Water Separator, Drain Water and Sediment.......................................... 587 Replace Fuel Prefilter Cartridge........................................................... 588 Examine Fuel Main Filter................................................................... 590 Examine Engine Oil Level (Oil Quantity in Oil Pan)......................................... 591 Examine Coolant Level (Expansion Tank)..................................................... 592 Examine Air Cleaner Clogging............................................................... 593 Examine Hydraulic Oil Level................................................................ 597 Examine Hydraulic Oil Strainer............................................................. 599 Examine Hydraulic Oil Filter............................................................... 600 Examine Oil Level in Front Axle............................................................ 602 Examine Oil Level in Rear Axle............................................................. 603 Examine Oil Level in Transmission Reduction Gear........................................... 603 Examine and Adjust Toe-in.................................................................. 604 Examine Wheel Nut Tightening............................................................... 604 Examine Electric Equipment................................................................. 604 Preparation for Troubleshooting of Electrical System........................................... 610 Preparation for Troubleshooting of Machine Monitor......................................... 610 Preparation for Troubleshooting of Engine Controller....................................... 612 Preparation for Troubleshooting of Machine Controller...................................... 613 Preparation for Troubleshooting of Pump Controller......................................... 613 Preparation for Troubleshooting of Gateway Function Controller............................. 614 Disconnect and Connect Connector with a Special Lock....................................... 614 Information Shown in Troubleshooting Table..................................................... 619 Connector Contact Connection Table............................................................. 621 T-Branch Box and T-Branch Adapter Table........................................................ 663 Fuse Location Table............................................................................ 669 Precautions When You Clean and Replace KDPF (KCSF and KDOC).................................... 672 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])........... 676 Failure Code Table............................................................................. 678 Troubleshooting by Failure Code (Display of Code).................................................. 689 Failure Code [6AZ0ZG].......................................................................... 689 Failure Code [6B2JMA].......................................................................... 691 Failure Code [879AKA].......................................................................... 692 Failure Code [879AKB].......................................................................... 693 Failure Code [879BKA].......................................................................... 694 Failure Code [879BKB].......................................................................... 696 Failure Code [879CKA].......................................................................... 698 Failure Code [879CKB].......................................................................... 699 Failure Code [879DKZ].......................................................................... 700 Failure Code [879EMC].......................................................................... 702 Failure Code [879FMC].......................................................................... 703 Failure Code [879GKX].......................................................................... 704 Failure Code [989L00].......................................................................... 706 Failure Code [989M00].......................................................................... 707 Failure Code [989N00].......................................................................... 708 Failure Code [A1U0N3].......................................................................... 709 Failure Code [A1U0N4].......................................................................... 711 Failure Code [A900FR].......................................................................... 713 Failure Code [A900N6].......................................................................... 714 Failure Code [A900NY].......................................................................... 715 Failure Code [AB00KE].......................................................................... 716 Failure Code [AQ10MB].......................................................................... 718 Failure Code [AQ10N3].......................................................................... 720 Failure Code [AS00R2].......................................................................... 722 Failure Code [AS00R3].......................................................................... 723 Failure Code [AS00R4].......................................................................... 724 Failure Code [AS00R6].......................................................................... 725 Failure Code [B@BAZG].......................................................................... 726 Failure Code [B@BCNS].......................................................................... 727 Failure Code [B@BCQA].......................................................................... 728 Failure Code [B@BCZK].......................................................................... 730 Failure Code [B@HANS].......................................................................... 732 Failure Code [CA115]........................................................................... 734 Failure Code [CA122]........................................................................... 735 Failure Code [CA123]........................................................................... 737 Failure Code [CA131]........................................................................... 739 Failure Code [CA132]........................................................................... 741 Failure Code [CA144]........................................................................... 743 Failure Code [CA145]........................................................................... 745 Failure Code [CA153]........................................................................... 747 Failure Code [CA154]........................................................................... 750 Failure Code [CA187]........................................................................... 753 Failure Code [CA221]........................................................................... 755 Failure Code [CA222]........................................................................... 757 Failure Code [CA227]........................................................................... 759 Failure Code [CA238]........................................................................... 760 Failure Code [CA239]........................................................................... 762 Failure Code [CA271]........................................................................... 764 Failure Code [CA272]........................................................................... 766 Failure Code [CA322]........................................................................... 768 Failure Code [CA324]........................................................................... 771 Failure Code [CA331]........................................................................... 774 Failure Code [CA343]........................................................................... 777 Failure Code [CA351]........................................................................... 778 Failure Code [CA352]........................................................................... 779 Failure Code [CA356]........................................................................... 781 Failure Code [CA357]........................................................................... 783 Failure Code [CA386]........................................................................... 786 Failure Code [CA435]........................................................................... 787 Failure Code [CA441]........................................................................... 789 Failure Code [CA442]........................................................................... 791 Failure Code [CA449]........................................................................... 792 Failure Code [CA451]........................................................................... 793 Failure Code [CA452]........................................................................... 795 Failure Code [CA515]........................................................................... 797 Failure Code [CA516]........................................................................... 799 Failure Code [CA553]........................................................................... 801 Failure Code [CA559]........................................................................... 802 Failure Code [CA689]........................................................................... 806 Failure Code [CA691]........................................................................... 808 Failure Code [CA692]........................................................................... 810 Failure Code [CA697]........................................................................... 812 Failure Code [CA698]........................................................................... 813 Failure Code [CA731]........................................................................... 814 Failure Code [CA778]........................................................................... 815 Failure Code [CA1117].......................................................................... 818 Failure Code [CA1664].......................................................................... 819 Failure Code [CA1691].......................................................................... 821 Failure Code [CA1695].......................................................................... 824 Failure Code [CA1696].......................................................................... 825 Failure Code [CA1879].......................................................................... 827 Failure Code [CA1881].......................................................................... 829 Failure Code [CA1883].......................................................................... 831 Failure Code [CA1896].......................................................................... 836 Failure Code [CA1921].......................................................................... 840 Failure Code [CA1922].......................................................................... 843 Failure Code [CA1961].......................................................................... 848 Failure Code [CA1993].......................................................................... 849 Failure Code [CA2185].......................................................................... 853 Failure Code [CA2186].......................................................................... 855 Failure Code [CA2249].......................................................................... 857 Failure Code [CA2272].......................................................................... 858 Failure Code [CA2311].......................................................................... 861 Failure Code [CA2349].......................................................................... 862 Failure Code [CA2353].......................................................................... 864 Failure Code [CA2357].......................................................................... 866 Failure Code [CA2637].......................................................................... 867 Failure Code [CA2639].......................................................................... 869 Failure Code [CA2765].......................................................................... 871 Failure Code [CA2777].......................................................................... 872 Failure Code [CA2973].......................................................................... 875 Failure Code [CA3133].......................................................................... 876 Failure Code [CA3134].......................................................................... 878 Failure Code [CA3135].......................................................................... 880 Failure Code [CA3251].......................................................................... 883 Failure Code [CA3253].......................................................................... 885 Failure Code [CA3254].......................................................................... 888 Failure Code [CA3255].......................................................................... 890 Failure Code [CA3256].......................................................................... 893 Failure Code [CA3311].......................................................................... 895 Failure Code [CA3312].......................................................................... 897 Failure Code [CA3313].......................................................................... 900 Failure Code [CA3314].......................................................................... 902 Failure Code [CA3315].......................................................................... 903 Failure Code [CA3316].......................................................................... 905 Failure Code [CA3317].......................................................................... 907 Failure Code [CA3318].......................................................................... 908 Failure Code [CA3319].......................................................................... 910 Failure Code [CA3321].......................................................................... 911 Failure Code [CA3322].......................................................................... 913 Failure Code [CA3419].......................................................................... 915 Failure Code [CA3421].......................................................................... 917 Failure Code [CA3724].......................................................................... 919 Failure Code [CA4151].......................................................................... 920 Failure Code [CA4158].......................................................................... 924 Failure Code [CA4161].......................................................................... 925 Failure Code [CA4162].......................................................................... 927 Failure Code [CA4163].......................................................................... 929 Failure Code [CA4259].......................................................................... 931 Failure Code [CA4264].......................................................................... 933 Failure Code [CA4952].......................................................................... 935 Failure Code [CA5271].......................................................................... 937 Failure Code [CA5272].......................................................................... 940 Failure Code [CA5383].......................................................................... 943 Failure Code [CA5631].......................................................................... 945 Failure Code [CA5938].......................................................................... 947 Failure Code [CA6654].......................................................................... 949 Failure Code [CA6887].......................................................................... 950 Failure Code [CA6891].......................................................................... 953 Failure Code [CA7681].......................................................................... 954 Failure Code [CA7797].......................................................................... 955 Failure Code [CA7798].......................................................................... 956 Failure Code [CA7822].......................................................................... 957 Failure Code [CA7869].......................................................................... 958 Failure Code [D110KB].......................................................................... 962 Failure Code [D19JKZ].......................................................................... 964 Failure Code [D19QKB].......................................................................... 967 Failure Code [D19QKY].......................................................................... 969 Failure Code [D1EMKA].......................................................................... 971 Failure Code [D1EMKB].......................................................................... 973 Failure Code [D1EMKY].......................................................................... 975 Failure Code [D1EMMA].......................................................................... 977 Failure Code [D811MC].......................................................................... 979 Failure Code [D862KA].......................................................................... 980 Failure Code [D8ALKA].......................................................................... 981 Failure Code [D8ALKB].......................................................................... 983 Failure Code [D8AQKR].......................................................................... 985 Failure Code [D8G1KT].......................................................................... 990 Failure Code [D8G6KT].......................................................................... 991 Failure Code [DA20MC].......................................................................... 992 Failure Code [DA22KK].......................................................................... 993 Failure Code [DA25KP].......................................................................... 996 Failure Code [DA26KP].......................................................................... 999 Failure Code [DA29KQ]..........................................................................1001 Failure Code [DA2LKA]..........................................................................1003 Failure Code [DA2LKB]..........................................................................1005 Failure Code [DA2QKR]..........................................................................1007 Failure Code [DA2RKR]..........................................................................1013 Failure Code [DAB0KT]..........................................................................1018 Failure Code [DAC3KB]..........................................................................1019 Failure Code [DAC3KY]..........................................................................1021 Failure Code [DAF0MB]..........................................................................1023 Failure Code [DAF0MC]..........................................................................1024 Failure Code [DAF8KB]..........................................................................1025 Failure Code [DAF9KQ]..........................................................................1027 Failure Code [DAFGMC]..........................................................................1028 Failure Code [DAFLKA]..........................................................................1029 Failure Code [DAFLKB]..........................................................................1031 Failure Code [DAFQKR]..........................................................................1033 Failure Code [DAZ9KQ]..........................................................................1039 Failure Code [DAZQKR]..........................................................................1040 Failure Code [DB2QKR]..........................................................................1044 Failure Code [DB2RKR]..........................................................................1050 Failure Code [DCS0MC]..........................................................................1055 Failure Code [DCS2KK]..........................................................................1056 Failure Code [DCS5KP]..........................................................................1059 Failure Code [DCS9KQ]..........................................................................1061 Failure Code [DCSLKA]..........................................................................1063 Failure Code [DCSLKB]..........................................................................1065 Failure Code [DCSQKR]..........................................................................1067 Failure Code [DCSRKR]..........................................................................1073 Failure Code [DCS0KT]..........................................................................1079 Failure Code [DCS7KP]..........................................................................1080 Failure Code [DDA1L5]..........................................................................1082 Failure Code [DDB6KA]..........................................................................1084 Failure Code [DDB6KB]..........................................................................1086 Failure Code [DDK8KA]..........................................................................1088 Failure Code [DDK8KB]..........................................................................1090 Failure Code [DDKNKA]..........................................................................1092 Failure Code [DDKNKB]..........................................................................1094 Failure Code [DDKPKA]..........................................................................1096 Failure Code [DDKPKB]..........................................................................1098 Failure Code [DDNRKA]..........................................................................1100 Failure Code [DDNRKY]..........................................................................1102 Failure Code [DDNS00]..........................................................................1104 Failure Code [DDP4KX]..........................................................................1106 Failure Code [DDP6L5]..........................................................................1107 Failure Code [DDQ1KA]..........................................................................1109 Failure Code [DDQ1KB]..........................................................................1112 Failure Code [DDWCKZ]..........................................................................1114 Failure Code [DDWMKZ]..........................................................................1117 Failure Code [DFB1KZ]..........................................................................1119 Failure Code [DFB2KZ]..........................................................................1122 Failure Code [DFB3L8]..........................................................................1125 Failure Code [DFB4L8]..........................................................................1126 Failure Code [DFB5KZ]..........................................................................1127 Failure Code [DFB6KZ]..........................................................................1130 Failure Code [DFE1L8]..........................................................................1133 Failure Code [DFE2KZ]..........................................................................1134 Failure Code [DFE3KZ]..........................................................................1137 Failure Code [DFF1KA]..........................................................................1140 Failure Code [DFF1KB]..........................................................................1142 Failure Code [DGH2KA]..........................................................................1144 Failure Code [DGH2KB]..........................................................................1146 Failure Code [DHA4KA]..........................................................................1147 Failure Code [DHAAMA]..........................................................................1149 Failure Code [DHACMA]..........................................................................1150 Failure Code [DHPAMA]..........................................................................1151 Failure Code [DHS3MA]..........................................................................1154 Failure Code [DHS4MA]..........................................................................1157 Failure Code [DHS5KX]..........................................................................1160 Failure Code [DHS8MA]..........................................................................1163 Failure Code [DHS9MA]..........................................................................1166 Failure Code [DHSAMA]..........................................................................1169 Failure Code [DHSBMA]..........................................................................1172 Failure Code [DHSCMA]..........................................................................1175 Failure Code [DHSDMA]..........................................................................1178 Failure Code [DHT8KA]..........................................................................1181 Failure Code [DHT8KB]..........................................................................1183 Failure Code [DHU1KA]..........................................................................1185 Failure Code [DHU1KY]..........................................................................1187 Failure Code [DHUCKA]..........................................................................1189 Failure Code [DHUCKY]..........................................................................1192 Failure Code [DHUGKA]..........................................................................1194 Failure Code [DHUGKY]..........................................................................1196 Failure Code [DHX1MA]..........................................................................1198 Failure Code [DK10KA]..........................................................................1200 Failure Code [DK10KB]..........................................................................1203 Failure Code [DKULKA]..........................................................................1205 Failure Code [DKULKB]..........................................................................1207 Failure Code [DKULKY]..........................................................................1209 Failure Code [DLM5KA]..........................................................................1211 Failure Code [DLM5MB]..........................................................................1213 Failure Code [DLT4KA]..........................................................................1215 Failure Code [DLT4KB]..........................................................................1217 Failure Code [DNCHMC]..........................................................................1219 Failure Code [DNCJL4]..........................................................................1222 Failure Code [DNCKMC]..........................................................................1225 Failure Code [DNCLMC]..........................................................................1228 Failure Code [DR21KX]..........................................................................1231 Failure Code [DV20KB]..........................................................................1233 Failure Code [DW40KA]..........................................................................1235 Failure Code [DW40KB]..........................................................................1237 Failure Code [DW40KY]..........................................................................1239 Failure Code [DW45KA]..........................................................................1241 Failure Code [DW45KB]..........................................................................1244 Failure Code [DW45KY]..........................................................................1247 Failure Code [DW4AKA]..........................................................................1249 Failure Code [DW4AKB]..........................................................................1251 Failure Code [DW4AKY]..........................................................................1253 Failure Code [DW4BKA]..........................................................................1254 Failure Code [DW4BKB]..........................................................................1256 Failure Code [DW4BKY]..........................................................................1258 Failure Code [DW4CKY]..........................................................................1260 Failure Code [DW4MKA]..........................................................................1262 Failure Code [DW4MKB]..........................................................................1264 Failure Code [DW4MKY]..........................................................................1266 Failure Code [DW4YKA]..........................................................................1267 Failure Code [DW4YKB]..........................................................................1269 Failure Code [DW4YKY]..........................................................................1271 Failure Code [DW4ZKA]..........................................................................1273 Failure Code [DW4ZKB]..........................................................................1275 Failure Code [DW4ZKY]..........................................................................1277 Failure Code [DW9KKA]..........................................................................1279 Failure Code [DW9KKB]..........................................................................1281 Failure Code [DW9KKY]..........................................................................1283 Failure Code [DW9LKA]..........................................................................1284 Failure Code [DW9LKB]..........................................................................1286 Failure Code [DW9LKY]..........................................................................1288 Failure Code [DW9PKA]..........................................................................1289 Failure Code [DW9PKB]..........................................................................1291 Failure Code [DW9PKY]..........................................................................1293 Failure Code [DWB1KA]..........................................................................1294 Failure Code [DWB1KB]..........................................................................1296 Failure Code [DWA2KA]..........................................................................1298 Failure Code [DWA2KB]..........................................................................1300 Failure Code [DWA2KY]..........................................................................1302 Failure Code [DWB2KA]..........................................................................1303 Failure Code [DWB2KB]..........................................................................1305 Failure Code [DWB2KY]..........................................................................1307 Failure Code [DWB3KA]..........................................................................1309 Failure Code [DWB3KB]..........................................................................1311 Failure Code [DWB3KY]..........................................................................1313 Failure Code [DWB4KA]..........................................................................1315 Failure Code [DWB4KB]..........................................................................1317 Failure Code [DWB4KY]..........................................................................1319 Failure Code [DWB5KA]..........................................................................1321 Failure Code [DWB5KB]..........................................................................1323 Failure Code [DWB5KY]..........................................................................1325 Failure Code [DWD2KA]..........................................................................1327 Failure Code [DWD2KB]..........................................................................1329 Failure Code [DWD2KY]..........................................................................1331 Failure Code [DWD3KA]..........................................................................1333 Failure Code [DWD3KB]..........................................................................1335 Failure Code [DWD3KY]..........................................................................1337 Failure Code [DWD4KA]..........................................................................1339 Failure Code [DWD4KB]..........................................................................1341 Failure Code [DWD4KY]..........................................................................1343 Failure Code [DWD5KA]..........................................................................1345 Failure Code [DWD5KB]..........................................................................1347 Failure Code [DWD5KY]..........................................................................1349 Failure Code [DWN5KA]..........................................................................1351 Failure Code [DWN5KB]..........................................................................1353 Failure Code [DWN5KY]..........................................................................1355 Failure Code [DXA8KA]..........................................................................1357 Failure Code [DXA8KB]..........................................................................1359 Failure Code [DXE7KA]..........................................................................1361 Failure Code [DXE7KB]..........................................................................1363 Failure Code [DXE7KY]..........................................................................1365 Failure Code [DXE8KA]..........................................................................1367 Failure Code [DXE8KB]..........................................................................1369 Failure Code [DXE8KY]..........................................................................1371 Failure Code [DXE9KA]..........................................................................1373 Failure Code [DXE9KB]..........................................................................1375 Failure Code [DXE9KY]..........................................................................1377 Failure Code [DXEAKA]..........................................................................1379 Failure Code [DXEAKB]..........................................................................1381 Failure Code [DXEAKY]..........................................................................1383 Failure Code [DXEKKA]..........................................................................1385 Failure Code [DXEKKB]..........................................................................1387 Failure Code [DXEKKY]..........................................................................1389 Failure Code [DXELKA]..........................................................................1390 Failure Code [DXELKB]..........................................................................1392 Failure Code [DXELKY]..........................................................................1394 Failure Code [DXK3KA]..........................................................................1395 Failure Code [DXK3KB]..........................................................................1397 Failure Code [DXK3KY]..........................................................................1399 Failure Code [DXNNKA]..........................................................................1400 Failure Code [DXNNKB]..........................................................................1401 Failure Code [DXNNKY]..........................................................................1402 Failure Code [DXNPKA]..........................................................................1403 Failure Code [DXNPKB]..........................................................................1404 Failure Code [DXNPKY]..........................................................................1405 Failure Code [DY20KA]..........................................................................1407 Failure Code [DY20MA]..........................................................................1409 Failure Code [DY2CKB]..........................................................................1411 Failure Code [DY2DKB]..........................................................................1414 Failure Code [DY2EKB]..........................................................................1416 Failure Code [F313KA]..........................................................................1418 Failure Code [F313KB]..........................................................................1419 Failure Code [F318KB]..........................................................................1420 Failure Code [F318KY]..........................................................................1421 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)......................................1422 Information Shown in Troubleshooting Table (H-Mode)............................................1422 Failure Mode and Cause Table...................................................................1423 All Work Equipment, Swing, and Travel Lack Speed or Power......................................1434 Engine Speed Drops Largely or Engine Stops.....................................................1436 All Work Equipment, Swing and Travel Do Not Work...............................................1438 Unusual Noise is Heard from Around Hydraulic Pump..............................................1439 Fine Control Performance or Response is Unsatisfactory.........................................1440 Boom Speed or Power is Low.....................................................................1441 2-Piece Boom Speed or Power is Low.............................................................1443 Arm Speed or Power is Low......................................................................1446 Bucket Speed or Power is Low...................................................................1449 Boom Swing Speed or Power is Low...............................................................1452 Blade or Outrigger Speed or Power is Low.......................................................1454 Boom and Blade or Outrigger Speed or Power are Low.............................................1457 Work Equipment Does Not Move in Single Operation...............................................1458 Hydraulic Drift of Boom is Large...............................................................1459 Hydraulic Drift of 2-Piece Boom is Large.......................................................1460 Hydraulic Drift of Arm is Large................................................................1461 Hydraulic Drift of Bucket is Large.............................................................1462 Hydraulic Drift of Blade or Outrigger is Large.................................................1463 Time Lag of Work Equipment is Large............................................................1464 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower............1465 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low............................1466 In Mixed Operation of Work Equipment or Swing and Travel, Travel Speed Falls Largely...........1467 Travel Speed is Low............................................................................1469 Travel Power is Slow...........................................................................1471 Travel speed is Slow or Fast...................................................................1473 Wheels Do Not Run..............................................................................1474 Upper Structure Does Not Swing in Two Directions of Right and Left.............................1475 Upper Structure Swings Only in One Direction...................................................1476 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left...................1477 Swing Acceleration or Swing Speed is Low in Only One Direction.................................1478 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)...............1479 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)...........1480 Shock is Large When Upper Structure Stops Swing Operation......................................1481 Large Unusual Noise is Made When Upper Structure Stops Swing Operation.........................1482 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied).........................1483 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)........................1484 Oil Flow in Attachment Circuit Cannot be Changed...............................................1485 Mechanical Gear Speed Change is Noise When You Travel..........................................1486 Parking Brake Does Not Work....................................................................1487 Service Brake Does Not Work....................................................................1488 Steering System Does Not Work or Does Not Work Properly (2WS, 4WS-R, 4WS-C)....................1489 Troubleshooting of Engine (S-Mode).................................................................1490 Information Shown in Troubleshooting Table (S-Mode)............................................1490 Engine Does Not Crank When Starting Switch is Turned to Start Position.........................1491 Engine Cranks but No Exhaust Smoke Comes Out...................................................1492 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)........1493 Engine Startability is Unsatisfactory..........................................................1494 Engine Does Not Pick Up Smoothly...............................................................1496 Engine Stops During Operation..................................................................1498 Engine Does Not Rotate Smoothly................................................................1500 Engine Lacks Output (or Lacks Power)...........................................................1501 Exhaust Color is Black (KDPF Becomes Clogged in Short Time)....................................1503 Engine Oil Consumption is Excessive............................................................1505 Engine Oil Becomes Dirty Quickly...............................................................1506 Fuel Consumption is Excessive..................................................................1507 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)..........................1508 Engine Oil Pressure Drops......................................................................1509 Fuel Mixes Into Engine Oil.....................................................................1510 Water Mixes Into Engine Oil (Milky)............................................................1511 Coolant Temperature Increases Too High (Overheat)..............................................1512 Unusual Noise is Heard.........................................................................1513 Vibration is Excessive.........................................................................1515 Air Cannot be Bled from Fuel Circuit...........................................................1516 Active Regeneration is Done Frequently.........................................................1517 Active Regeneration Continues Long.............................................................1518 White Smoke is Exhausted During Active Regeneration............................................1519 50 Disassembly and Assembly............................................................................1521 Table of Contents..................................................................................1522 Related Information on Disassembly and Assembly....................................................1526 How to Read This Manual........................................................................1526 Coating Materials List.........................................................................1528 Prepare............................................................................................1532 Drain and Add Coolant..........................................................................1532 How to Drain Coolant.......................................................................1533 How to Add Coolant.........................................................................1534 Drain and Add Hydraulic Oil....................................................................1535 How to Drain Hydraulic Oil.................................................................1536 How to Add Hydraulic Oil...................................................................1537 Drain and Add Fuel.............................................................................1539 How to Drain Fuel..........................................................................1540 How to Add Fuel............................................................................1540 Collect and Refill Refrigerant.................................................................1542 How to Collect Refrigerant.................................................................1542 How to Refill Refrigerant..................................................................1543 Engine and Cooling System..........................................................................1544 Remove and Install Supply Pump Assembly........................................................1544 How to Remove Supply Pump Assembly.........................................................1545 How to Install Supply Pump Assembly........................................................1555 Remove and Install Injector Assembly...........................................................1563 How to Remove Injector Assembly............................................................1564 How to Install Injector Assembly...........................................................1568 Remove and Install Cylinder Head Assembly......................................................1575 How to Remove Cylinder Head Assembly.......................................................1577 How to Install Cylinder Head Assembly......................................................1604 Remove and Install EGR Valve Assembly..........................................................1640 How to Remove EGR Valve Assembly...........................................................1641 How to Install EGR Valve Assembly..........................................................1642 Remove and Install EGR Cooler Assembly.........................................................1645 How to Remove EGR Cooler Assembly..........................................................1646 Install EGR Cooler Assembly................................................................1652 Remove and Install Starter Assembly............................................................1658 How to Remove Starting Motor Assembly......................................................1658 How to Install Starting Motor Assembly.....................................................1661 Remove and Install Fan Belt....................................................................1664 Remove Fan Belt............................................................................1664 Install Fan Belt...........................................................................1667 Remove and Install Automatic Tensioner.........................................................1669 How to Remove Auto-Tensioner...............................................................1669 How to Install Auto-Tensioner..............................................................1670 Remove and Install Expansion Tank Assembly.....................................................1671 Remove Expansion Tank Assembly.............................................................1672 Install Expansion Tank Assembly............................................................1676 Remove and Install Radiator Assembly...........................................................1681 How to Remove Radiator Assembly............................................................1682 How to Install Radiator Assembly...........................................................1685 Remove and Install Hydraulic Oil Cooler Assembly...............................................1688 How to Remove Hydraulic Oil Cooler Assembly................................................1689 How to Install Hydraulic Oil Cooler Assembly...............................................1697 Remove and Install Aftercooler Assembly........................................................1707 How to Remove Aftercooler Assembly.........................................................1708 How to Install Aftercooler Assembly........................................................1710 Remove and Install Engine and Main Pump Assembly...............................................1713 How to Remove Engine and Main Pump Assembly................................................1715 How to Install Engine and Main Pump Assembly...............................................1736 Remove and Install Engine Front Oil Seal.......................................................1761 How to Remove Engine Front Oil Seal........................................................1762 How to Install Engine Front Oil Seal.......................................................1763 Remove and Install Engine Rear Oil Seal........................................................1766 How to Remove Engine Rear Oil Seal.........................................................1767 How to Install Engine Rear Oil Seal........................................................1769 Remove and Install Fuel Cooler Assembly........................................................1773 Remove Fuel Cooler Assembly................................................................1774 Install Fuel Cooler Assembly...............................................................1774 Remove and Install Engine Hood Assembly........................................................1776 How to Remove Engine Hood Assembly.........................................................1776 How to Install Engine Hood Assembly........................................................1779 Remove and Install KDPF Assembly...............................................................1782 How to Remove KDPF Assembly................................................................1783 How to Install KDPF Assembly...............................................................1791 Disassemble and Assemble KDPF Assembly.........................................................1800 How to Disassemble KDPF Assembly...........................................................1802 How to Assemble KDPF Assembly..............................................................1806 Remove and Install Fuel Tank Assembly..........................................................1812 How to Remove Fuel Tank Assembly...........................................................1813 How to Install Fuel Tank Assembly..........................................................1818 Remove and Install Air Cleaner Assembly........................................................1823 How to Remove Air Cleaner Assembly.........................................................1824 How to Install Air Cleaner Assembly........................................................1825 Remove and Install Air Conditioner Compressor Assembly.........................................1828 How to Remove Air Conditioner Compressor Assembly..........................................1829 How to Install Air Conditioner Compressor Assembly.........................................1831 Remove and Install Air Conditioner Condenser Assembly..........................................1833 How to Remove Air Conditioner Condenser Assembly...........................................1834 How to Install Air Conditioner Condenser Assembly..........................................1836 Power Train........................................................................................1838 Remove and Install Swing Motor and Swing Machinery Assembly....................................1838 How to Remove Swing Motor and Swing Machinery Assembly.....................................1839 How to Install Swing Motor and Swing Machinery Assembly....................................1844 Disassemble and Assemble Swing Machinery Assembly..............................................1849 How to Disassemble Swing Machinery Assembly................................................1850 How to Assemble Swing Machinery Assembly...................................................1855 Remove and Install Swing Circle Assembly.......................................................1861 How to Remove Swing Circle Assembly........................................................1861 How to Install Swing Circle Assembly.......................................................1862 Undercarriage and Frame............................................................................1863 How to Disassemble and Assemble Axles..........................................................1863 How to Disassemble.........................................................................1863 How to Assemble............................................................................1886 How to Disassemble and Assemble Transmission...................................................1921 How to Disassemble.........................................................................1921 How to Assemble............................................................................1929 How to Remove and Install of twin-type wheels with flap ring...................................1938 How to Remove twin-type wheels with flap ring..............................................1938 How to Install twin-type wheels with flap ring.............................................1940 How to Remove and Install Front Axle...........................................................1941 How to Remove Front Axle...................................................................1941 How to Install Front Axle..................................................................1943 How to Remove and Install Rear Axle............................................................1945 How to Remove Rear Axle....................................................................1945 How to Install Rear Axle...................................................................1947 How to Remove and Install Axle Lock Cylinder...................................................1950 How to Remove Axle Lock Cylinder...........................................................1950 How to Install Axle Lock Cylinder..........................................................1951 How to Remove and Install Revolving Frame Assembly.............................................1952 How to Remove Revolving Frame Assembly.....................................................1952 How to Install Revolving Frame Assembly....................................................1955 Remove and Install Counterweight Assembly......................................................1958 How to Remove Counterweight Assembly.......................................................1959 How to Install Counterweight Assembly......................................................1963 How to Remove and Install Travel Motor Assembly................................................1968 How to Remove Travel Motor.................................................................1968 How to Install Travel Motor................................................................1970 Hydraulic System...................................................................................1973 How to Remove and Install Center Swivel Joint Assembly.........................................1973 How to Remove Center Swivel Joint Assembly.................................................1973 How to Install Center Swivel Joint Assembly................................................1977 Remove and Install Hydraulic Tank Assembly.....................................................1981 How to Remove Hydraulic Tank Assembly......................................................1981 How to Install Hydraulic Tank Assembly.....................................................1985 Remove and Install Main Pump Assembly..........................................................1989 How to Remove Main Pump Assembly...........................................................1990 How to Install Main Pump Assembly..........................................................1997 Disassemble and Assemble Control Valve Assembly................................................2004 How to Assemble Control Valve Assembly.....................................................2004 Replace Pressure Reducing Valve Cartridge Assembly.........................................2005 Disassemble and Assemble Work Equipment PPC Valve Assembly.....................................2009 How to Disassemble Work Equipment PPC Valve Assembly.......................................2009 How to Assemble Work Equipment PPC Valve Assembly..........................................2010 Disassemble and Assemble of 2-piece boom Cylinder Assembly.....................................2011 How to Disassemble 2-piece Boom Cylinder Assembly..........................................2011 How to Assemble 2-piece Boom Cylinder Assembly.............................................2013 Work Equipment.....................................................................................2017 Remove and Install Work Equipment Assembly.....................................................2017 How to Remove Work Equipment Assembly......................................................2018 How to Install Work Equipment Assembly.....................................................2022 Disassemble and Assemble Boom Cylinder Assembly................................................2026 How to Disassemble Boom Cylinder Assembly..................................................2026 How to Assemble Boom Cylinder Assembly.....................................................2028 Disassemble and Assemble Arm Cylinder Assembly.................................................2031 How to Disassemble Arm Cylinder Assembly...................................................2031 How to Assemble Arm Cylinder Assembly......................................................2033 Disassemble and Assemble Bucket Cylinder Assembly..............................................2037 How to Disassemble Bucket Cylinder Assembly................................................2037 How to Assemble Bucket Cylinder Assembly...................................................2039 Disassemble and Assemble Swing Cylinder Assembly...............................................2042 Disassemble Swing Cylinder Assembly........................................................2042 Assemble Swing Cylinder Assembly...........................................................2044 CAB Related Parts..................................................................................2048 Remove and Install Operator Cab Assembly.......................................................2048 How to Remove Operator Cab Assembly........................................................2049 How to Install Operator Cab Assembly.......................................................2065 Remove and Install Operator Cab Door...........................................................2081 How to Install Operator Cab Door...........................................................2082 Remove and Install Operator Cab Glass (Adhered Glass)..........................................2086 Remove Operator CAB Glass (Adhered Glass)..................................................2087 Install Operator CAB Glass (Adhered Glass).................................................2088 Remove and Install Front Window Assembly.......................................................2097 Remove Front Window Assembly...............................................................2097 Install Front Window Assembly..............................................................2099 Remove and Install Air Conditioner Unit Assembly...............................................2101 How to Remove Air Conditioner Unit Assembly................................................2102 How to Install Air Conditioner Unit Assembly...............................................2114 Remove and Install Operator Seat...............................................................2127 How to Remove Operator Seat................................................................2128 How to Install Operator Seat...............................................................2129 How to Remove and Install Seat Belt............................................................2132 How to Remove Seat Belt....................................................................2133 How to Install Seatbelt....................................................................2133 Electrical System..................................................................................2134 Remove and Install Engine Controller Assembly..................................................2134 How to Remove Engine Controller Assembly...................................................2135 How to Install Engine Controller Assembly..................................................2137 Remove and Install Machine Controller Assembly.................................................2140 How to Remove Machine Controller Assembly..................................................2141 How to Install Machine Controller Assembly.................................................2142 Remove and Install Pump Controller Assembly....................................................2144 Remove Pump Controller Assembly............................................................2145 Install Pump Controller Assembly...........................................................2147 Remove and Install Machine Monitor Assembly....................................................2149 How to Remove Machine Monitor Assembly.....................................................2150 How to Install Machine Monitor Assembly....................................................2155 Remove and Install Mass Air Flow and Temperature Sensor........................................2159 How to Remove Mass Air Flow and Temperature Sensor.........................................2160 How to Install Mass Air Flow and Temperature Sensor........................................2161 Remove and Install KDPF Temperature Sensor.....................................................2162 How to Remove KDPF Temperature Sensor......................................................2163 How to Install KDPF Temperature Sensor.....................................................2167 Remove and Install KDPF Differential Pressure Sensor...........................................2171 How to Remove KDPF Differential Pressure Sensor............................................2172 How to Install KDPF Differential Pressure Sensor...........................................2174 Remove and Install Gateway Function Controller.................................................2176 How to Remove Gateway Function Controller..................................................2177 How to Install Gateway Function Controller.................................................2179 60 Maintenance Standard................................................................................2183 Table of Contents..................................................................................2184 Engine and Cooling System..........................................................................2185 Maintenance Standard for Engine Mount..........................................................2185 Maintenance Standard for PTO...................................................................2186 Maintenance Standard for Cooling System........................................................2187 Swing System.......................................................................................2188 Maintenance Standard for Swing Circle..........................................................2188 Maintenance Standard for Swing Machinery.......................................................2190 Maintenance Standard for Swing Motor...........................................................2192 Power Train........................................................................................2194 Maintenance for Front Axle.....................................................................2194 Pinion and Differential....................................................................2194 Brakes.....................................................................................2194 Final Reduction............................................................................2194 Steering Cylinder..........................................................................2195 Maintenance for Transmission...................................................................2196 Maintenance for Rear Axle......................................................................2198 Differential...............................................................................2198 Final Reduction............................................................................2198 Steering Cylinder..........................................................................2199 Brakes.....................................................................................2200 Maintenance for Parking Brake Cylinder.........................................................2201 Maintenance for Axle Locking Cylinder..........................................................2202 Maintenance for Travel Motor...................................................................2203 Hydraulic System...................................................................................2204 Maintenance Standard for Hydraulic Tank........................................................2204 Maintenance Standard for Control Valve.........................................................2205 Maintenance Standard for Hydraulic Pump........................................................2213 Maintenance Standard for Servo Valve...........................................................2214 Maintenance Standard for Work Equipment and Swing PPC Valve....................................2215 Maintenance Standard for 2-Piece Boom PPC Valve................................................2218 Maintenance Standard for Boom Anti-Drop Valve..................................................2220 Maintenance Standard for Arm Anti-Drop Valve...................................................2222 Maintenance Standard for 5-Spool Solenoid Valve................................................2224 Maintenance Standard for 4-Spool Solenoid Valve................................................2225 Maintenance Standard for Travel and Attachment Solenoid Valve..................................2226 Maintenance Standard for Attachment And Boom Swing Flow Adjustment EPC Valve...................2227 Maintenance Standard for Steering Control Solenoid Valve.......................................2228 Work Equipment.....................................................................................2229 Maintenance Standard for Work Equipment........................................................2229 Dimensions of Arm..........................................................................2235 Dimensions of Bucket.......................................................................2239 Maintenance Standard for Boom Cylinder.........................................................2241 Maintenance Standard for 2-Piece Boom Cylinder.................................................2242 Maintenance Standard for Arm Cylinder..........................................................2243 Maintenance Standard for Bucket Cylinder.......................................................2244 Maintenance Standard for Boom Swing Cylinder...................................................2245 Maintenance Standard for Blade Cylinder........................................................2246 80 APPENDIX............................................................................................2247 Table of Contents..................................................................................2248 Air Conditioner System.............................................................................2250 Precautions for Refrigerant....................................................................2250 Air Conditioner Component......................................................................2251 Specifications of Air Conditioner..............................................................2253 Structure and Function of Refrigeration Cycle..................................................2254 Outline of Refrigeration Cycle.................................................................2255 Component Parts of Air Conditioner System..........................................................2257 Air Conditioner Unit...........................................................................2257 Configuration Diagram of Air Conditioner Unit..............................................2257 Function of Air Conditioner Unit...........................................................2259 Component Parts of Air Conditioner Unit........................................................2260 Function of Evaporator as Air Conditioner Unit Component...................................2261 Function of Heater Core as Air Conditioner Unit Component..................................2261 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component................2261 Function of Servo Motor as Air Conditioner Unit Component..................................2262 Structure of Expansion Valve as Air Conditioner Unit Component.............................2263 Function of Expansion Valve as Air Conditioner Unit Component..............................2263 Operate Expansion Valve as Air Conditioner Unit Component..................................2263 Function of Dual Pressure Switch...........................................................2264 Air Conditioner Controller.....................................................................2265 Structure of Air Conditioner Controller....................................................2265 Compressor.....................................................................................2266 Structure of Compressor....................................................................2266 Specifications of Compressor...............................................................2266 Function of Compressor.....................................................................2266 Condenser......................................................................................2267 Structure of Condenser.....................................................................2267 Specifications of Condenser................................................................2267 Function of Condenser......................................................................2267 Receiver Drier.................................................................................2268 Structure of Receiver Dryer................................................................2268 Specifications of Receiver Dryer...........................................................2268 Function of Receiver Dryer.................................................................2268 Air Conditioner Related Sensors................................................................2269 Structure of Sunlight Sensor...............................................................2269 Function of Sunlight Sensor................................................................2269 Structure of Outside Temperature Sensor....................................................2269 Function of Outside Air Temperature Sensor.................................................2269 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner........................2271 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.............................2273 System Diagram of Air Conditioner..................................................................2275 Input and Output Signals of Air Conditioner Controller.........................................2276 Function of Air Conditioner Controller.....................................................2277 Locations of Air Conditioner Parts and Layout of Connectors........................................2278 Examine Air Leakage (Duct).........................................................................2284 How to Examine Air Leakage (Duct)..............................................................2284 Examine Air Conditioner with Self-Diagnosis Function...............................................2285 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor............2286 Examine Vent (Mode) Changeover.....................................................................2287 How to Examine Vent (Mode) Changeover..........................................................2287 Examine Fresh/Recirc Air Changeover................................................................2288 How to Examine Fresh/Recirc Air Changeover.....................................................2288 Examine Sunlight Sensor............................................................................2289 How to Examine Sunlight Sensor.................................................................2289 Examine Refrigerant (Dual) Pressure Switch.........................................................2290 How to Examine Refrigerant (Dual) Pressure Switch..............................................2290 Examine Relay......................................................................................2292 How to Examine Relay...........................................................................2292 Air Conditioner Troubleshooting Chart 1............................................................2293 Air Conditioner Troubleshooting Chart 2............................................................2294 Information Shown in Troubleshooting Table.........................................................2297 Failure Code [879AKA]..............................................................................2298 Failure Code [879AKB]..............................................................................2299 Failure Code [879BKA]..............................................................................2300 Failure Code [879BKB]..............................................................................2302 Failure Code [879CKA]..............................................................................2304 Failure Code [879CKB]..............................................................................2305 Failure Code [879DKZ]..............................................................................2306 Failure Code [879EMC]..............................................................................2308 Failure Code [879FMC]..............................................................................2309 Failure Code [879GKX]..............................................................................2310 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate).........................2312 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)..........................2314 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal).................2317 Troubleshooting for Fresh/Recirc Air Changeover....................................................2319 Troubleshooting by Gauge Pressure..................................................................2321 Connect Service Tool...............................................................................2324 How to Connect Service Tool....................................................................2324 Precautions for Disconnection and Connection of Air Conditioner Piping.............................2326 Handle Compressor Oil..............................................................................2328 90 Circuit Diagrams....................................................................................2331 Table of Contents..................................................................................2332 How to Read the Codes for Electric Cable...........................................................2333 Hydraulic Circuit Diagram..........................................................................2337 Symbols Used in Hydraulic Circuit Diagram......................................................2337 Hydraulic Circuit Diagram (1/2)................................................................2341 Hydraulic Circuit Diagram (2/2)................................................................2343 Electrical Circuit Diagram.........................................................................2345 Symbols Used in Electric Circuit Diagram.......................................................2345 Electrical Circuit Diagram (1/11)..............................................................2349 Electrical Circuit Diagram (2/11)..............................................................2351 Electrical Circuit Diagram (3/11)..............................................................2353 Electrical Circuit Diagram (4/11)..............................................................2355 Electrical Circuit Diagram (5/11)..............................................................2357 Electrical Circuit Diagram (6/11)..............................................................2359 Electrical Circuit Diagram (7/11)..............................................................2361 Electrical Circuit Diagram (8/11)..............................................................2363 Electrical Circuit Diagram (9/11)..............................................................2365 Electrical Circuit Diagram (10/11).............................................................2367 Electrical Circuit Diagram (11/11).............................................................2369 Index...................................................................................................2371
DESCRIPTION:
KOMATSU PW98MR-11E0 WHEELED EXCAVATOR SHOP MANUAL WENBM00290 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for Testing and Adjusting are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 21/12/24
