Komatsu Wheeled Excavator PW98MR-10 service & repair manual

Description Komatsu Wheeled Excavator PW98MR-10 service & repair manual

Komatsu Wheeled Hydraulic Excavator PW98MR-10 pdf workshop service manual + operation & maintenance manual

Serial number F10003 and up

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

MANUAL CONTENT:
Index and foreword
Foreword, safety and general information
Important safety notice
Fire prevention
Dispose of waste materials
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Overall dimensions
Working range drawings
Specifications
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Engine related parts
PTO
Variable flow turbocharger
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDOC muffler
Cooling system
Power train
Power train overview
Swing circle
Swing machinery
Undercarriage and frame
Front axle
Transmission
Rear axle
Hydraulic system
Hydraulic component layout
Valve control
Hydraulic tank
Control valve
CLSS
Hydraulic pump
Self-reducing pressure valve
Swing motor
Travel motor
Work equipment and swing PPC valve
Boom swing and 2 piece boom PPC valve
Travel PPC valve
Brakes pump
Swivel joint
Solenoid valve
Steering control solenoid valve group
1-Attachment flow adjustment EPC valve
2-Attachment flow adjustment EPC valve
Travel speed and direction control solenoid valve
Boom/Outrigger schematic
Undercarriage attachment schematic
Accumulator
Travel by-pass control valve
Anti-drop valve
Blade/outriggers safety valve
2-piece boom safety valve
Boom swing safety valve
Hydraulic quick coupler
Work equipment
Work equipment shim
Bucket play adjustment shim
Cab and its attachments
Cab mount and cab tipping stopper
ROPS cab
Steering column
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
Sensor
PPC Levers
Overload warning device

Standard value tables
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system

Testing and adjusting
Related information on testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing and adjusting air conditioner compressor belt tension
Replacing fan belt
Writing compensation values at replacement of injector and engine controller
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Checking leakages in the steering cylinders
Testing and adjusting steering circuit oil pressure
Testing the braking system pressure
Checking wear in the brake disks
Bleeding air from the brake lines
Hydraulic system
Releasing remaining pressure from hydraulic circuit
Checking and regulating pressure in the hydraulic circuits
Releasing remaining pressure from work equipment
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting swing circuit oil pressure
Testing oil pressure of control circuit
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing outlet pressure of solenoid valve
Testing PPC valve outlet pressure
Adjusting play of work equipment and swing PPC valves
Testing main pump flow rate
Travel hydraulic equipment checking procedure
Testing and adjusting the automatic displacement control system in the travel motor
Checking for leakages in the travel motor
Checking and adjusting the speed of the travel propeller shaft
Adjustment of the speed sensor
Isolating the parts causing hydraulic drift in work equipment
Testing oil leakage
Checking for leakages in the travel motor
Bleeding air from hydraulic circuit
Cab and its attachments
Testing, cleaning and lubricating slide door rail and roller
Adjusting mirrors
Testing and adjusting hood catcher
Electrical system
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Adjusting rearview camera angle
Adjusting headlight lamp alignment for street circulation
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm - Clinic Service

Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Testing in accordance with testing procedure
Testing in accordance with testing procedure
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Failure codes table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine and main pump assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of KDOC muffler
Removal and installation of KCCV ventilator
Removal and installation of air cleaner assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of fan belt
Power train system
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Removal and installation of twin-type wheels
Removal and installation front axle
Removal and installation of rear axle
Disassembly and assembly of axles
Removal and installation of transmission
Disassembly and assembly of transmission
Removal and installation of axle locking cylinders
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of travel motor
Removal and installation of center swivel joint assembly
Removal and installation of control valve cover
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of work equipment cylinder assembly
Disassembly and assembly of 2-piece boom and blade/outrigger cylinders assembly
Work equipment
Removal and installation of work equipment assembly
Removal and installation blade or outriggers
Removal and installation blade and outrigger arms
Removal and installation of boom swing bracket
Cab and its attachments
Removal and installation of operators cab assembly
Removal and installation of operators cab door
Removal and installation of operators cab glass (adhered glass)
Removal and installation of front window assembly 
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of operators seat
Removal and installation of seat belt
Removal and installation of front wiper assembly
Electrical system
Removal and installation of starting motor assembly
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of travel speed sensor
Removal and installation of steering sensor
Removal and installation of revolving frame swing position sensor
Removal and installation of direction indicator, head light dipper beam control group
Removal and installation of KOMTRAX terminal assembly

Maintenance standard
Engine and cooling system
Engine mount
PTO
Cooling system
Power train system
Swing circle
Swing machinery
Undercarriage and frame
Front axle
Transmission
Rear axle
Hydraulic system
Hydraulic tank
Hydraulic pump
Swing motor
Self-reducing pressure valve
PPC valve
Boom swing and 2-piece boom PPC valve
Travel motor
Solenoid valve
Steering control solenoid valve
1-Attachment flow adjustment EPC valve
2-Attachment flow adjustment EPC valve
Travel speed and direction control solenoid valve
Anti drop valve
Blade safety valve
Cab and its attachments
Cab mount and cab tipping stopper
Work equipment
Boom cylinder
2-piece boom cylinder
Arm cylinder
Bucket cylinder
Boom swing cylinder
Blade and outrigger cylinder

Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Condenser
Receiver drier
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit
Failure code [879AKB] A/C Recirc Air Temp Sens Short
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Malfunction
Failure code [879FMC] Air Mix Damper Malfunction
Failure code [879GKX] Refrigerant Press Input Sig Out of Range
A-1 Troubleshooting for power supply system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting refrigerant piping
Handling of compressor oil

Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram

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