Komatsu Wheeled Excavator PW98MR-8 service & repair manual

Description Komatsu Wheeled Excavator PW98MR-8 service & repair manual

Komatsu Wheeled Hydraulic Excavator PW98MR-8 pdf workshop service & repair manual

Serial number F80003 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 and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of hydraulic components
Method of disconnecting and connecting push-pull type coupler
Handling of electric equipment
How to read electric wire code
Precautions when performing work
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specifications drawing
Table of weight
Table of fuel, coolant and lubricants

Structure and function
Engine mount
PTO
Cooling system
Power train overview
Front axle
Pinion and differential
Brakes
Final reduction
Steering cylinder
Steering and convergency angle
Rear axle
Differential
Final reduction
Steering cylinder
Steering and convergency angle
Parking brake cylinder
Steering system
Axle locking cylinder
Solenoid valve group
Priority valve
Steering unit
Swing circle
Swing machinery
Hydraulic tank and filter
Hydraulic pump
Control valve
Outline
11-spool valve
CLSS
Outline of CLSS
Basic principle
Function and operation by valve
Hydraulic circuit diagram and name of valves
1. Unload valve
2. Introduction of LS pressure
3. LS bypass plug
4. Pressure compensation valve
5. Surface area ratio of pressure compensation valve
6. Travel LS bypass circuit
7. Boom regeneration circuit
8. Boom hydraulic drift prevention valve
PPC valve
Work equipment and swing PPC valve
Blade, outrigger, variable 2-piece boom and boom swing PPC valve
Travel PPC valve
Brakes pump
Swing motor
Travel motor
Displacement automatic control high pressure related
Travel motor brake valves
Swivel joint
Solenoid valve
1 - Attachment oil flow adjuster EPC valve
2 - Attachment oil flow adjuster EPC valve
PPC accumulator
For PPC circuit
Anti-drop valve
Work equipment
Dimensions of components
Arm
Bucket
Work equipment cylinder

Standard value table
Standard value table for engine
Standard value table for chassis

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing exhaust temperature
Checking exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return rate and fuel leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Testing and adjusting alternator belt tension
Checking and adjusting air conditioner compressor belt tension
Measuring the swing circle axial clearance
Checking and regulating pressure in the hydraulic circuits
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting swing and attachment 2 circuit oil pressure
Testing control circuit basic pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing LS differential pressure and adjusting LS valve
Testing solenoid valve output pressure
Testing main pump flow rate
Testing and adjusting steering circuit oil pressure
Testing the braking system pressure
Checking wear in the brake disks
Bleeding air from the brake lines
Adjusting the parking brake
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
Checking parts which cause hydraulic drift of work equipment
Air bleeding from hydraulic circuits
Releasing residual pressure from the circuits
Checking leakages in the steering cylinders
Adjusting travel PPC valves clearance
Wheel types set up
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes

Troubleshooting
Failure code table and fuse locations
Failure code table
Failure code table of steering controller
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Information in troubleshooting table
Phenomena looking like troubles and troubleshooting Nos.
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code
Troubleshooting by failure code steering controller
Troubleshooting of electrical system
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel tank assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of engine hood assembly
Power train
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery
Removal and installation of swing circle assembly
Undercarriage and frame
Removal and installation front axle
Removal and installation of rear axle
Disassembly and assembly of axles
Removal and installation of axle locking cylinders
Removal and installation of transmission
Disassembly and assembly of the transmission
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of travel motor
Removal and installation of hydraulic tank assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Removal and installation of boom swing cylinder assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of boom cylinder
Removal and installation of 2-piece boom cylinder
Removal and installation swivel joint
Work equipment
Removal and installation work equipment assembly
Removal and installation blade and outriggers
Removal and installation blade and outrigger arms
Removal and installation of boom swing bracket
Removal and installation of upper equipment
Cab and its attachment
Removal and installation of operator cab assembly
Removal and installation of operators cab glass (Stuck glass)
Removal and installation of front window assembly
Electrical system
Removal and installation of air conditioner compressor assembly
Removal and Installation of air conditioner condenser assembly
Removal and installation of air conditioner unit assembly
Removal and installation of machine monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
Removal and installation of KOMTRAX terminal assembly
Removal and installation of transmission - reverser, direction indicator and headlight dipper beam control group

Diagrams and drawings
Hydraulic diagram
Electrical diagram

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