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KOMATSU PW98MR-10 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00120 – PDF DOWNLOAD
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KOMATSU PW98MR-10 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00120 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW98MR-10 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00120 – PDF DOWNLOAD
Language : English
Pages : 1726
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PW98MR-10 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00120 – PDF DOWNLOAD
00 Index and foreword.......................................................................................................... 3 Table of contents.......................................................................................................... 4 Foreword, safety and general information................................................................................... 19 Important safety notice................................................................................................ 19 Fire prevention........................................................................................................ 24 Dispose of waste materials............................................................................................. 25 How to read the shop manual............................................................................................ 26 Explanation of terms for maintenance standard.......................................................................... 28 Handling equipment of fuel system devices.............................................................................. 30 Handling of intake system parts........................................................................................ 31 Handling of hydraulic equipment........................................................................................ 32 Method of disconnecting and connecting of push-pull type coupler....................................................... 34 Type 1............................................................................................................. 34 Type 2............................................................................................................. 35 Type 3............................................................................................................. 36 Handling of electrical equipment....................................................................................... 37 How to read electric wire code......................................................................................... 45 Precautions when performing operation.................................................................................. 48 Practical use of KOMTRAX............................................................................................... 53 Standard tightening torque table....................................................................................... 54 List of abbreviation................................................................................................... 60 Conversion table....................................................................................................... 65 01 Specification............................................................................................................... 71 Contents................................................................................................................... 72 Specifications............................................................................................................. 73 Overall dimensions..................................................................................................... 73 Working range drawings................................................................................................. 74 Specifications......................................................................................................... 76 Weight table........................................................................................................... 81 Table of fuel, coolant, and lubricants................................................................................. 83 10 Structure and function...................................................................................................... 85 Contents................................................................................................................... 86 Engine and cooling system.................................................................................................. 88 Engine related parts................................................................................................... 88 PTO.................................................................................................................... 90 Variable flow turbocharger............................................................................................. 91 EGR system piping drawing.............................................................................................. 95 EGR system circuit diagram............................................................................................. 97 EGR valve.............................................................................................................. 98 EGR cooler............................................................................................................. 100 KCCV layout drawing.................................................................................................... 101 KCCV ventilator........................................................................................................ 104 CDR valve.......................................................................................................... 105 KDOC muffler........................................................................................................... 106 Cooling system......................................................................................................... 108 Power train................................................................................................................ 111 Power train overview................................................................................................... 111 Swing circle........................................................................................................... 113 Swing machinery........................................................................................................ 115 Undercarriage and frame.................................................................................................... 117 Front axle............................................................................................................. 117 Pinion and differential............................................................................................ 117 Brakes............................................................................................................. 119 Final reduction.................................................................................................... 120 Steering cylinder.................................................................................................. 121 Steering and convergency angle..................................................................................... 122 Transmission........................................................................................................... 123 Rear axle.............................................................................................................. 125 Differential....................................................................................................... 125 Final reduction.................................................................................................... 127 Steering cylinder.................................................................................................. 128 Steering and convergency angle..................................................................................... 129 Brakes............................................................................................................. 130 Braking system..................................................................................................... 132 Parking brake cylinder............................................................................................. 134 Steering system.................................................................................................... 137 Axle locking cylinder.............................................................................................. 142 Priority valve..................................................................................................... 145 Steering unit...................................................................................................... 146 Hydraulic system........................................................................................................... 147 Hydraulic component layout............................................................................................. 147 Valve control.......................................................................................................... 149 Hydraulic tank......................................................................................................... 151 Pressure valve..................................................................................................... 153 Breather........................................................................................................... 154 Control valve.......................................................................................................... 155 Outline............................................................................................................ 156 CLSS................................................................................................................... 167 Structure of CLSS.................................................................................................. 167 Function and operation by valve.................................................................................... 171 1. Unload valve.................................................................................................... 173 2. Introduction of LS pressure..................................................................................... 176 3. LS bypass plug.................................................................................................. 178 4. Pressure compensation valve..................................................................................... 179 5. Surface area ratio of pressure compensation valve............................................................... 180 6. Travel LS bypass circuit........................................................................................ 181 7. Boom regeneration circuit....................................................................................... 183 Hydraulic pump......................................................................................................... 185 Servo valve........................................................................................................ 192 Self-reducing pressure valve........................................................................................... 198 Swing motor............................................................................................................ 204 Swing parking brake................................................................................................ 207 Relief valve....................................................................................................... 209 Travel motor........................................................................................................... 215 Function........................................................................................................... 216 Operation.......................................................................................................... 217 Work equipment and swing PPC valve..................................................................................... 219 Boom swing and 2 piece boom PPC valve.................................................................................. 226 Travel PPC valve....................................................................................................... 228 Brakes pump............................................................................................................ 229 Swivel joint........................................................................................................... 231 Solenoid valve......................................................................................................... 233 Steering control solenoid valve group.................................................................................. 235 1-Attachment flow adjustment EPC valve................................................................................. 236 2-Attachment flow adjustment EPC valve................................................................................. 237 Travel speed and direction control solenoid valve...................................................................... 238 Boom/Outrigger schematic............................................................................................... 239 Undercarriage attachment schematic..................................................................................... 240 Accumulator............................................................................................................ 241 PPC circuit accumulator............................................................................................ 241 Brake circuit accumulator.......................................................................................... 242 Attachment circuit accumulator (for low pressure circuit).......................................................... 243 Travel by-pass control valve........................................................................................... 244 Anti-drop valve........................................................................................................ 245 for boom cylinder and arm cylinder................................................................................. 245 Function........................................................................................................... 246 Operation.......................................................................................................... 246 Blade/outriggers safety valve.......................................................................................... 250 2-piece boom safety valve.............................................................................................. 251 Boom swing safety valve................................................................................................ 252 Hydraulic quick coupler................................................................................................ 253 Schematic.......................................................................................................... 253 Operation.......................................................................................................... 254 Hydraulic quick coupler solenoid valve............................................................................. 254 Specification...................................................................................................... 254 Quick coupler error logic.......................................................................................... 255 Quick coupler indication logic..................................................................................... 255 Work equipment............................................................................................................. 256 Work equipment......................................................................................................... 256 Work equipment shim.................................................................................................... 257 Bucket play adjustment shim............................................................................................ 258 Cab and its attachments.................................................................................................... 259 Cab mount and cab tipping stopper...................................................................................... 259 ROPS cab............................................................................................................... 261 Take wiring harness out of cab..................................................................................... 262 Steering column........................................................................................................ 263 Electrical system.......................................................................................................... 264 Electrical control system.............................................................................................. 264 Engine control function............................................................................................ 265 Engine and pump combined control function.......................................................................... 267 Auto-deceleration function......................................................................................... 272 Engine automatic warm-up function.................................................................................. 274 Overheat prevention function....................................................................................... 276 Turbocharger protection function................................................................................... 277 Swing control function............................................................................................. 278 Travel control function............................................................................................ 280 Travel by-pass control function (Machine controller)............................................................... 285 2WS-4WS mode control............................................................................................... 287 Parking brake function (travel).................................................................................... 290 Autocruise control function........................................................................................ 291 PPC lock function.................................................................................................. 292 Automatic engine idle stop......................................................................................... 294 Work equipment automatic lock function............................................................................. 297 System operating lamp function..................................................................................... 299 Battery disconnect switch function................................................................................. 300 Refueling pump..................................................................................................... 302 Oil flow adjuster function for attachment.......................................................................... 303 System component parts............................................................................................. 305 Pump controller.................................................................................................... 311 Machine controller................................................................................................. 315 Fuel control dial.................................................................................................. 319 Resister for PC-EPC valve.......................................................................................... 320 CAN terminating resistor........................................................................................... 320 Engine oil pressure switch......................................................................................... 321 PPC oil pressure switch............................................................................................ 322 Suspension lock pressure switch.................................................................................... 322 Stop lights and Cruise control pressure switch..................................................................... 323 Quick coupler low oil pressure switch.............................................................................. 323 Machine monitor system................................................................................................. 324 Machine monitor.................................................................................................... 325 Display............................................................................................................ 328 Gauges............................................................................................................. 332 Caution lamps...................................................................................................... 334 Pilot display...................................................................................................... 337 Steering and road circulation display.............................................................................. 340 Switches........................................................................................................... 344 Guidance icon and function switch.................................................................................. 346 KOMTRAX system......................................................................................................... 353 KOMTRAX terminal................................................................................................... 354 Sensor................................................................................................................. 356 Ambient pressure sensor............................................................................................ 356 Charge (boost) pressure and temperature sensor..................................................................... 356 Coolant temperature sensor......................................................................................... 357 Ne (crankshaft) speed sensor....................................................................................... 357 Bkup (camshaft) speed sensor....................................................................................... 358 Common rail pressure sensor........................................................................................ 358 Variable flow turbocharger motor (with built-in position sensor)................................................... 359 EGR valve (with built-in position sensor).......................................................................... 359 Mass air flow and temperature sensor............................................................................... 360 Crankcase pressure sensor.......................................................................................... 361 Fuel level sensor.................................................................................................. 361 Hydraulic oil temperature sensor................................................................................... 362 Front pump / Service brake / Low Brake / Overload oil pressure sensor.............................................. 362 PPC oil pressure sensor............................................................................................ 363 Steering alignment sensors......................................................................................... 364 Speed revolution sensor............................................................................................ 364 Gear engagement sensor............................................................................................. 365 Swing alignment sensor............................................................................................. 366 PPC Levers............................................................................................................. 367 L.H. PPC lever..................................................................................................... 367 R.H. PPC lever..................................................................................................... 368 Overload warning device................................................................................................ 369 Outline............................................................................................................ 369 20 Standard value tables....................................................................................................... 371 Contents................................................................................................................... 372 Standard service value table............................................................................................... 373 Standard value table for engine........................................................................................ 373 Standard value table for machine....................................................................................... 375 Engine speed....................................................................................................... 375 Travel of control lever............................................................................................ 375 Control effort of control lever.................................................................................... 376 Hydraulic pressure................................................................................................. 377 Swing.............................................................................................................. 379 Travel............................................................................................................. 381 Work equipment..................................................................................................... 382 Pump performance................................................................................................... 386 Machine posture and procedure for measuring performance............................................................ 387 Standard value table for electrical system............................................................................. 392 Controller......................................................................................................... 392 Engine control..................................................................................................... 393 Machine control.................................................................................................... 394 30 Testing and adjusting....................................................................................................... 401 Table of contents.......................................................................................................... 402 Related information on testing and adjusting............................................................................... 404 Sketch of tools for testing and adjusting.............................................................................. 404 P4: Sensor adapter................................................................................................. 404 P4: Nipple (the internal parts of the sensor adapter shown in the above figure).................................... 405 -: Socket.......................................................................................................... 405 Engine and cooling system.................................................................................................. 406 Testing engine speed................................................................................................... 406 Testing exhaust gas color.............................................................................................. 407 Testing............................................................................................................ 407 Testing and adjusting valve clearance.................................................................................. 408 Testing............................................................................................................ 408 Adjusting.......................................................................................................... 408 Testing compression pressure........................................................................................... 410 Testing............................................................................................................ 410 Testing blowby pressure................................................................................................ 412 Testing............................................................................................................ 412 Testing engine oil pressure............................................................................................ 413 Testing............................................................................................................ 413 Testing fuel pressure.................................................................................................. 414 Testing............................................................................................................ 414 Testing fuel return rate and leakage................................................................................... 415 Testing............................................................................................................ 416 Bleeding air from fuel system.......................................................................................... 418 Bleeding air....................................................................................................... 418 Testing fuel circuit for leakage....................................................................................... 420 Testing............................................................................................................ 420 Handling cylinder cutout mode operation................................................................................ 421 Handling no-injection cranking operation............................................................................... 422 Testing and adjusting air conditioner compressor belt tension.......................................................... 423 Testing............................................................................................................ 423 Adjusting.......................................................................................................... 423 Replacing fan belt..................................................................................................... 424 Replace............................................................................................................ 424 Writing compensation values at replacement of injector and engine controller........................................... 426 Connecting PC...................................................................................................... 426 Power train................................................................................................................ 430 Testing swing circle bearing clearance................................................................................. 430 Testing............................................................................................................ 430 Undercarriage and frame.................................................................................................... 431 Checking leakages in the steering cylinders............................................................................ 431 Testing and adjusting steering circuit oil pressure.................................................................... 432 Testing............................................................................................................ 432 Testing the braking system pressure.................................................................................... 434 Checking wear in the brake disks....................................................................................... 437 Bleeding air from the brake lines...................................................................................... 438 Hydraulic system........................................................................................................... 439 Releasing remaining pressure from hydraulic circuit.................................................................... 439 Releasing remaining pressure....................................................................................... 439 Checking and regulating pressure in the hydraulic circuits............................................................. 441 Preparation........................................................................................................ 442 Releasing remaining pressure from work equipment....................................................................... 443 Pressure reducing plug............................................................................................. 443 Testing and adjusting oil pressure in work equipment and travel circuits............................................... 444 Testing............................................................................................................ 444 Measuring method by using machine monitor.......................................................................... 444 Testing and adjusting swing circuit oil pressure....................................................................... 446 Testing............................................................................................................ 446 Adjusting.......................................................................................................... 447 Testing oil pressure of control circuit................................................................................ 448 Testing............................................................................................................ 448 Testing and adjusting oil pressure in pump PC control circuit.......................................................... 449 Testing............................................................................................................ 449 Adjusting.......................................................................................................... 450 Testing and adjusting oil pressure in pump LS control circuit.......................................................... 451 Testing............................................................................................................ 451 Testing oil pressure with sensor adapter (special tool)............................................................ 452 Adjusting.......................................................................................................... 452 Testing outlet pressure of solenoid valve.............................................................................. 454 Testing solenoid output pressure................................................................................... 454 Testing swing brake pressure....................................................................................... 455 Testing locking axle pressure...................................................................................... 455 Testing PPC valve outlet pressure...................................................................................... 456 Testing............................................................................................................ 457 Adjusting play of work equipment and swing PPC valves.................................................................. 458 Adjusting.......................................................................................................... 458 Testing main pump flow rate............................................................................................ 459 Flowmeter installation............................................................................................. 459 Flow rate measurement.............................................................................................. 460 P/Q Diagram master................................................................................................. 461 Travel hydraulic equipment checking procedure.......................................................................... 462 Upper part component of system..................................................................................... 462 Lower part of the system........................................................................................... 462 Testing and adjusting the automatic displacement control system in the travel motor.................................... 463 Preparation work................................................................................................... 463 Testing............................................................................................................ 463 Adjustment......................................................................................................... 464 Work after finishing test.......................................................................................... 464 Checking for leakages in the travel motor.............................................................................. 465 Testing............................................................................................................ 465 Preparation work................................................................................................... 465 Checking........................................................................................................... 465 Checking and adjusting the speed of the travel propeller shaft......................................................... 466 Test............................................................................................................... 466 Adjustment......................................................................................................... 466 Adjustment of the speed sensor......................................................................................... 467 Isolating the parts causing hydraulic drift in work equipment.......................................................... 468 Testing............................................................................................................ 468 Testing oil leakage.................................................................................................... 469 Testing............................................................................................................ 469 Checking for leakages in the travel motor.............................................................................. 472 Testing............................................................................................................ 472 Bleeding air from hydraulic circuit.................................................................................... 473 Bleeding air....................................................................................................... 473 Cab and its attachments.................................................................................................... 476 Testing, cleaning and lubricating slide door rail and roller........................................................... 476 Testing............................................................................................................ 476 Adjusting mirrors...................................................................................................... 477 Adjusting mirrors (A) and (A1)..................................................................................... 477 Adjusting mirror (B)............................................................................................... 477 Adjusting mirror (C)............................................................................................... 478 Testing and adjusting hood catcher..................................................................................... 479 Electrical system.......................................................................................................... 481 Special functions of machine monitor................................................................................... 481 Ordinary functions and special functions of machine monitor........................................................ 483 Operator mode (outline)............................................................................................ 485 KOMTRAX terminal start-up procedure.................................................................................... 535 Adjusting rearview camera angle........................................................................................ 539 Adjusting.......................................................................................................... 539 Adjusting headlight lamp alignment for street circulation.............................................................. 541 Checking........................................................................................................... 541 Adjusting.......................................................................................................... 542 Handling voltage circuit of engine controller.......................................................................... 543 Handling battery disconnect switch..................................................................................... 544 Testing diodes......................................................................................................... 545 Testing............................................................................................................ 545 Pm - Clinic Service.................................................................................................... 546 40 Troubleshooting............................................................................................................. 549 Table of contents.......................................................................................................... 550 Related information on troubleshooting..................................................................................... 558 Troubleshooting points................................................................................................. 558 Sequence of events in troubleshooting.................................................................................. 560 Checks before troubleshooting.......................................................................................... 562 Inspection procedure before troubleshooting............................................................................ 564 Walk-around check.................................................................................................. 564 Testing in accordance with testing procedure........................................................................... 566 Preparation for troubleshooting of electrical system................................................................... 584 Classification and procedures for troubleshooting...................................................................... 589 Symptom and troubleshooting numbers.................................................................................... 592 Information in troubleshooting table................................................................................... 592 Troubleshooting method for open circuit in wiring harness of pressure sensor system.................................... 594 Connector list and layout.............................................................................................. 596 Layout of connectors (1/15)........................................................................................ 603 Layout of connectors (2/15)........................................................................................ 604 Layout of connectors (3/15)........................................................................................ 605 Layout of connectors (4/15)........................................................................................ 606 Layout of connectors (5/15)........................................................................................ 607 Layout of connectors (6/15)........................................................................................ 608 Layout of connectors (7/15)........................................................................................ 609 Layout of connectors (8/15)........................................................................................ 610 Layout of connectors (9/15)........................................................................................ 611 Layout of connectors (10/15)....................................................................................... 612 Layout of connectors (11/15)....................................................................................... 613 Layout of connectors (12/15)....................................................................................... 614 Layout of connectors (13/15)....................................................................................... 615 Layout of connectors (14/15)....................................................................................... 616 Layout of connectors (15/15)....................................................................................... 617 Connector contact identification....................................................................................... 618 T-branch box and T-branch adapter table................................................................................ 660 Fuse location table.................................................................................................... 665 Failure codes table.................................................................................................... 668 Troubleshooting by failure code (Display of code).......................................................................... 678 Failure code [2G00MA] - Brake oil pressure abnormality................................................................. 678 Failure code [6AZ0ZG] - Quick coupler Pressure Low..................................................................... 679 Failure code [6B2JMA] - Travel hydraulic abnormality................................................................... 681 Failure code [879AKA] - A/C Recirc Air Temp Sens Open Circuit.......................................................... 682 Failure code [879AKB] - A/C Recirc Air Temp Sens Short................................................................. 683 Failure code [879BKA] - A/C Fresh Air Temp Sens Open Circuit........................................................... 684 Failure code [879BKB] - A/C Fresh Air Temp Sens Short Circuit.......................................................... 685 Failure code [879CKA] - Ventilating Sensor Open Circuit................................................................ 686 Failure code [879CKB] - Ventilating Sensor Short Circuit............................................................... 687 Failure code [879DKZ] - Sunlight Sensor Open or Short Circuit.......................................................... 688 Failure code [879EMC] - Ventilation Damper Malfunction................................................................. 689 Failure code [879FMC] - Air Mix Damper Malfunction..................................................................... 690 Failure code [879GKX] - Refrigerant Press Input Sig Out of Range....................................................... 691 Failure code [989L00] - Engine Controller Lock Caution 1............................................................... 692 Failure code [989M00] - Engine Controller Lock Caution 2............................................................... 693 Failure code [989N00] - Engine Controller Lock Caution 3............................................................... 694 Failure code [A900FR] - Abrupt Engine Stop by Auto Idle Stop 3......................................................... 695 Failure code [A900N6] - Abrupt Engine Stop by Auto Idle Stop 1......................................................... 696 Failure code [A900NY] - Abrupt Engine Stop by Auto Idle Stop 2......................................................... 697 Failure code [AB00KE] - Charge Voltage Low............................................................................. 698 Failure code [B@BAZG] - Eng Oil Press Low.............................................................................. 700 Failure code [B@BCNS] - Eng Water Overheat............................................................................. 701 Failure code [B@HANS] - Hydraulic oil overheat......................................................................... 702 Failure code [CA115] - Eng Ne and Bkup Speed Sens Error................................................................ 703 Failure code [CA122] - Charge Air Pressure Sensor High Error........................................................... 704 Failure code [CA123] - Charge Air Pressure Sensor Low Error............................................................ 706 Failure code [CA131] - Throttle Sensor High Error...................................................................... 708 Failure code [CA132] - Throttle Sensor Low Error....................................................................... 710 Failure code [CA144] - Coolant Temperature Sensor High Error........................................................... 712 Failure code [CA145] - Coolant Temperature Sensor Low Error............................................................ 714 Failure code [CA153] - Charge Air Temperature Sensor High Error........................................................ 716 Failure code [CA154] - Charge Air Temperature Sensor Low Error......................................................... 718 Failure code [CA187] - Sensor 2 Supply Voltage Low Error............................................................... 720 Failure code [CA221] - Ambient Pressure Sensor High Error.............................................................. 722 Failure code [CA222] - Ambient Pressure Sensor Low Error............................................................... 724 Failure code [CA227] - Sensor 2 Supply Voltage High Error.............................................................. 726 Failure code [CA234] - Engine Overspeed................................................................................ 727 Failure code [CA238] - NE Speed Sensor Supply Voltage Error............................................................ 728 Failure code [CA239] - NE Speed Sensor Supply Voltage High Error....................................................... 729 Failure code [CA271] - PCV1 Short Circuit Error........................................................................ 730 Failure code [CA272] - PCV1 Open Circuit Error......................................................................... 731 Failure code [CA322] - Injector #1 (L#1) Open or Short Circuit......................................................... 732 Failure code [CA324] - Injector #3 (L#3) Open or Short Circuit......................................................... 734 Failure code [CA331] - Injector #2 (L#2) Open or Short Circuit......................................................... 736 Failure code [CA332] - Injector #4 (L#4) Open or Short Circuit......................................................... 738 Failure code [CA343] - Engine Controller Internal Failure.............................................................. 740 Failure code [CA351] Injectors Drive Circuit Error..................................................................... 741 Failure code [CA352] - Sensor1 Supply Voltage Low Error................................................................ 742 Failure code [CA356] - MAF Sensor High Error........................................................................... 744 Failure code [CA357] - MAF Sensor Low Error............................................................................ 746 Failure code [CA386] - Sensor1 Supply Voltage High Error............................................................... 748 Failure code [CA435] - Engine Oil Pressure SW Error.................................................................... 749 Failure code [CA441] - Battery Voltage Low Error....................................................................... 750 Failure code [CA442] - Battery Voltage High Error...................................................................... 752 Failure code [CA449] - Common Rail Pressure High Error 2............................................................... 753 Failure code [CA451] - Common Rail Pressure Sensor High Error.......................................................... 754 Failure code [CA452] - Common Rail Pressure Sensor Low Error........................................................... 756 Failure code [CA466] - KVGT Motor Driver Position Error................................................................ 758 Failure code [CA515] - Rail Pressure Sensor Sup Volt High Error........................................................ 760 Failure code [CA516] - Rail Pressure Sensor Sup Volt Low Error......................................................... 762 Failure code [CA553] - Common Rail Pressure High Error 1............................................................... 764 Failure code [CA555] - Crankcase Pressure High Error 1................................................................. 765 Failure code [CA556] - Crankcase Pressure High Error 2................................................................. 766 Failure code [CA559] - Common Rail Pressure Low Error 1................................................................ 767 Failure code [CA689] - Engine NE Speed Sensor Error.................................................................... 770 Failure code [CA691] - Intake Air Temperature Sensor High Error........................................................ 772 Failure code [CA692] - Intake Air Temperature Sensor Low Error......................................................... 774 Failure code [CA697] - Engine Con Internal Temp Sens High Error........................................................ 776 Failure code [CA698] - Engine Con Internal Temp Sens Low Error......................................................... 777 Failure code [CA731] - Engine Backup Speed Sensor Phase Error.......................................................... 778 Failure code [CA778] - Engine Backup Speed Sensor Error................................................................ 780 Failure code [CA1117] - Engine Controller Partial Data Lost Error...................................................... 784 Failure code [CA1695] - Sensor 5 Supply Voltage High Error............................................................. 785 Failure code [CA1696] - Sensor 5 Supply Voltage Low Error.............................................................. 786 Failure code [CA1843] - Crankcase Pressure Sensor High Error........................................................... 787 Failure code [CA1844] - Crankcase Pressure Sensor Low Error............................................................ 789 Failure code [CA1896] - EGR Valve Stuck Error.......................................................................... 791 Failure code [CA1942] - Crankcase Pressure Sensor In Range Error....................................................... 792 Failure code [CA1961] - EGR_Motor Driver IC Over Temp Error............................................................ 793 Failure code [CA2185] - Throttle Sensor Supply Voltage High Error...................................................... 794 Failure code [CA2186] - Throttle Sensor Supply Voltage Low Error....................................................... 796 Failure code [CA2249] - Common Rail Pressure Low Error 2............................................................... 798 Failure code [CA2272] - EGR Valve Position Sensor Low Error............................................................ 799 Failure code [CA2311] - IMV Solenoid Error............................................................................. 801 Failure code [CA2349] - EGR Valve Solenoid Open Circuit Error.......................................................... 802 Failure code [CA2353] - EGR Valve Solenoid Short Circuit Error......................................................... 804 Failure code [CA2357] - EGR Valve Servo Error.......................................................................... 806 Failure code [CA2765] - Injector Trim Data Mismatch.................................................................... 807 Failure code [CA3419] - MAF Sensor Supply Voltage High Error........................................................... 808 Failure code [CA3421] - MAF Sensor Supply Voltage Low Error............................................................ 810 Failure code [CA3724] - EGR/KVGT Motor Driver Power Low Error.......................................................... 812 Failure code [CA3918] - KVGT Stuck Error (D37-CA3918-400-A-Z0-A)....................................................... 814 Failure code [CA3919] - KVGT Motor Driver IC Over Temp Error........................................................... 815 Failure code [CA3921] - KVGT Servo Error 2............................................................................. 816 Failure code [CA3922] - KVGT Motor Driver Open Error................................................................... 817 Failure code [CA3923] - KVGT Motor Driver Short Error.................................................................. 819 Failure code [D110KB] - Battery Relay Output Short Circuit............................................................. 821 Failure code [D19QKB] - Refuel pump relay short circuit................................................................ 823 Failure code [D19QKY] - Refuel pump relay hot short circuit............................................................ 825 Failure code [D19JKZ] - Personal Code Relay Open or Short.............................................................. 827 Failure code [D1EMKA] - Parking brake relay open circuit............................................................... 830 Failure code [D1EMKB] - Parking brake relay short circuit.............................................................. 832 Failure code [D1EMKY] - Parking brake relay hot short circuit.......................................................... 834 Failure code [D811MC] - KOMTRAX Malfunction............................................................................ 836 Failure code [D862KA] - GPS Antenna Open Circuit....................................................................... 837 Failure code [D8ALKA] - Operating Lamp Open Circuit (KOMTRAX).......................................................... 838 Failure code [D8ALKB] - Operating Lamp Short Circuit (KOMTRAX)......................................................... 840 Failure code [D8AQKR] - CAN 2 Defective Communication (KOMTRAX)........................................................ 842 Failure code [DA20MC] - Pump Controller Malfunction.................................................................... 844 Failure code [DA22KK] - Pump Con Solenoid Power Volt Low Error......................................................... 845 Failure code [DA25KP] - 5V Sensor 1 Power Voltage Low or High Error.................................................... 847 Failure code [DA26KP] - 5V Sensor 2 Power Voltage Low or High Error.................................................... 849 Failure code [DA29KQ] - Model Selection Sig Mismatch (Pump Con)........................................................ 851 Failure code [DA2LKA] - Operating Lamp Open Circuit (Pump Con)......................................................... 853 Failure code [DA2LKB] - Operating Lamp Short Circuit (Pump Con)........................................................ 855 Failure code [DA2QKR] - CAN 2 Defective Communication (Pump Con)....................................................... 857 Failure code [DA2RKR] - CAN 1 Defective Communication (Pump Con)....................................................... 859 Failure code [DAB0KT] - Internal flash memory error (Pump con)......................................................... 860 Failure code [DAC3KB] - Cruise control system power supply short circuit............................................... 861 Failure code [DAC3KY] - Cruise control system power supply hot short circuit........................................... 863 Failure code [DAF0MB] - Monitor ROM Abnormality........................................................................ 865 Failure code [DAF0MC] - Monitor Malfunction............................................................................ 866 Failure code [DAF8KB] - Camera Power Supply Short Circuit.............................................................. 867 Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor)........................................................ 869 Failure code [DAFGMC] - GPS Module Malfunction......................................................................... 870 Failure code [DAFLKA] - Operating Lamp Open Circuit (Monitor).......................................................... 871 Failure code [DAFLKB] - Operating Lamp Short Circuit (Monitor)......................................................... 873 Failure code [DAFQKR] - CAN 2 Defective Communication (Monitor)........................................................ 875 Failure code [DAZ9KQ] - Model Selection Sig Mismatch (A/C)............................................................. 876 Failure code [DAZQKR] - CAN2 Defective Communication (A/C ECU)......................................................... 877 Failure code [DB2QKR] - CAN2 Defective Communication (Engine Con)...................................................... 881 Failure code [DB2RKR] - CAN1 Defective Communication (Engine Con)...................................................... 885 Failure code [DCS0MC] - Machine Controller Malfunction................................................................. 889 Failure code [DCS2KK] - Machine Con Solenoid Power Volt Low Error...................................................... 890 Failure code [DCS5KP] - 5V Sensor 1 Power Voltage Low or High Error.................................................... 892 Failure code [DCS9KQ] - Model Selection Sig Mismatch (Machine Con)..................................................... 894 Failure code [DCSLKA] - Operating Lamp Open Circuit (Machine Con)...................................................... 896 Failure code [DCSLKB] - Operating Lamp Short Circuit (Machine Con)..................................................... 898 Failure code [DCSQKR] - CAN 2 Defective Communication (Machine Con).................................................... 900 Failure code [DCSRKR] - CAN 1 Defective Communication (Machine Con).................................................... 902 Failure code [DCS0KT] - Internal flash memory error (Machine con)...................................................... 903 Failure code [DCS7KP] - 24V Sensor Power Voltage Low Error............................................................. 904 Failure code [DDK8KA] - SUSLock forced sw open circuit................................................................. 906 Failure code [DDK8KB] - SUSLock forced sw short circuit................................................................ 908 Failure code [DDKNKA] - Steering mode selection SW1 (switch 2WS - 4WS) open circuit.................................... 910 Failure code [DDKNKB] - Steering mode selection SW1 (switch 2WS - 4WS) short circuit................................... 912 Failure code [DDKPKA] - Steering mode selection SW2 (switch LOCK - 4WS-C) open circuit................................. 914 Failure code [DDKPKB] - Steering mode selection SW2 (switch LOCK - 4WS-C) short circuit................................ 916 Failure code [DDNRKA] - WE Lever Lock SW Open Circuit.................................................................. 918 Failure code [DDNRKY] - WE Lever Lock SW Short Circuit................................................................. 920 Failure code [DDNS00] - Lock Lever Auto Lock Release SW On............................................................. 922 Failure code [DDP4KX] - Travel PPC pressure switch abnormality......................................................... 924 Failure code [DDP6L5] - Service brake press sw abnormality............................................................. 926 Failure code [DDQ1KA] - SUSLock mode (circuit lock or AUTO) selection sw open circuit.................................. 928 Failure code [DDQ1KB] - SUSLock mode (circuit lock or AUTO) selection sw short circuit................................. 930 Failure code [DDWCKZ] - Travel Direction switch abnormality............................................................ 932 Failure code [DDWMKZ] - FBR attachment SW abnormality.................................................................. 934 Failure code [DFB1KZ] - Service lever main potentio 1 abnormality (ATT1)............................................... 936 Failure code [DFB2KZ] - Service lever main potentio 2 abnormality (ATT2)............................................... 939 Failure code [DFB3L8] - Service lever 1 potentio (ATT1) error.......................................................... 942 Information........................................................................................................ 942 Failure code [DFB4L8] - Service lever 2 potentio (ATT2) error.......................................................... 943 Information........................................................................................................ 943 Failure code [DFB5KZ] - Service lever sub potentio (ATT1) abnormality.................................................. 944 Failure code [DFB6KZ] - Service lever sub potentio (ATT2) abnormality.................................................. 947 Failure code [DGH2KB] - Hydraulic Oil Temp Sensor Ground Fault......................................................... 950 Failure code [DHPAMA] - Front Pump Press Sens Defective Function....................................................... 952 Failure code [DHS3MA] - Arm IN PPC Press Sensor Def Function........................................................... 954 Failure code [DHS4MA] - Bucket CURL PPC Press Sens Def Function........................................................ 956 Failure code [DHS5KX] - Travel PPC Sensor Abnormality.................................................................. 958 Failure code [DHS8MA] - Boom Raise PPC Press Sens Def Function......................................................... 960 Failure code [DHS9MA] - Boom Lower PPC Press Sens Def Function......................................................... 962 Failure code [DHSAMA] - Swing Right PPC Press Sens Def Function........................................................ 964 Failure code [DHSBMA] - Swing Left PPC Press Sensor Def Function....................................................... 966 Failure code [DHSCMA] - Arm OUT PPC Press Sens Def Function............................................................ 968 Failure code [DHSDMA] - Bucket DUMP PPC Press Sens Def Function........................................................ 970 Failure code [DHSPMA] - Boom Swing LH PPC Press Sensor Abnormality..................................................... 972 Failure code [DHSQMA] - Boom Swing RH PPC Press Sensor Abnormality..................................................... 974 Failure code [DHU1KA] - Brake accumulator press sensor open circuit or short circuit................................... 976 Failure code [DHU1KY] - Brake accumulator press sensor hot short circuit............................................... 978 Failure code [DHUCKA] - Parking brake press sensor open circuit or short circuit....................................... 980 Failure code [DHUCKY] - Parking brake press sensor hot short circuit................................................... 982 Failure code [DHUGKA] - Service brake press sensor open circuit or short circuit....................................... 984 Failure code [DHUGKY] - Service brake press sensor hot short circuit................................................... 986 Failure code [DHX1MA] - Overload sensor abnormality (analog)........................................................... 988 Failure code [DKULKA] - PPC Lock Relay Open Circuit.................................................................... 990 Failure code [DKULKB] - PPC Lock Relay Short Circuit................................................................... 992 Failure code [DKULKY] - PPC Lock Relay Hot Short Circuit............................................................... 994 Failure code [DLT4KA] - Disconnection in transmission speed sensor..................................................... 996 Failure code [DLT4KB] - Short circuit in transmission speed sensor..................................................... 998 Failure code [DNCHMC] - Front steering cylinder SW failure.............................................................1000 Failure code [DNCJL4] - Steering cylinder alignment SW abnormality.....................................................1002 Failure code [DNCKMC] - Rear steering cylinder (Right small range) SW1 failure.........................................1004 Failure code [DNCLMC] - Rear steering cylinder (Left large range) SW2 failure..........................................1006 Failure code [DV20KB] - Travel Alarm Short Circuit.....................................................................1008 Failure code [DW44KA] - Disconnection in travel F/R solenoid...........................................................1010 Failure code [DW44KB] - Short circuit in travel F/R solenoid...........................................................1012 Failure code [DW44KY] - Travel F/R sol hot short circuit...............................................................1014 Failure code [DW45KA] - Swing Parking Brake Solenoid Open Circuit......................................................1016 Failure code [DW45KB] - Swing Parking Brake Solenoid Short Circuit.....................................................1019 Failure code [DW45KY] - Swing Brake Sol Hot Short Circuit..............................................................1022 Failure code [DW91KA] - Disconnection in travel neutral solenoid.......................................................1024 Failure code [DW91KB] - Short circuit in travel neutral solenoid.......................................................1026 Failure code [DW91KY] - Hot Short circuit in travel neutral solenoid...................................................1028 Failure code [DW4AKA] - Disconnection in suspension lock solenoid......................................................1030 Failure code [DW4AKB] - Short circuit in suspension lock solenoid......................................................1032 Failure code [DW4AKY] - SUSLock sol hot short circuit..................................................................1034 Failure code [DW4CKY] - PPC lock Sol Hot Short Circuit.................................................................1035 Failure code [DW4MKA] - Disconnection in creep solenoid................................................................1037 Failure code [DW4MKB] - Short circuit in creep solenoid................................................................1038 Failure code [DW4MKY] - Hot short circuit in creep solenoid............................................................1040 Failure code [DW4UKA] - Disconnection in Travel return bypass solenoid.................................................1041 Failure code [DW4UKB] - Short circuit in Travel return bypass solenoid.................................................1043 Failure code [DW4UKY] - Travel return bypass hot short circuit.........................................................1045 Failure code [DW4YKA] - Disconnection in High gear solenoid............................................................1046 Failure code [DW4YKB] - Short circuit in High gear solenoid............................................................1048 Failure code [DW4YKY] - High gear hot short circuit....................................................................1050 Failure code [DW4ZKA] - Disconnection in Low gear solenoid.............................................................1051 Failure code [DW4ZKB] - Short circuit in Low gear solenoid.............................................................1053 Failure code [DW4ZKY] - Low gear hot short circuit.....................................................................1055 Failure code [DW9PKA] - Disconnection in travel motor quick drain solenoid.............................................1056 Failure code [DW9PKB] - Short circuit in travel motor quick drain solenoid.............................................1058 Failure code [DW9PKY] - Hot Short circuit in travel motor quick drain solenoid.........................................1059 Failure code [DWB1KA] - Disconnection in outrigger/boom operation relay (or GND short circuit of controller output)....1060 Failure code [DWB1KB] - Hot Short circuit in outrigger/boom operation relay (or relay internal short circuit)..........1062 Failure code [DWB2KA] - Disconnection in 1st outrigger solenoid (front right outrigger lock)...........................1064 Failure code [DWB2KB] - Short circuit in 1st outrigger solenoid (Front right outrigger lock)...........................1066 Failure code [DWB2KY] - Hot Short circuit in 1st outrigger solenoid (Front right outrigger lock).......................1068 Failure code [DWB3KA] - Disconnection in 2nd outrigger solenoid (Front left outrigger or front blade lock).............1070 Failure code [DWB3KB] - Short circuit in 2nd outrigger solenoid (Front left outrigger or front blade lock).............1072 Failure code [DWB3KY] - Hot Short circuit in 2nd outrigger solenoid (Front left outrigger or front blade lock).........1074 Failure code [DWB4KA] - Disconnection in 3rd outrigger solenoid (Rear right outrigger lock)............................1076 Failure code [DWB4KB] - Short circuit in 3rd outrigger solenoid (Rear right outrigger lock)............................1078 Failure code [DWB4KY] - Hot Short circuit in 3rd outrigger solenoid (Rear right outrigger lock)........................1080 Failure code [DWB5KA] - Disconnection in 4th outrigger solenoid (Rear left outrigger lock).............................1082 Failure code [DWB5KB] - Short circuit in 4th outrigger solenoid (Rear left outrigger lock).............................1084 Failure code [DWB5KY] - Hot Short circuit in 4th outrigger solenoid (Rear left outrigger lock).........................1086 Failure code [DWD2KA] - Disconnection in 2WS Steering solenoid.........................................................1088 Failure code [DWD2KB] - Short circuit in 2WS Steering solenoid.........................................................1090 Failure code [DWD2KY] - Hot Short circuit in 2WS Steering solenoid.....................................................1092 Failure code [DWD3KA] - Disconnection in 4WS Steering solenoid.........................................................1094 Failure code [DWD3KB] - Short circuit in 4WS Steering solenoid.........................................................1096 Failure code [DWD3KY] - Hot Short circuit in 4WS Steering solenoid.....................................................1098 Failure code [DWD4KA] - Disconnection in 4WS-R Steering solenoid.......................................................1100 Failure code [DWD4KB] - Short circuit in 4WS-R Steering solenoid.......................................................1102 Failure code [DWD4KY] - Hot Short circuit in 4WS-R Steering solenoid...................................................1104 Failure code [DWD5KA] - Disconnection in 4WS-C Steering solenoid.......................................................1106 Failure code [DWD5KB] - Short circuit in 4WS-C Steering solenoid.......................................................1108 Failure code [DWD5KY] - Hot Short circuit in 4WS-C Steering solenoid...................................................1110 Failure code [DXA8KA] - Front Pump PC-EPC Solenoid Open Circuit........................................................1112 Failure code [DXA8KB] - Front Pump PC-EPC Solenoid Short Circuit.......................................................1114 Failure code [DXE7KA] - Att Flow Regulating EPC ATT1 RH Solenoid Open Circuit..........................................1116 Failure code [DXE7KB] - Att Flow Regulating EPC ATT1 RH Short Circuit..................................................1118 Failure code [DXE7KY] - Att Flow Regulating EPC ATT1 RH Hot Short Circuit..............................................1120 Failure code [DXE8KA] - Att Flow Regulating EPC ATT2 RH Solenoid Open Circuit..........................................1122 Failure code [DXE8KB] - Att Flow Regulating EPC ATT2 RH Short Circuit..................................................1124 Failure code [DXE8KY] - Att Flow Regulating EPC ATT2 RH Hot Short Circuit..............................................1126 Failure code [DXE9KA] - Att Flow Regulating EPC ATT2 LH Open Circuit...................................................1128 Failure code [DXE9KB] - Att Flow Regulating EPC ATT2 LH Short Circuit..................................................1130 Failure code [DXE9KY] - Service Current EPC ATT2 LH Hot Short Circuit..................................................1132 Failure code [DXEAKA] - Att Flow Regulating EPC ATT1 LH Open Circuit...................................................1134 Failure code [DXEAKB] - Att Flow Regulating EPC ATT1 LH Short Circuit..................................................1136 Failure code [DXEAKY] - Service Current EPC ATT1 LH Hot Short Circuit..................................................1138 Failure code [DY20KA] - Wiper Motor Open Circuit.......................................................................1140 Failure code [DY20MA] - Wiper Motor Defective Function.................................................................1142 Failure code [DY2CKB] - Washer Motor Short Circuit.....................................................................1144 Failure code [DY2DKB] - Wiper Motor (Normal) Short Circuit or Hot Short................................................1146 Failure code [DY2EKB] - Wiper Motor (Reverse) Short Circuit............................................................1148 Troubleshooting of electrical system (E-mode)..............................................................................1150 E-1 Engine does not start (Engine does not crank)......................................................................1150 E-2 Manual preheating system does not work.............................................................................1156 E-3 While preheating is working, preheating monitor does not light up..................................................1159 E-4 When starting switch is turned to ON position, machine monitor displays nothing....................................1161 E-5 Engine coolant temperature monitor lights up in white while engine is running......................................1164 E-6 Hydraulic oil temperature monitor lights up in white while engine is running.......................................1165 E-7 Charge level monitor lights up while engine is running.............................................................1166 E-8 Fuel level monitor lights up in red while engine is running........................................................1167 E-9 Engine coolant temperature monitor lights up in red while engine is running........................................1168 E-10 Hydraulic oil temperature monitor lights up in red while engine is running........................................1169 E-11 Engine oil pressure monitor lights up in red while engine is running..............................................1170 E-12 Fuel gauge display does not move from minimum or maximum..........................................................1171 E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty)..........................................1172 E-14 Engine coolant temperature gauge display does not move from minimum or maximum....................................1173 E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty)...............1174 E-16 Hydraulic oil temperature gauge does not move from minimum or maximum.............................................1175 E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty)................1177 E-18 Some areas of machine monitor screen are not displayed............................................................1178 E-19 Function switch does not work.....................................................................................1179 E-20 Automatic warm-up system does not operate (in cold season)........................................................1180 E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated.......1181 E-22 Auto-deceleration function does not operate or is not canceled while lever is operated............................1182 E-23 Working mode selection screen is not displayed while working mode selector switch is operated.....................1184 E-24 Setting of engine and hydraulic pump is not changed while working mode is changed.................................1185 E-25 Travel speed monitor does not change when travel speed switch is operated.........................................1186 E-26 Alarm buzzer does not stop sounding if cancel switch is pressed...................................................1187 E-27 Service meter is not displayed, while starting switch is in OFF position..........................................1188 E-28 Service mode cannot be selected...................................................................................1189 E-29 Any of work equipment, swing and travel does not work.............................................................1190 E-30 Any of work equipment, swing and travel cannot be locked..........................................................1193 E-31 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position..................1195 E-32 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position....................1197 E-33 Work equipment does not operate while lock lever automatic release switch is in release position (emergency)......1199 E-34 Alarm does not sound during travel................................................................................1201 E-35 Alarm does not stop sounding while machine is stopped.............................................................1202 E-36 Horn does not sound...............................................................................................1203 E-37 Horn does not stop sounding.......................................................................................1205 E-38 Wiper does not operate while wiper switch is operated.............................................................1206 E-39 Window washer does not operate while window washer switch is operated.............................................1208 E-40 Boom LOWER is not displayed correctly with monitoring function....................................................1210 A-41 Arm OUT is not displayed correctly with monitoring function.......................................................1211 E-42 Arm IN is not displayed correctly with monitoring function........................................................1212 E-43 Boom RAISE is not displayed correctly with monitoring function....................................................1213 E-44 Bucket CURL is not displayed correctly with monitoring function...................................................1214 E-45 Bucket DUMP is not displayed correctly with monitoring function...................................................1215 E-46 Boom swing left is not displayed correctly with monitoring function...............................................1216 E-47 Boom swing right is not displayed correctly with monitoring function..............................................1217 E-48 Swing is not displayed correctly with monitoring function.........................................................1218 E-49 Travel is not displayed correctly with monitoring function........................................................1219 E-50 KOMTRAX system does not operate normally..........................................................................1220 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................1222 Information described in troubleshooting table (H-mode)................................................................1222 System chart of hydraulic and mechanical systems.......................................................................1223 Failure mode and cause table...........................................................................................1225 H-1 All of work equipments, swing and travel operations lack speed or power............................................1236 H-2 Engine speed drops significantly or engine stalls..................................................................1238 H-3 Any of work equipment, swing and travel does not work..............................................................1239 H-4 Unusual sound is heard from around hydraulic pump..................................................................1240 H-5 Fine control performance or response is poor.......................................................................1241 H-6 Boom speed or power is low.........................................................................................1242 H-7 2-piece boom speed or power is low.................................................................................1244 H-8 Arm speed or power is low..........................................................................................1246 H-9 Bucket speed or power is low.......................................................................................1248 H-10 Boom swing speed or power is low..................................................................................1250 H-11 Blade/outrigger speed or power is low.............................................................................1252 H-12 Work equipment does not move in single operation..................................................................1254 H-13 Hydraulic drift of boom is large..................................................................................1255 H-14 Hydraulic drift of 2-piece boom is large..........................................................................1256 H-15 Hydraulic drift of arm is large...................................................................................1257 H-16 Hydraulic drift of bucket is large................................................................................1258 H-17 Hydraulic drift of blade/outriggers is large......................................................................1259 H-18 Time lag of work equipment is large...............................................................................1260 H-19 In combined operation of work equipment, equipment having heavier load moves slower...............................1261 H-20 In combined operation of swing and boom RAISE, boom rising speed is low...........................................1262 H-21 In combined operation of work equipment or swing and travel, travel speed drops largely...........................1263 H-22 Travel speed is slow..............................................................................................1264 H-23 Travel power is low...............................................................................................1265 H-24 Travel speed is too slow or fast..................................................................................1266 H-25 Wheels do not run.................................................................................................1267 H-26 Upper structure does not swing to the right or left...............................................................1268 H-27 Upper structure swing only to the right or left...................................................................1269 H-28 Swing acceleration or swing speed is low in both directions (right and left.......................................1270 H-29 Swing acceleration performance is poor or swing speed is slow in only one direction...............................1271 H-30 Upper structure overruns excessively when it stops swinging (both right and left).................................1272 H-31 Upper structure overruns excessively when it stops swinging (either right or left)................................1273 H-32 Shock is large when upper structure stops swinging................................................................1274 H-33 Large unusual noise is heard when upper structure stops swinging..................................................1275 H-34 Swing drift on a slope is large while swing parking brake is applied..............................................1276 H-35 Swing drift on a slope is large while swing parking brake is released.............................................1277 H-36 Oil flow in attachment circuit cannot be controlled...............................................................1278 H-37 Parking brake doesn’t work........................................................................................1279 H-38 Service brake doesn’t work........................................................................................1280 H-39 Steering system doesn’t work or doesn’t work properly (2WS, 4WS-R, 4WS-C).........................................1281 Troubleshooting of engine (S-mode).........................................................................................1282 Information mentioned in troubleshooting table (S mode)................................................................1282 S-1 Engine does not crank when starting switch is turned to START position.............................................1283 S-2 Engine cranks but no exhaust smoke comes out.......................................................................1284 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start).....................1285 S-4 Engine startability is poor........................................................................................1286 S-5 Engine does not pick up smoothly...................................................................................1288 S-6 Engine stops during operation......................................................................................1290 S-7 Engine runs rough or is unstable...................................................................................1292 S-8 Engine lacks power.................................................................................................1293 S-9 Exhaust smoke is black.............................................................................................1294 S-10 Engine oil consumption is excessive...............................................................................1296 S-11 Oil becomes contaminated quickly..................................................................................1297 S-12 Fuel consumption is excessive.....................................................................................1298 S-13 Oil is in coolant (or coolant spurts or coolant level goes down)..................................................1299 S-14 Oil pressure drops................................................................................................1300 S-15 Fuel mixes into engine oil........................................................................................1301 S-16 Water mixes into engine oil (milky)...............................................................................1302 S-17 Coolant temperature rises too high (overheating)..................................................................1303 S-18 Unusual noise is heard............................................................................................1304 S-19 Vibration is excessive............................................................................................1305 S-20 Air cannot be bled from fuel circuit..............................................................................1306 50 Disassembly and assembly....................................................................................................1307 Contents...................................................................................................................1308 General information on disassembly and assembly............................................................................1310 How to read this manual................................................................................................1310 Coating materials list.................................................................................................1312 Adhesive...........................................................................................................1312 Liquid gasket......................................................................................................1313 Molybdenum disulfide lubricant.....................................................................................1313 Seizure prevention compound........................................................................................1314 Grease.............................................................................................................1314 Primer.............................................................................................................1315 Adhesive...........................................................................................................1315 Caulking material..................................................................................................1315 Special tools list.....................................................................................................1316 Sketches of special tools..............................................................................................1317 A2 Push tool.......................................................................................................1317 A3: Plate..........................................................................................................1317 F7: Push tool......................................................................................................1318 R: Guide...........................................................................................................1318 Engine and cooling system..................................................................................................1319 Removal and installation of supply pump assembly.......................................................................1319 Removal............................................................................................................1319 Installation.......................................................................................................1321 Removal and installation of injector assembly..........................................................................1322 Removal............................................................................................................1322 Installation.......................................................................................................1324 Removal and installation of cylinder head assembly.....................................................................1328 Removal............................................................................................................1328 Installation.......................................................................................................1334 Removal and installation of radiator assembly..........................................................................1340 Removal............................................................................................................1340 Installation.......................................................................................................1342 Removal and installation of hydraulic oil cooler assembly..............................................................1343 Removal............................................................................................................1343 Installation.......................................................................................................1345 Removal and installation of aftercooler assembly.......................................................................1346 Removal............................................................................................................1346 Installation.......................................................................................................1347 Removal and installation of engine and main pump assembly..............................................................1348 Removal............................................................................................................1348 Installation.......................................................................................................1354 Removal and installation of engine front oil seal......................................................................1355 Removal............................................................................................................1355 Installation.......................................................................................................1356 Removal and installation of engine rear oil seal.......................................................................1357 Removal............................................................................................................1357 Installation.......................................................................................................1357 Removal and installation of fuel cooler assembly.......................................................................1359 Removal............................................................................................................1359 Installation.......................................................................................................1359 Removal and installation of fuel tank assembly.........................................................................1360 Removal............................................................................................................1360 Installation.......................................................................................................1361 Removal and installation of engine hood assembly.......................................................................1362 Removal............................................................................................................1362 Installation.......................................................................................................1363 Removal and installation of KDOC muffler...............................................................................1364 Removal............................................................................................................1364 Installation.......................................................................................................1366 Removal and installation of KCCV ventilator............................................................................1367 Removal............................................................................................................1367 Installation.......................................................................................................1368 Removal and installation of air cleaner assembly.......................................................................1369 Removal............................................................................................................1369 Installation.......................................................................................................1370 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly............................................1371 Removal............................................................................................................1371 Installation.......................................................................................................1372 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly.............................................1373 Removal............................................................................................................1373 Installation.......................................................................................................1373 Removal and installation of fan belt...................................................................................1374 Removal............................................................................................................1374 Installation.......................................................................................................1374 Power train system.........................................................................................................1375 Removal and installation of swing motor and swing machinery assembly...................................................1375 Removal............................................................................................................1375 Installation.......................................................................................................1375 Disassembly and assembly of swing machinery assembly...................................................................1377 Disassembly........................................................................................................1377 Assembly...........................................................................................................1380 Removal and installation of swing circle assembly......................................................................1385 Removal............................................................................................................1385 Installation.......................................................................................................1385 Undercarriage and frame....................................................................................................1386 Removal and installation of twin-type wheels...........................................................................1386 Removal............................................................................................................1386 Installation.......................................................................................................1387 Removal and installation front axle....................................................................................1388 Removal............................................................................................................1388 Installation.......................................................................................................1388 Removal and installation of rear axle..................................................................................1389 Removal............................................................................................................1389 Installation.......................................................................................................1390 Disassembly and assembly of axles......................................................................................1391 Special tools......................................................................................................1391 Disassembly........................................................................................................1391 Assembly...........................................................................................................1410 Removal and installation of transmission...............................................................................1439 Removal............................................................................................................1439 Installation.......................................................................................................1440 Disassembly and assembly of transmission...............................................................................1441 Disassembly........................................................................................................1441 Assembly...........................................................................................................1447 Removal and installation of axle locking cylinders.....................................................................1454 Removal............................................................................................................1454 Installation.......................................................................................................1454 Removal and installation of revolving frame assembly...................................................................1455 Removal............................................................................................................1455 Installation.......................................................................................................1456 Removal and installation of counterweight assembly.....................................................................1457 Removal............................................................................................................1457 Installation.......................................................................................................1458 Hydraulic system...........................................................................................................1459 Removal and installation of travel motor...............................................................................1459 Removal............................................................................................................1459 Installation.......................................................................................................1459 Removal and installation of center swivel joint assembly...............................................................1461 Removal............................................................................................................1461 Installation.......................................................................................................1463 Removal and installation of control valve cover........................................................................1465 Removal............................................................................................................1465 Installation.......................................................................................................1466 Removal and installation of hydraulic tank assembly....................................................................1467 Removal............................................................................................................1467 Installation.......................................................................................................1469 Removal and installation of main pump assembly.........................................................................1470 Removal............................................................................................................1470 Installation.......................................................................................................1472 Removal and installation of control valve assembly.....................................................................1473 Removal............................................................................................................1473 Installation.......................................................................................................1476 Disassembly and assembly of control valve assembly.....................................................................1477 Assembly of control valve cover....................................................................................1477 Removal and installation of pressure reducing valve................................................................1478 Disassembly and assembly of work equipment PPC valve assembly..........................................................1481 Disassembly........................................................................................................1481 Assembly...........................................................................................................1481 Disassembly and assembly of work equipment cylinder assembly...........................................................1483 Disassembly........................................................................................................1483 Assembly...........................................................................................................1484 Disassembly and assembly of 2-piece boom and blade/outrigger cylinders assembly........................................1487 Special tools......................................................................................................1487 Disassembly........................................................................................................1487 Assembly...........................................................................................................1488 Work equipment.............................................................................................................1492 Removal and installation of work equipment assembly....................................................................1492 Removal............................................................................................................1492 Installation.......................................................................................................1493 Removal and installation blade or outriggers...........................................................................1494 Removal............................................................................................................1494 Installation.......................................................................................................1494 Removal and installation blade and outrigger arms......................................................................1495 Removal............................................................................................................1495 Installation.......................................................................................................1495 Removal and installation of boom swing bracket.........................................................................1496 Removal............................................................................................................1496 Installation.......................................................................................................1496 Cab and its attachments....................................................................................................1497 Removal and installation of operator's cab assembly....................................................................1497 Removal............................................................................................................1497 Installation.......................................................................................................1500 Removal and installation of operator's cab door........................................................................1501 Installation.......................................................................................................1501 Removal and installation of operator's cab glass (adhered glass).......................................................1504 Removal............................................................................................................1505 Installation.......................................................................................................1506 Removal and installation of front window assembly......................................................................1514 Removal............................................................................................................1514 Installation.......................................................................................................1514 Removal and installation of air conditioner unit assembly..............................................................1515 Removal............................................................................................................1515 Installation.......................................................................................................1519 Removal and installation of air conditioner compressor assembly........................................................1521 Removal............................................................................................................1521 Installation.......................................................................................................1522 Removal and installation of air conditioner condenser assembly.........................................................1523 Removal............................................................................................................1523 Installation.......................................................................................................1523 Removal and installation of operator's seat............................................................................1525 Removal............................................................................................................1525 Installation.......................................................................................................1525 Removal and installation of seat belt..................................................................................1526 Removal............................................................................................................1526 Installation.......................................................................................................1526 Removal and installation of front wiper assembly.......................................................................1527 Removal............................................................................................................1527 Installation.......................................................................................................1529 Electrical system..........................................................................................................1534 Removal and installation of starting motor assembly....................................................................1534 Removal............................................................................................................1534 Installation.......................................................................................................1534 Removal and installation of engine controller assembly.................................................................1535 Removal............................................................................................................1535 Installation.......................................................................................................1535 Removal and installation of pump controller assembly...................................................................1536 Removal............................................................................................................1536 Installation.......................................................................................................1536 Removal and installation of machine monitor assembly...................................................................1537 Removal............................................................................................................1537 Installation.......................................................................................................1538 Removal and installation of mass air flow and temperature sensor.......................................................1539 Removal............................................................................................................1539 Installation.......................................................................................................1539 Removal and installation of travel speed sensor........................................................................1540 Removal............................................................................................................1540 Installation.......................................................................................................1540 Removal and installation of steering sensor............................................................................1541 Removal............................................................................................................1541 Installation.......................................................................................................1541 Removal and installation of revolving frame swing position sensor......................................................1542 Removal............................................................................................................1542 Installation.......................................................................................................1542 Removal and installation of direction indicator, head light dipper beam control group..................................1543 Removal............................................................................................................1543 Installation.......................................................................................................1543 Removal and installation of KOMTRAX terminal assembly..................................................................1544 Removal............................................................................................................1544 Installation.......................................................................................................1544 60 Maintenance standard........................................................................................................1545 Contents...................................................................................................................1546 Engine and cooling system..................................................................................................1547 Engine mount...........................................................................................................1547 PTO....................................................................................................................1548 Cooling system.........................................................................................................1549 Power train system.........................................................................................................1551 Swing circle...........................................................................................................1551 Swing machinery........................................................................................................1552 Undercarriage and frame....................................................................................................1554 Front axle.............................................................................................................1554 Pinion and differential............................................................................................1554 Brakes.............................................................................................................1556 Final reduction....................................................................................................1557 Steering cylinder..................................................................................................1558 Transmission...........................................................................................................1559 Rear axle..............................................................................................................1561 Differential.......................................................................................................1561 Final reduction....................................................................................................1563 Steering cylinder..................................................................................................1564 Brakes.............................................................................................................1565 Parking brake cylinder.............................................................................................1566 Hydraulic system...........................................................................................................1567 Control valve..........................................................................................................1567 (1/5)..............................................................................................................1568 (2/5)..............................................................................................................1570 (3/5)..............................................................................................................1572 (4/5)..............................................................................................................1573 (5/5)..............................................................................................................1574 Hydraulic tank.........................................................................................................1575 Hydraulic pump.........................................................................................................1576 Servo valve........................................................................................................1577 Swing motor............................................................................................................1578 Self-reducing pressure valve...........................................................................................1580 PPC valve..............................................................................................................1581 Work equipment and swing PPC valve.................................................................................1581 Boom swing and 2-piece boom PPC valve..................................................................................1584 Travel motor...........................................................................................................1586 Solenoid valve.........................................................................................................1587 Steering control solenoid valve........................................................................................1588 1-Attachment flow adjustment EPC valve.................................................................................1589 2-Attachment flow adjustment EPC valve.................................................................................1590 Travel speed and direction control solenoid valve......................................................................1591 Anti drop valve........................................................................................................1592 Blade safety valve.....................................................................................................1593 Cab and its attachments....................................................................................................1594 Cab mount and cab tipping stopper......................................................................................1594 Work equipment.............................................................................................................1595 Work equipment.........................................................................................................1595 Dimensions of arm..................................................................................................1601 Dimensions of bucket...............................................................................................1605 Boom cylinder..........................................................................................................1607 2-piece boom cylinder..................................................................................................1608 Arm cylinder...........................................................................................................1609 Bucket cylinder........................................................................................................1610 Boom swing cylinder....................................................................................................1611 Blade and outrigger cylinder...........................................................................................1612 80 Appendix....................................................................................................................1613 Contents...................................................................................................................1614 Air conditioner components.................................................................................................1615 Precautions for refrigerant............................................................................................1615 Air conditioner component..............................................................................................1616 Specifications.....................................................................................................1618 Configuration and function of refrigeration cycle......................................................................1619 Outline of refrigeration cycle.........................................................................................1620 Air conditioner unit...................................................................................................1622 Function...........................................................................................................1623 Functions of major components......................................................................................1624 Dual pressure switch...................................................................................................1627 Function...........................................................................................................1627 Air conditioner controller.............................................................................................1628 Compressor.............................................................................................................1629 Specification......................................................................................................1629 Function...........................................................................................................1629 Condenser..............................................................................................................1630 Specification......................................................................................................1630 Function...........................................................................................................1630 Receiver drier.........................................................................................................1631 Function...........................................................................................................1631 Specification......................................................................................................1631 Sunlight sensor........................................................................................................1632 Function...........................................................................................................1632 Output characteristics.............................................................................................1632 Outer temperature sensor (outside air temperature sensor)..............................................................1633 Function...........................................................................................................1633 Procedure for testing and troubleshooting..............................................................................1634 Circuit diagram and arrangement of connector pins......................................................................1636 System diagram.........................................................................................................1638 Input and output signals of the air conditioner controller.............................................................1639 Function...........................................................................................................1639 Air conditioner unit...................................................................................................1641 Parts and connectors layout............................................................................................1643 Details............................................................................................................1643 Testing air leakage (duct).............................................................................................1649 Testing............................................................................................................1649 Testing with self-diagnosis function...................................................................................1651 Testing outline....................................................................................................1651 How to open the electrical system abnormality record screen in service mode of the machine monitor.................1651 Testing vent (mode) changeover.........................................................................................1654 Testing............................................................................................................1654 Testing FRESH/RECIRC air changeover....................................................................................1655 Testing............................................................................................................1655 Testing sunlight sensor................................................................................................1656 Testing............................................................................................................1656 Testing (dual) pressure switch for refrigerant.........................................................................1657 Testing............................................................................................................1657 Testing relays.........................................................................................................1659 Testing............................................................................................................1659 Troubleshooting chart 1................................................................................................1660 Troubleshooting chart 2................................................................................................1661 Information in troubleshooting table...................................................................................1664 Failure code list related to air conditioner...........................................................................1665 Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit............................................................1666 Failure code [879AKB] A/C Recirc Air Temp Sens Short...................................................................1667 Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit.............................................................1668 Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit............................................................1670 Failure code [879CKA] Ventilating Sensor Open Circuit..................................................................1672 Failure code [879CKB] Ventilating Sensor Short Circuit.................................................................1673 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit............................................................1674 Failure code [879EMC] Ventilation Damper Malfunction...................................................................1676 Failure code [879FMC] Air Mix Damper Malfunction.......................................................................1677 Failure code [879GKX] Refrigerant Press Input Sig Out of Range.........................................................1678 A-1 Troubleshooting for power supply system (Air conditioner does not operate).........................................1679 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)..........................................1681 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal).................................1684 A-4 Troubleshooting for FRESH/RECIRC air changeover....................................................................1686 Troubleshooting with gauge pressure....................................................................................1688 Connection of service tool.............................................................................................1691 Precautions for disconnecting and connecting refrigerant piping........................................................1693 Handling of compressor oil.............................................................................................1695 90 Diagrams and drawings.......................................................................................................1697 Contents...................................................................................................................1698 Hydraulic circuit diagram..................................................................................................1699 Symbols in hydraulic circuit diagram...................................................................................1699 Hydraulic circuit diagram (1/2)........................................................................................1703 Hydraulic circuit diagram (2/2)........................................................................................1705 Electric circuit diagram...................................................................................................1707 Symbols in electric circuit diagram....................................................................................1707 Electrical circuit diagram (1/8).......................................................................................1711 Electrical circuit diagram (2/8).......................................................................................1713 Electrical circuit diagram (3/8).......................................................................................1715 Electrical circuit diagram (4/8).......................................................................................1717 Electrical circuit diagram (5/8).......................................................................................1719 Electrical circuit diagram (6/8).......................................................................................1721 Electrical circuit diagram (7/8).......................................................................................1723 Electrical circuit diagram (8/8).......................................................................................1725
DESCRIPTION:
KOMATSU PW98MR-10 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00120 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place
S.S 31/12/24
