Komatsu PC88MR-10 Hydraulic Excavator Shop Manual SEN06467-13 PDF

Description

Komatsu PC88MR-10 Hydraulic Excavator Shop Manual SEN06467-13 –  PDF  DOWNLOAD

FILE DETAILS:

Komatsu PC88MR-10 Hydraulic Excavator Shop Manual SEN06467-13 –  PDF  DOWNLOAD

Language : English
Pages : 1572
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC88MR-10 Hydraulic Excavator Shop Manual SEN06467-13 –  PDF  DOWNLOAD

• SERIAL NUMBERS 7001 and up

Cover 1
00 Index and foreword . 3
Index . 4
Foreword, safety and general information 17
Important safety notice . 17
How to read the shop manual . 24
Explanation of terms for maintenance standard . 26
Handling equipment of fuel system devices . 28
Handling of intake system parts . 29
Handling of hydraulic equipment . 30
Method of disconnecting and connecting of push-pull type coupler 32
Handling of electrical equipment 35
How to read electric wire code 43
Precautions when performing operation . 46
Practical use of KOMTRAX 51
Standard tightening torque table 52
List of abbreviation 58
Conversion table 63
01 Specification 69
Table of contents . 70
Specifications 71
Specification drawing . 71
Working range drawings 72
Specifications 73
Weight table 77
Table of fuel, coolant, and lubricants 79
10 Structure and function . 81
Table of contents . 82
Engine and cooling system . 83
Engine related parts 83
PTO . 85
Variable flow turbocharger 86
EGR system piping drawing . 90
EGR system circuit diagram 92
EGR valve . 93
EGR cooler 95
KCCV layout drawing . 97
KCCV ventilator . 100
KDOC muffler 102
Cooling system 104
Power train . 107
Power train system 107
Swing circle 109
Swing machinery . 111
Undercarriage and frame . 113
Track frame . 113
Idler cushion . 115
Hydraulic system 116
Hydraulic component layout 116
Valve control . 118
Hydraulic tank 120
CLSS 124
Main pump . 128
Control valve . 140
Swing motor . 188
Travel motor 199
Work equipment and swing PPC valve 212
Travel PPC valve 219
Blade PPC valve . 225
Boom swing PPC valve 227
Solenoid valve 229
Multi-control valve . 233
Anti-drop valve for boom 234
Anti-drop valve for arm . 238
Center swivel joint . 242
Accumulator . 243
Work equipment 245
Work equipment 245
Work equipment shim . 246
Bucket play adjustment shim . 247
Cab and its attachments . 248
Cab mount and cab tipping stopper . 248
ROPS cab 250
Electrical system . 252
Electrical control system . 252
Machine monitor system 296
KOMTRAX system 318
Sensor 320
20 Standard value tables 329
Table of contents . 330
Standard service value table 331
Standard value table for engine . 331
Standard value table for machine 333
Standard value table for electrical system 349
30 Testing and adjusting 355
Table of contents . 356
Precautions before work 357
Related information on testing and adjusting 359
Tools for testing and adjusting . 359
Sketch of tools for testing and adjusting . 362
Engine and cooling system . 364
Testing engine speed 364
Testing exhaust gas color . 365
Testing and adjusting valve clearance . 366
Testing compression pressure 368
Testing blowby pressure . 370
Testing engine oil pressure . 371
Visual check inside of EGR valve . 372
Clean inside of EGR valve 373
Testing fuel pressure . 376
Testing fuel return rate and leakage 377
Bleeding air from fuel system . 380
Testing fuel circuit for leakage 382
Handling cylinder cutout mode operation . 383
Handling no-injection cranking operation 384
Testing and adjusting air conditioner compressor belt tension . 385
Check fan belt, replace . 386
Check auto-tensioner, replace . 388
Writing compensation values at replacement of injector and engine controller 391
Power train . 395
Testing swing circle bearing clearance 395
Undercarriage and frame . 396
Testing and adjusting track tension . 396
Hydraulic system 397
Releasing remaining pressure from hydraulic circuit . 397
Testing and adjusting oil pressure in work equipment and travel circuits 402
Testing and adjusting swing and blade circuit oil pressure 405
Testing oil pressure of control circuit . 408
Testing and adjusting oil pressure in pump PC control circuit . 409
Testing and adjusting oil pressure in pump LS control circuit . 412
Testing outlet pressure of solenoid valve . 415
Testing PPC valve outlet pressure . 416
Adjusting play of work equipment and swing PPC valves . 417
Isolating the parts causing hydraulic drift in work equipment . 418
Testing and adjusting travel deviation 419
Testing oil leakage . 421
Bleeding air from hydraulic circuit . 425
Cab and its attachments . 428
Testing, cleaning and lubricating slide door rail and roller 428
How to examine and adjust slide door . 429
Adjusting mirrors . 455
Testing and adjusting hood catcher 457
Electrical system . 459
Special functions of machine monitor 459
KOMTRAX terminal start-up procedure . 507
Adjusting rearview camera angle . 511
Handling voltage circuit of engine controller . 513
Handling battery disconnect switch 514
Testing diodes 515
Pm clinic . 516
Pm Clinic service . 516
40 Troubleshooting 525
Table of contents . 526
Precautions before work 532
Related information on troubleshooting 534
Troubleshooting points 534
Sequence of events in troubleshooting . 536
Checks before troubleshooting . 538
Inspection procedure before troubleshooting . 540
Preparation for troubleshooting of electrical system 557
Classification and procedures for troubleshooting . 562
Symptom and troubleshooting numbers . 565
Information in troubleshooting table 568
Troubleshooting method for open circuit in wiring harness of pressure sensor system . 570
Connector list and layout . 572
Connector contact identification 582
T-branch box and T-branch adapter table . 621
Fuse location table . 626
Failure codes table . 628
Troubleshooting by failure code (Display of code) . 635
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit . 635
Failure code [879AKB] A/C Recirc Air Temp Sens Short 636
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit 637
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit . 638
Failure code [879CKA] Ventilating Sensor Open Circuit . 639
Failure code [879CKB] Ventilating Sensor Short Circuit 640
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit . 641
Failure code [879EMC] Ventilation Damper Malfunction 642
Failure code [879FMC] Air Mix Damper Malfunction 643
Failure code [879GKX] Refrigerant Press Input Sig Out of Range 644
Failure code [989L00] Engine Controller Lock Caution 1 645
Failure code [989M00] Engine Controller Lock Caution 2 646
Failure code [989N00] Engine Controller Lock Caution 3 647
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 648
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 649
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 650
Failure code [AB00KE] Charge Voltage Low 651
Failure code [B@BAZG] Eng Oil Press Low . 653
Failure code [B@BCNS] Eng Water Overheat 654
Failure code [B@HANS] Hyd Oil Overheat . 655
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 657
Failure code [CA122] Charge Air Pressure Sensor High Error 658
Failure code [CA123] Charge Air Pressure Sensor Low Error . 660
Failure code [CA131] Throttle Sensor High Error . 662
Failure code [CA132] Throttle Sensor Low Error 664
Failure code [CA144] Coolant Temperature Sensor High Error 666
Failure code [CA145] Coolant Temperature Sensor Low Error . 668
Failure code [CA153] Charge Air Temperature Sensor High Error . 670
Failure code [CA154] Charge Air Temperature Sensor Low Error 672
Failure code [CA187] Sensor 2 Supply Voltage Low Error 674
Failure code [CA221] Ambient Pressure Sensor High Error . 676
Failure code [CA222] Ambient Pressure Sensor Low Error 678
Failure code [CA227] Sensor 2 Supply Voltage High Error . 680
Failure code [CA234] Engine Overspeed . 681
Failure code [CA238] NE Speed Sensor Supply Voltage Error . 682
Failure code [CA239] NE Speed Sensor Supply Voltage High Error 683
Failure code [CA271] PCV1 Short Circuit Error . 684
Failure code [CA272] PCV1 Open Circuit Error 685
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit 686
Failure code [CA324] Injector #3 (L#3) Open or Short Circuit 688
Failure code [CA331] Injector #2 (L#2) Open or Short Circuit 690
Failure code [CA332] Injector #4 (L#4) Open or Short Circuit 692
Failure code [CA343] Engine Controller Internal Failure . 694
Failure code [CA351] Injectors Drive Circuit Error 695
Failure code [CA352] Sensor1 Supply Voltage Low Error . 696
Failure code [CA356] MAF Sensor High Error 698
Failure code [CA357] MAF Sensor Low Error . 700
Failure code [CA386] Sensor1 Supply Voltage High Error 702
Failure code [CA435] Engine Oil Pressure SW Error . 703
Failure code [CA441] Battery Voltage Low Error 704
Failure code [CA442] Battery Voltage High Error . 706
Failure code [CA449] Common Rail Pressure High Error 2 707
Failure code [CA451] Common Rail Pressure Sensor High Error . 708
Failure code [CA452] Common Rail Pressure Sensor Low Error 710
Failure code [CA466] KVGT Motor Driver Position Error . 712
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error . 714
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error 716
Failure code [CA553] Common Rail Pressure High Error 1 718
Failure code [CA555] Crankcase Pressure High Error 1 719
Failure code [CA556] Crankcase Pressure High Error 2 720
Failure code [CA559] Common Rail Pressure Low Error 1 . 721
Failure code [CA689] Engine NE Speed Sensor Error . 724
Failure code [CA691] Intake Air Temperature Sensor High Error . 726
Failure code [CA692] Intake Air Temperature Sensor Low Error 728
Failure code [CA697] Engine Con Internal Temp Sens High Error . 730
Failure code [CA698] Engine Con Internal Temp Sens Low Error 731
Failure code [CA731] Engine Backup Speed Sensor Phase Error . 732
Failure code [CA778] Engine Backup Speed Sensor Error . 734
Failure code [CA1117] Engine Controller Partial Data Lost Error . 738
Failure code [CA1695] Sensor 5 Supply Voltage High Error 739
Failure code [CA1696] Sensor 5 Supply Voltage Low Error . 740
Failure code [CA1843] Crankcase Pressure Sensor High Error 741
Failure code [CA1844] Crankcase Pressure Sensor Low Error . 743
Failure code [CA1896] EGR Valve Stuck Error . 745
Failure code [CA1942] Crankcase Pressure Sensor In Range Error 750
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error . 751
Failure code [CA2185] Throttle Sensor Supply Voltage High Error . 752
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error 754
Failure code [CA2249] Common Rail Pressure Low Error 2 756
Failure code [CA2272] EGR Valve Position Sensor Low Error . 757
Failure code [CA2311] IMV Solenoid Error 759
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error . 760
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error 762
Failure code [CA2357] EGR Valve Servo Error . 764
Failure code [CA2765] Injector Trim Data Mismatch . 765
Failure code [CA3419] MAF Sensor Supply Voltage High Error 766
Failure code [CA3421] MAF Sensor Supply Voltage Low Error . 768
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error . 770
Failure code [CA3918] KVGT Stuck Error 772
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 773
Failure code [CA3921] KVGT Servo Error 2 774
Failure code [CA3922] KVGT Motor Driver Open Error 775
Failure code [CA3923] KVGT Motor Driver Short Error . 777
Failure code [D110KB] Battery Relay Output Short Circuit 779
Failure code [D19JKZ] Personal Code Relay Open or Short . 781
Failure code [D811MC] KOMTRAX Malfunction . 784
Failure code [D862KA] GPS Antenna Open Circuit 785
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) . 786
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 788
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX) . 789
Failure code [DA20MC] Pump Controller Malfunction . 791
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error 792
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error . 794
Failure code [DA26KP] 5V Sensor 2 Power Voltage Low Error 796
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) . 798
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 800
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) . 802
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con) 803
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con) 805
Failure code [DAF0MB] Monitor ROM Abnormality . 806
Failure code [DAF0MC] Monitor Malfunction . 807
Failure code [DAF8KB] Camera Power Supply Short Circuit . 808
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) . 809
Failure code [DAFGMC] GPS Module Malfunction 810
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) . 811
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 813
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) . 814
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) 815
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) 816
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con) . 820
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con) . 824
Failure code [DDNRKA] WE Lever Lock SW Open Circuit . 828
Failure code [DDNRKY] WE Lever Lock SW Short Circuit 830
Failure code [DDNS00] Lock Lever Auto Lock Release SW On 832
Failure code [DFB1KZ] Service Lever Potentiometer 1 Open Circuit orShort Circuit . 834
Failure code [DFB2KZ] Service Lever Potentiometer 2 Open Circuit orShort Circuit . 836
Failure code [DFB3L8] Service Lever 1 Potentiometer SignalIncompatibility 838
Failure code [DFB4L8] Service Lever 2 Potentiometer SignalIncompatibility 840
Failure code [DFB5KZ] Service Lever sub-Potentiometer 1 Open Circuitor Short Circuit . 842
Failure code [DFB6KZ] Service Lever sub-Potentiometer 2 Open Circuitor Short Circuit . 844
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault 846
Failure code [DHPAMA] Front Pump Press Sens Defective Function 848
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function 850
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function . 852
Failure code [DHS5MA] Travel PPC Sensor Abnormality . 854
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function 856
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function 858
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function . 860
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function 862
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function . 864
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function . 866
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality 868
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality 870
Failure code [DKULKA] PPC Lock Relay Open Circuit . 872
Failure code [DKULKB] PPC Lock Relay Short Circuit 874
Failure code [DKULKY] PPC Lock Relay Hot Short Circuit 876
Failure code [DV20KB] Travel Alarm Short Circuit 878
Failure code [DW43KA] Travel Speed Solenoid Open Circuit 880
Failure code [DW43KB] Travel Speed Solenoid Short Circuit . 882
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit 884
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit . 885
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit 888
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit . 890
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit 892
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 894
Failure code [DWJ0KB] Merge-divider Sol Short Circuit . 896
Failure code [DWJ0KY] Merge-divider Sol Short Circuit . 898
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit . 899
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit 901
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit 903
Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit . 905
Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit . 907
Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit 909
Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit . 911
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit 913
Failure code [DY20KA] Wiper Motor Open Circuit 915
Failure code [DY20MA] Wiper Motor Defective Function 917
Failure code [DY2CKB] Washer Motor Short Circuit 919
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit 921
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit . 923
Troubleshooting of electrical system (E-mode) . 925
E-1 Engine does not start (Engine does not crank) . 925
E-2 Manual preheating system does not work 931
E-3 While preheating is working, preheating monitor does not light up . 934
E-4 When starting switch is turned to ON position, machine monitor displays nothing . 936
E-5 Engine coolant temperature monitor lights up in white while engine is running . 939
E-6 Hydraulic oil temperature monitor lights up in white while engine is running 940
E-7 Charge level monitor lights up while engine is running 941
E-8 Fuel level monitor lights up in red while engine is running . 942
E-9 Engine coolant temperature monitor lights up in red while engine is running . 943
E-10 Hydraulic oil temperature monitor lights up in red while engine is running . 944
E-11 Engine oil pressure monitor lights up in red while engine is running . 945
E-12 Fuel gauge display does not move from minimum or maximum . 946
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty) . 947
E-14 Engine coolant temperature gauge display does not move from minimum or maximum . 948
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) 949
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum 950
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) . 952
E-18 Some areas of machine monitor screen are not displayed . 953
E-19 Function switch does not work 954
E-20 Automatic warm-up system does not operate (in cold season) . 955
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 956
E-22 Auto-deceleration function does not operate or is not canceled while lever is operated . 957
E-23 Working mode selection screen is not displayed while working mode selector switch is operated 959
E-24 Setting of engine and hydraulic pump is not changed while working mode is changed 960
E-25 Travel speed monitor does not change when travel speed switch is operated 961
E-26 Travel speed does not change while travel speed selection is changed . 962
E-27 Alarm buzzer does not stop sounding 963
E-28 Service meter is not displayed, while starting switch is in OFF position . 964
E-29 Service mode cannot be selected 965
E-30 Any of work equipment, swing and travel does not work 966
E-31 Any of work equipment, swing and travel cannot be locked . 968
E-32 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position . 970
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position . 972
E-34 Work equipment does not operate while lock lever automatic release switch is in release position . 974
E-35 Alarm does not sound during travel . 976
E-36 Alarm does not stop sounding while machine is stopped 977
E-37 Horn does not sound 978
E-38 Horn does not stop sounding 980
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated 981
E-40 Wiper does not operate while wiper switch is operated 982
E-41 Window washer does not operate while window washer switch is operated 984
E-42 Boom LOWER is not displayed correctly with monitoring function . 985
E-43 Arm OUT is not displayed correctly with monitoring function 986
E-44 Arm IN is not displayed correctly with monitoring function . 987
E-45 Boom RAISE is not displayed correctly with monitoring function . 988
E-46 Bucket CURL is not displayed correctly with monitoring function 989
E-47 Bucket DUMP is not displayed correctly with monitoring function 990
E-48 Boom swing left is not displayed correctly with monitoring function 991
E-49 Boom swing right is not displayed correctly with monitoring function . 992
E-50 Swing is not displayed correctly with monitoring function 993
E-51 Travel is not displayed correctly with monitoring function . 994
E-52 Blade RAISE ON is not displayed correctly with monitoring function . 995
E-53 Blade LOWER ON is not displayed correctly with monitoring function . 997
E-54 KOMTRAX system does not operate normally . 999
Troubleshooting of hydraulic and mechanical system (H-mode) .1001
Information described in troubleshooting table (H-mode) .1001
System chart of hydraulic and mechanical systems 1002
Failure mode and cause table 1004
H-1 All of work equipments, swing and travel operations lack speed or power .1012
H-2 Engine speed drops significantly or engine stalls .1014
H-3 Any of work equipment, swing and travel does not work .1015
H-4 Unusual sound is heard from around hydraulic pump .1016
H-5 Fine control performance or response is poor 1017
H-6 Boom speed or power is low 1018
H-7 Arm speed or power is low .1021
H-8 Bucket speed or power is low 1023
H-9 Boom swing speed or power is low 1025
H-10 Blade speed or power is low 1027
H-11 Work equipment does not move in single operation .1029
H-12 Hydraulic drift of boom is large .1030
H-13 Hydraulic drift of arm is large 1031
H-14 Hydraulic drift of bucket is large .1032
H-15 Hydraulic drift of blade is large 1033
H-16 Time lag of work equipment is large 1034
H-17 In combined operation of work equipment , equipment having heavier load moves slower .1036
H-18 In combined operation of swing and boom RAISE, boom rising speed is low 1037
H-19 In combined operation of work equipment or swing and travel, travel speed drops largely 1038
H-20 Machine does not travel straight .1040
H-21 Travel speed is slow .1042
H-22 Machine is hard to steer or travel power is low 1044
H-23 Travel speed does not change, or travel speed is too slow or fast 1047
H-24 One of tracks does not run .1048
H-25 Upper structure does not swing to the right or left 1050
H-26 Upper structure swing only to the right or left 1051
H-27 Swing acceleration or swing speed is low in both directions (right and left) .1052
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction 1053
H-29 Upper structure overruns excessively when it stops swinging (both right and left) 1054
H-30 Upper structure overruns excessively when it stops swinging (either right or left) .1055
H-31 Shock is large when upper structure stops swinging .1056
H-32 Large unusual noise is heard when upper structure stops swinging .1057
H-33 Swing drift on a slope is large while swing parking brake is applied .1058
H-34 Swing drift on a slope is large while swing parking brake is released 1059
H-35 Oil flow in attachment circuit cannot be controlled 1060
Troubleshooting of engine (S-mode) 1061
Information mentioned in troubleshooting table (S mode) .1061
S-1 Engine does not crank when starting switch is turned to START position 1062
S-2 Engine cranks but no exhaust smoke comes out 1063
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1064
S-4 Engine startability is poor .1065
S-5 Engine does not pick up smoothly 1067
S-6 Engine stops during operation .1069
S-7 Engine runs rough or is unstable 1071
S-8 Engine lacks power 1072
S-9 Exhaust smoke is black 1074
S-10 Engine oil consumption is excessive 1076
S-11 Oil becomes contaminated quickly .1077
S-12 Fuel consumption is excessive 1078
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .1079
S-14 Oil pressure drops .1080
S-15 Fuel mixes into engine oil .1081
S-16 Water mixes into engine oil (milky) 1082
S-17 Coolant temperature rises too high (overheating) .1083
S-18 Unusual noise is heard .1084
S-19 Vibration is excessive .1085
S-20 Air cannot be bled from fuel circuit .1086
50 Disassembly and assembly .1087
Table of contents .1088
Precautions before work 1090
Related information on disassembly and assembly .1092
How to read this manual .1092
Coating materials list 1094
Special tools list 1098
Sketches of special tools .1103
Engine and cooling system .1105
Removal and installation of supply pump assembly 1105
Removal and installation of injector assembly .1108
Removal and installation of cylinder head assembly 1115
Removal and installation of radiator assembly .1127
Removal and installation of hydraulic oil cooler assembly .1131
Removal and installation of aftercooler assembly 1134
Removal and installation of engine and main pump assembly .1137
Removal and installation of engine front oil seal .1145
Removal and installation of engine rear oil seal 1146
Removal and installation of fuel cooler assembly 1148
Removal and installation of fuel tank assembly 1149
Removal and installation of engine hood assembly 1151
Removal and installation of KDOC muffler 1152
Removal and installation of KCCV ventilator .1155
Removal and installation of air cleaner assembly 1157
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .1159
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1161
Removal and installation of fan belt 1162
Power train system 1164
Removal and installation of travel motor and final drive assembly .1164
Disassembly and assembly of travel motor and final drive assembly (Applicable machine: #7001 to 8864) 1166
Disassembly and assembly of travel motor and final drive assembly (Applicable machine: #8865 and up) .1214
Removal and installation of swing motor and swing machinery assembly 1265
Disassembly and assembly of swing machinery assembly 1267
Removal and installation of swing circle assembly .1275
Undercarriage and frame .1276
Separation and connection of track 1276
Removal and installation of sprocket 1277
Removal and installation of idler and idler cushion assembly 1278
Disassembly and assembly of idler assembly 1279
Disassembly and assembly of idler cushion assembly 1282
Disassembly and assembly of track roller assembly .1285
Removal and installation of revolving frame assembly 1288
Removal and installation of counterweight assembly [For machines with additional counterweight] .1290
Hydraulic system 1292
Removal and installation of center swivel joint assembly 1292
Disassembly and assembly of center swivel joint assembly 1294
Removal and installation of hydraulic tank assembly .1295
Removal and installation of main pump assembly 1298
Removal and installation of control valve assembly 1302
Disassembly and assembly of control valve assembly 1306
Disassembly and assembly of work equipment PPC valve assembly .1309
Disassembly and assembly of travel PPC valve assembly .1311
Disassembly and assembly of work equipment cylinder assembly 1312
Work equipment 1316
Removal and installation of work equipment assembly .1316
Removal and installation of boom swing bracket 1319
Removal and installation of anti-drop valve for boom assembly .1320
Removal and installation of anti-drop valve for arm assembly 1323
Disassembly and assembly of anti-drop valve assembly 1326
Removal and installation of blade assembly 1327
Cab and its attachments .1329
Removal and installation of operator’s cab assembly .1329
Removal and installation of slide door .1333
Removal and installation of operator’s cab glass (adhered glass) 1336
Removal and installation of front window assembly .1347
Removal and installation of floor frame assembly 1348
Removal and installation of air conditioner unit assembly .1353
Removal and installation of air conditioner compressor assembly .1358
Removal and installation of air conditioner condenser assembly 1360
Removal and installation of operator’s seat .1362
Removal and installation of seat belt .1363
Removal and installation of front wiper assembly 1364
Electrical system .1371
Removal and installation of starting motor assembly .1371
Removal and installation of engine controller assembly 1372
Removal and installation of pump controller assembly 1373
Removal and installation of machine monitor assembly 1374
Removal and installation of mass air flow and temperature sensor 1376
Removal and installation of KOMTRAX terminal assembly .1377
60 Maintenance standard .1379
Table of contents .1380
Engine and cooling system .1381
Engine mount 1381
PTO .1382
Cooling system 1383
Power train system 1385
Swing circle 1385
Swing machinery .1387
Sprocket 1389
Undercarriage and frame .1390
Track frame .1390
Idler cushion .1391
Idler .1392
Track roller 1393
Carrier roller 1394
Track shoe 1395
Hydraulic system 1401
Hydraulic tank 1401
Main pump .1402
Control valve .1406
Swing motor .1415
Travel motor 1417
PPC valve .1418
Work equipment and swing PPC valve 1418
Travel PPC valve 1421
Blade PPC valve .1423
Boom swing PPC valve 1425
Solenoid valve 1427
Anti-drop valve for boom 1429
Anti-drop valve for arm .1431
Center swivel joint .1433
Cab and its attachments .1434
Cab mount and cab tipping stopper .1434
Work equipment 1435
Work equipment 1435
Boom cylinder .1446
Arm cylinder 1447
Bucket cylinder .1448
Boom swing cylinder .1449
Blade cylinder 1450
80 Appendix .1451
Table of contents .1452
Precautions before work 1453
Air conditioner components 1455
Precautions for refrigerant .1455
Air conditioner component .1456
Configuration and function of refrigeration cycle .1459
Outline of refrigeration cycle 1460
Air conditioner unit 1462
Dual pressure switch 1467
Air conditioner controller 1468
Compressor 1469
Condenser .1470
Sunlight sensor .1472
Outer temperature sensor (outside air temperature sensor) .1473
Procedure for testing and troubleshooting .1474
Circuit diagram and arrangement of connector pins .1476
System diagram 1478
Input and output signals of the air conditioner controller 1479
Air conditioner unit 1481
Parts and connectors layout .1483
Testing air leakage (duct) 1489
Testing with self-diagnosis function 1491
Testing vent (mode) changeover 1494
Testing FRESH/RECIRC air changeover .1495
Testing sunlight sensor .1496
Testing (dual) pressure switch for refrigerant 1497
Testing relays 1499
Troubleshooting chart 1 .1500
Troubleshooting chart 2 .1501
Information in troubleshooting table 1504
Failure code list related to air conditioner 1505
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit .1506
Failure code [879AKB] A/C Recirc Air Temp Sens Short 1507
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit 1508
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit .1510
Failure code [879CKA] Ventilating Sensor Open Circuit .1512
Failure code [879CKB] Ventilating Sensor Short Circuit 1513
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .1514
Failure code [879EMC] Ventilation Damper Malfunction 1516
Failure code [879FMC] Air Mix Damper Malfunction 1517
Failure code [879GKX] Refrigerant Press Input Sig Out of Range 1518
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1519
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) .1521
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1524
A-4 Troubleshooting for FRESH/RECIRC air changeover .1526
Troubleshooting with gauge pressure .1528
Connection of service tool 1531
Precautions for disconnecting and connecting refrigerant piping .1533
Handling of compressor oil 1535
90 Diagrams and drawings 1537
Table of contents .1538
Hydraulic circuit diagram .1539
Symbols in hydraulic circuit diagram 1539
Hydraulic circuit diagram .1543
Electric circuit diagram 1547
Symbols in electric circuit diagram .1547
Electrical circuit diagram 1551
Electrical circuit diagram of air conditioner unit 1561
INDEX 1563

DESCRIPTION:

Komatsu PC88MR-10 Hydraulic Excavator Shop Manual SEN06467-13 –  PDF  DOWNLOAD

• SERIAL NUMBERS 7001 and up

Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

G.B 26/12/24