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Komatsu PC88MR-8 Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : РСЗЗМR-8 А90001 and up
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Description
Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC88MR-8
Serial Number: А90001 and up
Book Code: CEBM007301
Language: English
Pages: 1001
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
FOREWORD:
1 GENERAL :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts. It explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
OTHER:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
CEBM007301 - PC88MR-8 sn A90001-up........................................................................... 0 CONTENTS................................................................................................. 2 REVISED PAGES............................................................................................ 3 SAFETY................................................................................................... 19 Safety Notice........................................................................................ 19 Important Safety Notice.......................................................................... 19 General Precautions.............................................................................. 19 Preparations For Work............................................................................ 19 Precautions During Work.......................................................................... 19 GENERAL.................................................................................................. 22 HOW TO READ THE SHOP MANUAL.............................................................................. 23 Volumes.............................................................................................. 23 Distribution And Updating............................................................................ 23 Filing Method........................................................................................ 23 Revised Edition Mark................................................................................. 23 Revisions............................................................................................ 23 Symbols.............................................................................................. 23 HOISTING INSTRUCTIONS.................................................................................... 24 Hoisting............................................................................................. 24 Wire Ropes........................................................................................... 24 PUSH PULL COUPLER........................................................................................ 25 Type 1............................................................................................... 25 Disconnection.................................................................................... 25 Connection....................................................................................... 25 Type 2............................................................................................... 26 Disconnection.................................................................................... 26 Connection....................................................................................... 26 Type 3............................................................................................... 27 Disconnection.................................................................................... 27 Connection....................................................................................... 27 EXPLANATION OF MAINTENANCE STANDARD TERMS................................................................ 28 STANDARD TIGHTENING TORQUE............................................................................... 30 Bolts And Nuts....................................................................................... 30 Tightening Torque Of Hose Nuts....................................................................... 31 Tightening Torque Of Split Flange Bolts.............................................................. 31 Tightening Torque For Flared Nuts.................................................................... 31 Tightening Torques For O-ring Boss Piping Joints..................................................... 32 Table Of Tightening Torques For O-ring Boss Plugs.................................................... 32 Torque Table For Hoses (Taper Seal Type And Face Seal Type).......................................... 32 ELECTRIC WIRE CODE....................................................................................... 33 Classification By Thickness.......................................................................... 33 Classification By Color And Code..................................................................... 33 How To Read Electric Wire Code....................................................................... 34 CONVERSION TABLES........................................................................................ 37 Method Of Using The Conversion Table................................................................. 37 COATING MATERIALS........................................................................................ 43 01 GENERAL................................................................................................... 45 SPECIFICATIONS DIMENSION DRAWING......................................................................... 46 Working Range Diagram................................................................................ 47 Specifications....................................................................................... 48 Weight Table......................................................................................... 52 TABLE FOR FUEL, COOLANT AND LUBRICANTS................................................................... 54 Selection According to Ambient Temperature........................................................... 54 Mixing Rate of Water and Antifreeze.................................................................. 55 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.............................................................. 57 ENGINE AND COOLING SYSTEM................................................................................ 62 Engine Mount......................................................................................... 62 Cooling System....................................................................................... 64 Power Take Off (PTO)................................................................................. 66 POWER TRAIN.............................................................................................. 67 Power Train.......................................................................................... 67 Swing Circle......................................................................................... 68 Swing Machinery...................................................................................... 70 UNDERCARRIAGE AND FRAME.................................................................................. 72 Track Frame.......................................................................................... 72 Idler Cushion........................................................................................ 73 Idler................................................................................................ 74 Track Roller......................................................................................... 76 Carrier Roller....................................................................................... 77 Sprocket............................................................................................. 78 Track Shoe........................................................................................... 80 City Pad Shoe, Road Liner, Triple Grouser Shoe................................................... 80 City Pad Shoe, Triple Grouser Shoe............................................................... 83 Road Liner....................................................................................... 84 HYDRAULIC SYSTEM......................................................................................... 86 Hydraulic Equipment Layout Drawing................................................................... 86 Valve Control........................................................................................ 87 Hydraulic Tank and Filter............................................................................ 88 Oil Filler Cap Breather.......................................................................... 89 Hydraulic Pump....................................................................................... 90 Model: LPD45+45.................................................................................. 90 Operation of Pump................................................................................ 95 Servo Valve...................................................................................... 96 Control of Delivery.............................................................................. 98 LS Valve......................................................................................... 99 PC Valve......................................................................................... 99 Action of Spring................................................................................. 100 When Pump Pressure (PAVE) is Low................................................................. 100 When Pump Pressure (PAVE) is High................................................................ 100 When Swing Gear Pump Pressure Increases or Decreases............................................. 100 When PC-EPC Valve Operates....................................................................... 100 When Load is Light............................................................................... 101 When Load is Heavy............................................................................... 102 When Balanced.................................................................................... 103 Control Valve........................................................................................ 104 10-Spool Valve (EU Specification)................................................................ 104 Sectional Views.................................................................................. 106 9-Spool Valve (North America Specification)...................................................... 118 CLSS................................................................................................. 120 Outline of CLSS.................................................................................. 120 Features..................................................................................... 120 Composition.................................................................................. 120 Basic principle.................................................................................. 121 Pump swash plate angle control............................................................... 121 LS differential pressure (rPLS) and pump swash plate angle................................... 121 Pressure compensation control................................................................ 122 Functions and Operation by Valve..................................................................... 124 Hydraulic Circuit Diagram and the Name of Valves................................................. 124 9-Spool Valve (North America Specification)...................................................... 125 Unload Valve..................................................................................... 126 Merge-Divider Valve.............................................................................. 136 Introduction of LS Pressure...................................................................... 138 Travel Valve..................................................................................... 139 LS Bypass Valve.................................................................................. 140 LS Select Valve.................................................................................. 142 Boom RAISE Merge Valve........................................................................... 144 Pressure compensation valve...................................................................... 147 Boom hydraulic drift prevention valve............................................................ 148 Boom regeneration circuit........................................................................ 151 Travel junction valve............................................................................ 154 Travel LS Bleed Circuit and Travel Junction Valve................................................ 158 PPC Valve............................................................................................ 162 Work Equipment and Swing PPC Valve............................................................... 162 Travel PPC Valve................................................................................. 168 Blade and Boom Swing PPC Valve................................................................... 172 Swing Motor.......................................................................................... 174 Brake Valve...................................................................................... 178 Modulating Relief Valve.......................................................................... 180 Swing Holding Brake.............................................................................. 181 Reverse Prevention Valve......................................................................... 182 Travel Motor......................................................................................... 185 Center Swivel Joint.................................................................................. 193 Solenoid Valve....................................................................................... 194 4-Spool Solenoid Valve........................................................................... 194 Check Valve...................................................................................... 195 Solenoid Valve................................................................................... 196 EPC Valve........................................................................................ 198 PPC Accumulator...................................................................................... 201 Anti-Drop Valve...................................................................................... 203 Multi-Control Valve.................................................................................. 208 WORK EQUIPMENT........................................................................................... 209 Dimensions of Components............................................................................. 212 Arm.............................................................................................. 212 Bucket........................................................................................... 216 Work Equipment Cylinder.............................................................................. 218 Boom Cylinder.................................................................................... 218 Arm Cylinder..................................................................................... 218 Bucket Cylinder.................................................................................. 218 Boom Swing Cylinder.............................................................................. 219 Blade Cylinder................................................................................... 219 AIR CONDITIONER.......................................................................................... 222 Air Conditioner Piping Diagram....................................................................... 222 Refrigerant Circuit Diagram...................................................................... 224 Air Conditioner Unit................................................................................. 226 Air Conditioner Controller....................................................................... 229 Compressor........................................................................................... 230 Condenser............................................................................................ 231 Receiver............................................................................................. 232 Sensors.............................................................................................. 233 Sunlight Sensor.................................................................................. 233 Ambient Air Temperature Sensor................................................................... 233 ELECTRICAL SYSTEM........................................................................................ 234 Electrical Control System............................................................................ 234 Machine Control System Diagram................................................................... 234 Engine Control Function.......................................................................... 236 Engine and Pump Mutual Control Function.......................................................... 238 Auto-Deceleration Function....................................................................... 242 Engine Automatic Warm-Up Function................................................................ 244 Turbocharger Protection Function................................................................. 246 Swing Control Function........................................................................... 248 Travel Control Function.......................................................................... 250 PPC Lock Function................................................................................ 252 Oil Flow Adjuster Function for Attachment........................................................ 253 System Components.................................................................................... 254 Engine Controller................................................................................ 254 Pump Controller.................................................................................. 256 Fuel control dial................................................................................ 258 Resistor......................................................................................... 259 Engine Oil Pressure Switch....................................................................... 260 PPC Oil Pressure Switch.......................................................................... 261 Monitor System....................................................................................... 262 Machine monitor.................................................................................. 264 Display.......................................................................................... 266 Switches......................................................................................... 270 Operator Mode Function............................................................................... 274 Service Mode Function............................................................................ 276 KOMTRAX System....................................................................................... 277 KOMTRAX terminal................................................................................. 278 Input and Output Signals......................................................................... 278 Sensor............................................................................................... 279 Atmospheric Pressure Sensor...................................................................... 279 Boost Pressure and Temperature Sensor............................................................ 279 Coolant Temperature Sensor....................................................................... 280 Crankshaft Speed Sensor.......................................................................... 280 Camshaft Speed Sensor............................................................................ 280 Common Rail Pressure Sensor...................................................................... 281 Hydraulic Oil Temperature Sensor................................................................. 281 Fuel Level Sensor................................................................................ 282 Pump Oil Pressure Sensor......................................................................... 283 Boom Cylinder Bottom Oil Pressure Sensor......................................................... 283 PPC Oil Pressure Sensor.......................................................................... 284 20 STANDARD VALUE TABLES..................................................................................... 285 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS............................................................ 286 STANDARD VALUE TABLE FOR CHASSIS......................................................................... 287 30 TESTING AND ADJUSTING..................................................................................... 295 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................ 298 ENGINE SPEED............................................................................................. 303 EXHAUST TEMPERATURE...................................................................................... 304 EXHAUST GAS COLOR........................................................................................ 306 VALVE CLEARANCE.......................................................................................... 308 COMPRESSION PRESSURE..................................................................................... 310 BLOW-BY PRESSURE......................................................................................... 312 ENGINE OIL PRESSURE...................................................................................... 314 HANDLING FUEL SYSTEM PARTS............................................................................... 316 Releasing Residual Pressure From Fuel System......................................................... 316 Testing Fuel Pressure................................................................................ 317 Testing Fuel Return Rate And Fuel Leakage............................................................ 318 Bleeding Air From Fuel Circuit....................................................................... 320 Checking Fuel Circuit for Leakage.................................................................... 322 ALTERNATOR BELT TENSION.................................................................................. 324 Testing.............................................................................................. 324 Adjusting............................................................................................ 325 AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................. 326 Checking............................................................................................. 326 Adjusting............................................................................................ 326 SWING CIRCLE BEARING CLEARANCE........................................................................... 327 TRACK SHOE TENSION....................................................................................... 328 Checking............................................................................................. 328 Adjusting............................................................................................ 328 Increasing tension............................................................................... 328 Decreasing tension............................................................................... 329 OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS....................................................... 330 Testing.............................................................................................. 330 Adjusting............................................................................................ 332 SWING AND BLADE CIRCUIT OIL PRESSURE..................................................................... 334 Testing.............................................................................................. 334 CONTROL CIRCUIT BASIC PRESSURE........................................................................... 338 OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.................................................................. 340 PC-EPC SOLENOID OUTPUT PRESSURE.......................................................................... 343 LS DIFFERENTIAL PRESSURE AND LS VALVE.................................................................... 344 Testing LS Differential Pressure..................................................................... 344 Adjusting LS Valve................................................................................... 345 SOLENOID VALVE OUTPUT PRESSURE........................................................................... 346 PPC VALVE OUTPUT PRESSURE................................................................................ 348 PLAY OF WORK EQUIPMENT AND SWING PPC VALVES.............................................................. 350 PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT...................................................... 352 TRAVEL DEVIATION......................................................................................... 354 Inspection........................................................................................... 354 Adjusting............................................................................................ 355 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT....................................................... 356 OIL LEAKAGE.............................................................................................. 358 Bleeding Air from Each Part.......................................................................... 362 MIRRORS.................................................................................................. 364 SPECIAL FUNCTIONS OF MACHINE MONITOR..................................................................... 366 Upper Section of Machine Monitor (Display Section)................................................... 367 Upper Section of Machine Monitor (Switch Section).................................................... 367 Lower Section of Machine Monitor (Switch Section).................................................... 367 Ordinary and Special Functions of Machine Monitor.................................................... 368 Operator Mode (Outline).......................................................................... 369 Service Mode..................................................................................... 382 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER............................................................ 420 PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................................................ 421 Machine Monitor...................................................................................... 421 Engine Controller.................................................................................... 422 Pump Controller...................................................................................... 422 KOMTRAX Communication Module......................................................................... 423 Engine Ne Speed Sensor (Crank Sensor)................................................................ 423 Engine Bkup Speed Sensor (Cam Sensor)................................................................ 423 Engine Oil Pressure Switch (Oil Pressure Switch)..................................................... 423 Boost Pressure and Temperature Sensor (Boost Press and Imt).......................................... 424 Supply Pump IMV Solenoid (Fuel Regulator)............................................................ 424 Common Rail Pressure Sensor (Fuel Rail Press)........................................................ 425 Engine Coolant Temperature Sensor (Coolant Temp)..................................................... 425 PROCEDURE FOR TESTING DIODES............................................................................. 426 When Using Digital Circuit Tester.................................................................... 426 When Using Analog Circuit Tester..................................................................... 427 PM CLINIC SERVICE........................................................................................ 428 Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge......... 428 Check sheet (PC88MR-8)............................................................................... 429 Engine............................................................................................... 429 Work equipment speed................................................................................. 429 Hydraulic drift of work equipment.................................................................... 429 Hydraulic circuit.................................................................................... 430 * Gauge changing work: Change hoses of gauges [3] and [4]............................................ 430 * Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5]............... 431 40 TROUBLESHOOTING........................................................................................... 433 GENERAL INFORMATION ON TROUBLESHOOTING................................................................... 438 Points to Remember When Troubleshooting.............................................................. 438 Sequence of Events in Troubleshooting................................................................ 440 Checks Before Troubleshooting........................................................................ 441 Classification and Procedures for Troubleshooting.................................................... 442 Procedure for Troubleshooting.................................................................... 442 Phenomena Looking Like Troubles and Troubleshooting Nos.............................................. 444 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................... 447 T-ADAPTER TABLE.......................................................................................... 470 FAILURE CODE TABLE....................................................................................... 474 FUSE LOCATIONS........................................................................................... 476 TROUBLESHOOTING BY FAILURE CODE.......................................................................... 479 Failure Code [989L00] Engine Controller Lock Caution 1............................................... 479 Failure Code [989M00] Engine Controller Lock Caution 2............................................... 480 Failure Code [989N00] Engine Controller Lock Caution 3............................................... 481 Failure Code [AB00KE] Charge Voltage Low............................................................. 482 Failure Code [B@BAZG] Eng Oil Press. Low............................................................. 484 Failure Code [B@BCNS] Eng Coolant Overheat........................................................... 484 Failure Code [B@HANS] Hyd. Oil Overheat.............................................................. 485 Failure Code [CA111] ECM Critical Internal Failure................................................... 486 Failure Code [CA115] Eng. Ne and Bkup Speed Sensor Error............................................. 489 Failure Code [CA122] Charge Air Press Sensor High Error.............................................. 490 Failure Code [CA123] Charge Air Press Sensor Low Error............................................... 492 Failure Code [CA131] Throttle Sensor High Error...................................................... 494 Failure Code [CA132] Throttle Sensor Low Error....................................................... 496 Failure Code [CA144] Coolant Temp. Sensor High Error................................................. 498 Failure Code [CA145] Coolant Temp. Sensor Low Error.................................................. 500 Failure Code [CA153] Charge Air Temp. Sensor High Error.............................................. 502 Failure Code [CA154] Charge Air Temp. Sensor Low Error............................................... 504 Failure Code [CA187] Sensor Sup. 2 Volt. Low Error................................................... 505 Failure Code [CA221] Ambient Air Press. Sensor High Error............................................ 506 Failure Code [CA227] Sensor Sup. 2 Volt. High Error.................................................. 509 Failure Code [CA234] Eng. Overspeed.................................................................. 510 Failure Code [CA238] Ne Speed Sensor Sup. Volt. Error................................................ 512 Failure Code [CA272] IMV/PCV1 Open Error............................................................. 516 Failure Code [CA322] Injector #1 (L #1) System Open/Short Error...................................... 518 Failure Code [CA324] Injector #3 (L #3) System Open/Short Error...................................... 520 Failure Code [CA331] Injector #2 (L #2) System Open/Short Error...................................... 522 Failure Code [CA332] Injector #4 (L #4) System Open/Short Error...................................... 524 Failure Code [CA351] Inj. Drive Circuit Error........................................................ 526 Failure Code [CA352] Sensor Sup. 1 Volt. Low Error................................................... 529 Failure Code [CA386] Sensor Sup. 1 Volt. High Error.................................................. 530 Failure Code [CA435] Abnormality in Engine Oil Pressure Switch....................................... 532 Failure Code [CA441] Battery Voltage Low Error....................................................... 533 Failure Code [CA442] Battery Voltage High Error...................................................... 534 Failure Code [CA449] Rail Press. Very High Error..................................................... 535 Failure Code [CA451] Rail Press. Sensor High Error................................................... 536 Failure Code [CA452] Rail Press. Sensor Low Error.................................................... 538 Failure Code [CA553] Rail Press. High Error.......................................................... 538 Failure Code [CA559] Rail Press. Low Error........................................................... 539 Failure Code [CA731] Eng. Bkup Speed Sensor Phase Error.............................................. 544 Failure Code [CA757] All Persistent Data Lost Error.................................................. 545 Failure Code [CA778] Eng. Bkup Speed Sensor Error.................................................... 546 Failure Code [CA1633] KOMNET Datalink Timeout Error.................................................. 548 Failure Code [CA2185] Throttle Sens. Sup. Volt. High Error........................................... 550 Failure Code [CA2186] Throttle Sens. Sup. Volt. Low Error............................................ 552 Failure Code [CA2249] Rail Press. Very Low Error..................................................... 553 Failure Code [CA2311] Abnormality in IMV Solenoid.................................................... 554 Failure Code [D110KB] Battery Relay Drive Short...................................................... 556 Failure Code [D19JKZ] Personal Code Relay Abnormality................................................ 558 Failure Code [D862KA] GPS Antenna Discon............................................................. 560 Failure Code [DA22KK] Pump Solenoid Power Low Error.................................................. 562 Failure Code [DA25KP] 5 V Sensor 1 Power Abnormality................................................. 564 Failure Code [DA26KP] 5 V Sensor 2 Power Abnormality................................................. 567 Failure Code [DA2RMC] CAN Discon (Pump Controller Detected).......................................... 568 Failure Code [DAFGMC] GPS Module Error............................................................... 570 Failure Code [DAFRMC] CAN Discon (Monitor Detected).................................................. 572 Failure Code [DFB1KZ] Service Lever Pot. 1 Abnormality............................................... 574 Failure Code [DFB2KZ] Service Lever Pot. 2 Abnormality............................................... 576 Failure Code [DFB3L8] Service Lever 1 Potentio Error................................................. 578 Failure Code [DFB4L8] Service Lever 2 Potentio Error................................................. 580 Failure Code [DFB5KZ] Service Lever sPot. 1 Abnormality.............................................. 582 Failure Code [DFB6KZ] Service Lever sPot. 2 Abnormality.............................................. 584 Failure Code [DGH2KB] Hydr Oil Sensor Short.......................................................... 586 Failure Code [DHPAMA] Pump Press Sensor Abnormality.................................................. 588 Failure Code [DHS5KX] Travel PPC Sensor Abnormality.................................................. 590 Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality.......................................... 592 Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality.......................................... 594 Failure Code [DHX1MA] Overload Sensor Abnormality.................................................... 596 Failure Code [DV20KB] Travel Alarm Short Circuit..................................................... 598 Failure Code [DW43KA] Travel Speed Sol Discon........................................................ 600 Failure Code [DW43KB] Travel Speed Sol Short......................................................... 601 Failure Code [DW45KA] Swing Brake Sol Discon......................................................... 602 Failure Code [DW45KB] Swing Brake Sol Short.......................................................... 604 Failure Code [DWJ0KA] Merge-Divider Sol Discon....................................................... 606 Failure Code [DWJ0KB] Merge-Divider Sol Short........................................................ 607 Failure Code [DXA8KA] PC-EPC Sol Discon.............................................................. 608 Failure Code [DXA8KB] PC-EPC Sol Short............................................................... 610 Failure Code [DXE7KA] Service Current EPC2 Open Circuit.............................................. 612 Failure Code [DXE7KB] Service Current EPC2 Short Circuit............................................. 614 Failure Code [DXE8KA] Service Current EPC3 Open Circuit.............................................. 616 Failure Code [DXE8KB] Service Current EPC3 Short Circuit............................................. 618 Failure Code [DXE9KA] Service Current EPC4 Open Circuit.............................................. 620 Failure Code [DXE9KB] Service Current EPC4 Short Circuit............................................. 622 Failure Code [DXEAKA] Service Current EPC1 Open Circuit.............................................. 624 Failure Code [DXEAKB] Service Current EPC1 Short Circuit............................................. 626 Failure Code [DY20KA] Wiper Working Abnormality...................................................... 628 Failure Code [DY20MA] Wiper Parking Abnormality...................................................... 630 Failure Code [DY2CKA] Washer Drive Open Circuit...................................................... 632 Failure Code [DY2CKB] Washer Drive Short Circuit..................................................... 634 Failure Code [DY2DKB] Wiper Drive (FWD) Short Circuit................................................ 636 Failure Code [DY2EKB] Wiper Drive (REV) Short Circuit................................................ 638 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)............................................................ 640 Before Carrying Out Troubleshooting of Electrical System............................................. 640 Connection table of fuse box..................................................................... 640 Locations of fusible links....................................................................... 641 Location of fuse box and fuse numbers............................................................ 641 Information in Troubleshooting Table................................................................. 642 E-1 When Starting Switch is Turned On, Machine Monitor Displays Nothing.............................. 644 E-2 Engine Does Not Start (Engine Does Not Turn)..................................................... 646 E-3 Preheater Does Not Operate....................................................................... 649 E-5 All Work Equipment, Swing, and Travel Mechanism Does Not Move or Cannot Be Locked................ 652 E-6 Precaution Lights Up While Engine Is Running..................................................... 654 E-7 Emergency Stop Item Lights Up While Engine Is Running............................................ 657 E-8 Engine Coolant Temperature Gauge Does Not Indicate Normally...................................... 658 E-9 Hydraulic oil temperature gauge does not indicate normally....................................... 660 E-10 Fuel Level Gauge Does Not Indicate Normally..................................................... 663 E-11 Contents of Display by Machine Monitor are Different From Applicable Machine.................... 665 E-12 Machine Monitor Does Not Display Some Items..................................................... 665 E-13 Function Switch Does Not Work................................................................... 665 E-14 Auto-decelerator Does Not Operate Normally...................................................... 666 E-15 Working Mode Does Not Change.................................................................... 667 E-16 Travel Speed Does Not Change.................................................................... 668 E-17 Alarm Buzzer Cannot Be Stopped.................................................................. 669 E-18 Windshield Wiper And Window Washer Do Not Operate............................................... 670 E-19 Swing Holding Brake Does Not Operate Normally................................................... 674 E-20 Travel Alarm Does Not Sound Or Does Not Stop Sounding........................................... 676 E-21 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)........ 677 E-22 While Starting Switch is in Off Position, Service Meter is not Displayed........................ 690 E-25 Komtrax System Does Not Operate Normally........................................................ 712 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).............................................. 715 Information Contained in Troubleshooting Table....................................................... 715 System Chart for Hydraulic and Mechanical Systems.................................................... 717 H-1 Speed or Power of all Work Equipment, Swing, and Travel are Low.................................. 719 H-2 Engine Speed Sharply Drops or Engine Stalls...................................................... 720 H-3 No Work Equipment, Travel and Swing Move......................................................... 721 H-4 Abnormal Noise is Heard from Around Hydraulic Pump............................................... 721 H-5 Fine Control Performance or Response of Work Equipment and Travel is Low......................... 722 H-6 Speed or Power of Boom is Low.................................................................... 723 H-7 Speed or Power of Arm is Low..................................................................... 724 H-8 Speed or Power of Bucket is Low.................................................................. 725 H-9 Speed or Power of Boom Swing is Low.............................................................. 726 H-10 Speed or Power of Blade is Low.................................................................. 727 H-11 Work Equipment Does Not Move in its Single Operation............................................ 728 H-12 Hydraulic Drift of Work Equipment is Large...................................................... 729 H-13 Time Lag of Work Equipment is Large............................................................. 731 H-14 Work Equipment Loaded More is Slower During Compound Operation.................................. 731 H-15 Boom RAISE Speed is Low in Compound Operation of Swing + Boom Raise............................. 731 H-16 Travel Speed Lowers Significantly During Compound Operation of Work Equipment/Swing + Travel.... 732 H-17 Machine Deviates During Travel.................................................................. 733 H-18 Travel Speed is Low............................................................................. 734 H-19 Machine Cannot be Steered Easily or Steering Power is Low....................................... 735 H-20 Travel Speed Does Not Change or it is Kept Low or High.......................................... 736 H-21 Track Does Not Move (Only Either Side).......................................................... 736 H-22 Machine Does Not Swing.......................................................................... 737 H-23 Swing Acceleration, Swing Speed and Swing Power are Low......................................... 739 H-24 Excessive Overrun when Stopping Swing........................................................... 741 H-25 When Upper Structure Stops Swinging, it Makes Large Shock....................................... 742 H-26 When Upper Structure Stops Swinging, it Makes Large Sound....................................... 742 H-27 Hydraulic Drift of Swing is Large............................................................... 743 H-28 Flow Rate in Attachment Circuit Cannot Be Adjusted.............................................. 744 50 DISASSEMBLY AND ASSEMBLY.................................................................................. 745 HOW TO READ THIS MANUAL.................................................................................. 750 Removal and Installation of Assemblies............................................................... 750 Special Tools.................................................................................... 750 Removal.......................................................................................... 750 Installation..................................................................................... 750 Disassembly and Assembly of Assemblies............................................................... 751 Special Tools.................................................................................... 751 Disassembly...................................................................................... 751 Assembly......................................................................................... 752 COATING MATERIALS LIST................................................................................... 754 SPECIAL TOOLS LIST....................................................................................... 758 SKETCHES OF SPECIAL TOOLS................................................................................ 762 CONNECTOR REPAIR PROCEDURES.............................................................................. 767 Stripping Insulation................................................................................. 767 Wire Inspection...................................................................................... 767 Contact Terminal Removal (HD30 Type)................................................................. 768 Crimping Contact Terminal (HD30 Type)................................................................ 769 Insertion of Contact Terminal (HD30 Type)............................................................ 770 Contact Terminal Removal (DT Type)................................................................... 771 Crimping Contact Terminal (DT Type).................................................................. 772 Insertion of Contact Terminal (DT Type).............................................................. 773 ENGINE AND COOLING SYSTEM................................................................................ 774 Fuel Supply Pump Assembly............................................................................ 774 Removal.......................................................................................... 774 Installation..................................................................................... 778 Fuel Injector Assembly............................................................................... 780 Removal.......................................................................................... 780 Installation..................................................................................... 784 Engine Front Seal.................................................................................... 786 Removal.......................................................................................... 786 Installation..................................................................................... 787 Engine Rear Seal..................................................................................... 788 Removal.......................................................................................... 788 Installation..................................................................................... 790 Cylinder Head Assembly............................................................................... 791 Removal.......................................................................................... 791 Installation..................................................................................... 801 Radiator Assembly.................................................................................... 806 Removal.......................................................................................... 806 Installation..................................................................................... 809 Aftercooler Assembly................................................................................. 810 Removal.......................................................................................... 810 Installation..................................................................................... 813 Hydraulic Oil Cooler Assembly........................................................................ 814 Removal.......................................................................................... 814 Installation..................................................................................... 817 Engine and Hydraulic Pump Assembly................................................................... 818 Removal.......................................................................................... 818 Installation..................................................................................... 830 Fuel Tank Assembly................................................................................... 834 Removal.......................................................................................... 834 Installation..................................................................................... 836 POWER TRAIN.............................................................................................. 838 Travel Motor and Final Drive Assembly................................................................ 838 Removal.......................................................................................... 838 Installation..................................................................................... 839 Swing Motor and Swing Machinery Assembly......................................................... 840 Installation..................................................................................... 841 Swing Machinery.................................................................................. 842 Disassembly...................................................................................... 842 Assembly......................................................................................... 848 Swing Circle Assembly................................................................................ 854 Removal.......................................................................................... 854 Installation..................................................................................... 855 UNDERCARRIAGE AND FRAME.................................................................................. 856 Track Roller Assembly................................................................................ 856 Disassembly...................................................................................... 856 Assembly......................................................................................... 858 Idler Assembly....................................................................................... 862 Disassembly...................................................................................... 862 Assembly......................................................................................... 863 Recoil Spring Assembly............................................................................... 866 Disassembly...................................................................................... 866 Assembly......................................................................................... 868 Track Shoe Assembly.................................................................................. 870 Spreading........................................................................................ 870 Installation..................................................................................... 871 Sprocket............................................................................................. 872 Removal.......................................................................................... 872 Installation..................................................................................... 872 Revolving Frame Assembly............................................................................. 874 Removal.......................................................................................... 874 Installation..................................................................................... 876 Counterweight Assembly............................................................................... 878 Removal.......................................................................................... 878 Installation..................................................................................... 883 HYDRAULIC SYSTEM......................................................................................... 884 Center Swivel Joint Assembly......................................................................... 884 Removal.......................................................................................... 884 Installation..................................................................................... 885 Disassembly...................................................................................... 886 Assembly......................................................................................... 887 Hydraulic Tank Assembly.............................................................................. 888 Removal.......................................................................................... 888 Installation..................................................................................... 891 Hydraulic Pump Assembly.............................................................................. 892 Removal.......................................................................................... 892 Installation..................................................................................... 897 Control Valve Assembly............................................................................... 898 Removal.......................................................................................... 898 Disassembly...................................................................................... 908 Assembly......................................................................................... 908 Work Equipment PPC Valve Assembly.................................................................... 916 Disassembly...................................................................................... 916 Assembly......................................................................................... 916 Travel PPC Valve Assembly............................................................................ 918 Assembly......................................................................................... 918 Boom Swing Cylinder Assembly......................................................................... 920 Removal.......................................................................................... 920 Installation..................................................................................... 923 Hydraulic Cylinder Assembly.......................................................................... 924 Disassembly...................................................................................... 925 Assembly......................................................................................... 928 WORK EQUIPMENT........................................................................................... 932 Work Equipment Assembly (Machine With Boom Hydraulic Drift Prevention Valve)......................... 932 Removal.......................................................................................... 932 Installation..................................................................................... 935 Boom Swing Bracket................................................................................... 936 Removal.......................................................................................... 936 Installation..................................................................................... 939 Blade Assembly....................................................................................... 940 Removal.......................................................................................... 940 Installation..................................................................................... 941 CAB AND ITS ATTACHMENTS.................................................................................. 942 Operator Cab Assembly................................................................................ 942 Removal.......................................................................................... 942 Installation..................................................................................... 948 Operator's Cab Glass (Stuck glass)................................................................... 950 Removal.......................................................................................... 951 Installation..................................................................................... 952 Front Window Assembly................................................................................ 961 Removal.......................................................................................... 961 Installation..................................................................................... 961 Floor Frame Assembly................................................................................. 962 Removal.......................................................................................... 962 Installation..................................................................................... 969 Air Conditioner Compressor Assembly.................................................................. 970 Removal.......................................................................................... 970 Installation..................................................................................... 971 Air Conditioner Condenser Assembly................................................................... 972 Removal.......................................................................................... 972 Installation..................................................................................... 972 Air Conditioner Unit Assembly........................................................................ 974 Removal.......................................................................................... 974 Installation..................................................................................... 979 ELECTRICAL SYSTEM........................................................................................ 980 Machine Monitor Assembly............................................................................. 980 Removal.......................................................................................... 980 Installation..................................................................................... 981 Pump Controller Assembly............................................................................. 982 Removal.......................................................................................... 982 Installation..................................................................................... 984 Engine Controller Assembly........................................................................... 986 Removal.......................................................................................... 986 Installation..................................................................................... 989 KOMTRAX Terminal Assembly............................................................................ 990 Removal.......................................................................................... 990 Installation..................................................................................... 990 90 DIAGRAMS AND SCHEMATICS................................................................................... 991 HYDRAULIC SYSTEM......................................................................................... 993 Hydraulic Circuit Diagram............................................................................ 993 ELECTRICAL SYSTEM........................................................................................ 0 Electrical Circuit Diagram (2/6)..................................................................... 995 Electrical Circuit Diagram (3/6)..................................................................... 996 Electrical Circuit Diagram (4/6)..................................................................... 997 Electrical Circuit Diagram (5/6)..................................................................... 998 Electrical Circuit Diagram (6/6)..................................................................... 999 Electrical Circuit Diagram for Air Conditioner.......................................................1000 Connector List and Stereogram........................................................................1001
KOMATSU PC88MR-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
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