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Komatsu PC88MR-8 Hydraulic Excavator Shop Manual SEN04329-11 – PDF DOWNLOAD
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Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS 5001 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: 5001 and up
Book Code: SEN04329-11
Language: English
Pages: 1065
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It 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:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC88MR-8 Hydraulic Excavator Shop Manual
COVER ....................................................................................................... 1 00 Index and foreword........................................................................................ 0 100 Index................................................................................................ 3 Composition of shop manual........................................................................... 4 Table of contents.................................................................................... 6 200 Foreword and general information..................................................................... 15 Safety notice........................................................................................ 16 How to read the shop manual.......................................................................... 21 Explanation of terms for maintenance standard........................................................ 23 Handling of electric equipment and hydraulic component............................................... 25 Handling of connectors newly used for engines........................................................ 34 How to read electric wire code....................................................................... 37 Precautions when carrying out operation.............................................................. 40 Method of disassembling and connecting push-pull type coupler........................................ 43 Standard tightening torque table..................................................................... 46 Conversion table..................................................................................... 50 01 Specification............................................................................................. 0 100 Specification and technical data..................................................................... 57 Specification dimension drawing...................................................................... 58 Working range diagram................................................................................ 59 Specifications....................................................................................... 60 Weight table......................................................................................... 63 Table of fuel, coolant and lubricants................................................................ 65 10 Structure, function and maintenance standard.............................................................. 0 100 Engine and cooling system............................................................................ 67 Engine mount......................................................................................... 68 PTO.................................................................................................. 69 Cooling system....................................................................................... 70 200 Power train.......................................................................................... 73 Power train.......................................................................................... 74 Swing circle......................................................................................... 76 Swing machinery...................................................................................... 78 300 Undercarriage and frame.............................................................................. 81 Track frame.......................................................................................... 82 Idler cushion........................................................................................ 83 Idler................................................................................................ 84 Track roller......................................................................................... 85 Carrier roller....................................................................................... 86 Sprocket............................................................................................. 87 Track shoe........................................................................................... 88 410 Hydraulic system, Part 1............................................................................. 95 Hydraulic equipment layout drawing................................................................... 96 Valve control........................................................................................ 98 Hydraulic tank and filter............................................................................ 100 Hydraulic pump....................................................................................... 102 420 Hydraulic system, Part 2............................................................................. 117 Control valve........................................................................................ 119 CLSS................................................................................................. 136 Functions and operation by valve..................................................................... 140 430 Hydraulic system, Part 3............................................................................. 171 PPC valve............................................................................................ 173 Swing motor.......................................................................................... 185 Travel motor......................................................................................... 195 Center swivel joint.................................................................................. 203 Solenoid valve....................................................................................... 204 PPC accumulator...................................................................................... 211 Anti-drop valve...................................................................................... 214 Multi-control valve.................................................................................. 219 500 Work equipment....................................................................................... 221 Work equipment....................................................................................... 222 Dimensions of components............................................................................. 224 Work equipment cylinder.............................................................................. 230 600 Cab and its attachments.............................................................................. 235 Air conditioner...................................................................................... 236 700 Electrical system.................................................................................... 249 Electrical control system............................................................................ 250 Monitor system....................................................................................... 284 KOMTRAX system....................................................................................... 298 Sensor............................................................................................... 249 20 Standard value table...................................................................................... 0 100 Standard service value table......................................................................... 307 Standard value table for engine related parts........................................................ 308 Standard value table for chassis..................................................................... 309 30 Testing and adjusting..................................................................................... 0 110 Testing and adjusting, Part 1........................................................................ 319 Tools for testing, adjusting, and troubleshooting.................................................... 321 Testing engine speed................................................................................. 326 Testing exhaust temperature.......................................................................... 327 Checking exhaust gas color........................................................................... 328 Adjusting valve clearance............................................................................ 329 Testing compression pressure......................................................................... 331 Testing blow-by pressure............................................................................. 333 Testing engine oil pressure.......................................................................... 334 Handling fuel system parts........................................................................... 335 Releasing residual pressure from fuel system......................................................... 335 Testing fuel pressure................................................................................ 336 Testing fuel return rate and fuel leakage............................................................ 337 Bleeding air from fuel circuit....................................................................... 339 Checking fuel circuit for leakage.................................................................... 341 Testing and adjusting alternator belt tension........................................................ 342 Checking and adjusting air conditioner compressor belt tension....................................... 344 Testing swing circle bearing clearance............................................................... 345 Checking and adjusting track shoe tension............................................................ 346 Testing and adjusting oil pressure in work equipment and travel circuits............................. 348 Testing and adjusting swing and blade circuit oil pressure........................................... 350 Testing control circuit basic pressure............................................................... 353 Testing and adjusting oil pressure in pump PC control circuit........................................ 354 Testing PC-EPC solenoid output pressure.............................................................. 357 Testing LS differential pressure and adjusting LS valve.............................................. 358 Testing solenoid valve output pressure............................................................... 360 Testing PPC valve output pressure.................................................................... 361 Adjusting play of work equipment and swing PPC valves................................................ 363 Checking parts which cause hydraulic drift of work equipment......................................... 364 Testing and adjusting travel deviation............................................................... 366 Releasing residual pressure from hydraulic circuit................................................... 368 Testing oil leakage.................................................................................. 369 Bleeding air from each part.......................................................................... 372 Adjusting mirrors.................................................................................... 374 Testing and adjusting hood catch..................................................................... 375 120 Testing and adjusting, Part 2........................................................................ 379 Special functions of machine monitor................................................................. 380 130 Testing and adjusting, Part 3........................................................................ 431 Handling voltage circuit of engine controller........................................................ 432 Preparation work for troubleshooting of electrical system............................................ 433 Procedure for testing diodes......................................................................... 438 Pm Clinic service.................................................................................... 439 40 Troubleshooting........................................................................................... 0 100 Failure code table and fuse locations................................................................ 445 Failure code table................................................................................... 446 Fuse locations....................................................................................... 449 200 General information on troubleshooting............................................................... 453 Points to remember when troubleshooting.............................................................. 454 Sequence of events in troubleshooting................................................................ 455 Checks before troubleshooting........................................................................ 456 Classification and procedures for troubleshooting.................................................... 457 Information in troubleshooting table................................................................. 458 Phenomena looking like troubles and troubleshooting Nos.............................................. 460 Connection table for connector pin numbers........................................................... 463 T- branch box and T- branch adapter table............................................................ 499 310 Troubleshooting by failure code, Part 1.............................................................. 503 Failure code [989L00] Engine controller lock caution 1............................................... 505 Failure code [989M00] Engine controller lock caution 2............................................... 506 Failure code [989N00] Engine controller lock caution 3............................................... 507 Failure code [AB00KE] Charge voltage low............................................................. 508 Failure code [B@BAZG] Eng oil press. low............................................................. 511 Failure code [B@BCNS] Eng coolant overheat........................................................... 512 Failure code [B@HANS] Hydr. oil overheat............................................................. 512 Failure code [CA111] ECM critical internal failure................................................... 513 Failure code [CA115] Eng. Ne and Bkup speed sensor error............................................. 516 Failure code [CA122] Charge air press sensor high error.............................................. 518 Failure code [CA123] Charge air press sensor low error............................................... 520 Failure code [CA131] Throttle sensor high error...................................................... 522 Failure code [CA132] Throttle sensor low error....................................................... 524 Failure code [CA144] Coolant temp. sensor high error................................................. 526 Failure code [CA145] Coolant temp. sensor low error.................................................. 528 Failure code [CA153] Charge air temp. sensor high error.............................................. 530 Failure code [CA154] Charge air temp. sensor low error............................................... 532 Failure code [CA187] Sensor sup. 2 volt. low error................................................... 533 Failure code [CA221] Ambient air press. sensor high error............................................ 534 Failure code [CA222] Ambient air press. sensor low error............................................. 536 Failure code [CA227] Sensor sup. 2 volt. high error.................................................. 537 Failure code [CA234] Eng. overspeed.................................................................. 538 Failure code [CA238] Ne speed sensor sup. volt. error................................................ 540 Failure code [CA271] IMV/PCV1 short error............................................................ 542 Failure code [CA272] IMV/PCV1 open error............................................................. 543 Failure code [CA322] Injector #1 (L #1) system open/short error...................................... 544 Failure code [CA324] Injector #3 (L #3) system open/short error...................................... 546 Failure code [CA331] Injector #2 (L #2) system open/short error...................................... 548 Failure code [CA332] Injector #4 (L #4) system open/short error...................................... 550 320 Troubleshooting by failure code, Part 2.............................................................. 553 Failure code [CA351] Inj. drive circuit error........................................................ 555 Failure code [CA352] Sensor sup. 1 volt. low error................................................... 558 Failure code [CA435] Abnormality in engine oil pressure switch....................................... 562 Failure code [CA441] Battery voltage low error....................................................... 563 Failure code [CA442] Battery voltage high error...................................................... 564 Failure code [CA449] Rail press. very high error..................................................... 565 Failure code [CA451] Rail press. sensor high error................................................... 566 Failure code [CA452] Rail press. sensor low error.................................................... 568 Failure code [CA553] Rail press. high error.......................................................... 568 Failure code [CA559] Rail press. low error........................................................... 569 Failure code [CA689] Eng. Ne speed sensor error...................................................... 572 Failure code [CA731] Eng. Bkup speed sensor phase error.............................................. 574 Failure code [CA757] All persistent data lost error.................................................. 575 Failure code [CA778] Eng. Bkup speed sensor error.................................................... 576 Failure code [CA1633] KOMNET datalink timeout error.................................................. 578 Failure code [CA2185] Throttle sens. sup. volt. high error........................................... 580 Failure code [CA2186] Throttle sens. sup. volt. low error............................................ 582 Failure code [CA2249] Rail press. very low error..................................................... 583 Failure code [CA2311] Abnormality in IMV solenoid.................................................... 584 Failure code [D110KB] Battery relay drive short...................................................... 585 Failure code [D19JKZ] Personal code relay abnormality................................................ 589 Failure code [D862KA] GPS antenna discon............................................................. 592 Failure code [DA22KK] Pump solenoid power low error.................................................. 593 Failure code [DA25KP] 5 V sensor 1 power abnormality................................................. 595 Failure code [DA26KP] 5 V sensor 2 power abnormality................................................. 598 330 Troubleshooting by failure code, Part 3.............................................................. 601 Failure code [DA2RMC] CAN discon (Pump controller detected).......................................... 602 Failure code [DAFGMC] GPS module error............................................................... 604 Failure code [DAFRMC] CAN discon (Monitor detected).................................................. 606 Failure code [DFB1KZ] Service lever pot. 1 abnormality............................................... 608 Failure code [DFB2KZ] Service lever pot. 2 abnormality............................................... 610 Failure code [DFB3L8] Service lever1 potentio error.................................................. 612 Failure code [DFB4L8] Service lever2 potentio error.................................................. 614 Failure code [DFB5KZ] Service lever sPot. 1 abnormality.............................................. 616 Failure code [DFB6KZ] Service lever sPot. 2 abnormality.............................................. 618 Failure code [DGH2KB] Hydr oil sensor short.......................................................... 620 Failure code [DHPAMA] Pump press sensor abnormality.................................................. 622 Failure code [DHS5KX] Travel PPC sensor abnormality.................................................. 624 Failure code [DHSAMA] Swing RH PPC press sensor abnormality.......................................... 626 Failure code [DHSBMA] Swing LH PPC press sensor abnormality.......................................... 628 Failure code [DHX1MA] Overload sensor abnormality.................................................... 630 Failure code [DV20KB] Travel alarm short circuit..................................................... 631 Failure code [DW43KA] Travel speed sol discon........................................................ 632 Failure code [DW43KB] Travel speed sol short......................................................... 633 Failure code [DW45KA] Swing brake sol discon......................................................... 634 Failure code [DW45KB] Swing brake sol short.......................................................... 636 Failure code [DWJ0KA] Merge-divider sol discon....................................................... 638 Failure code [DWJ0KB] Merge-divider sol short........................................................ 639 340 Troubleshooting by failure code, Part 4.............................................................. 641 Failure code [DXA8KA] PC-EPC sol discon.............................................................. 642 Failure code [DXA8KB] PC-EPC sol short............................................................... 644 Failure code [DXE7KA] Service current EPC2 open circuit.............................................. 646 Failure code [DXE7KB] Service current EPC2 short circuit............................................. 648 Failure code [DXE8KA] Service current EPC3 open circuit.............................................. 650 Failure code [DXE8KB] Service current EPC3 short circuit............................................. 652 Failure code [DXE9KA] Service current EPC4 open circuit.............................................. 654 Failure code [DXE9KB] Service current EPC4 short circuit............................................. 656 Failure code [DXEAKA] Service current EPC1 open circuit.............................................. 658 Failure code [DXEAKB] Service current EPC1 short circuit............................................. 660 Failure code [DY20KA] Wiper working abnormality...................................................... 662 Failure code [DY20MA] Wiper parking abnormality...................................................... 664 Failure code [DY2CKA] Washer drive open circuit...................................................... 666 Failure code [DY2CKB] Washer drive short circuit..................................................... 668 Failure code [DY2DKB] Wiper drive (fwd) short circuit................................................ 670 Failure code [DY2EKB] Wiper drive (rev) short circuit................................................ 672 400 Troubleshooting of electrical system (E-mode)........................................................ 675 Before carrying out troubleshooting of electrical system............................................. 677 Information in troubleshooting table................................................................. 680 E-1 When starting switch is turned ON, machine monitor displays nothing.............................. 682 E-2 Engine does not start (Engine does not turn)..................................................... 684 E-3 Preheater does not operate....................................................................... 688 E-4 Automatic warm-up system does not operate (in cold season)....................................... 691 E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked.................. 692 E-6 Precaution lights up while engine is running..................................................... 694 E-7 Emergency stop item lights up while engine is running............................................ 698 E-8 Engine coolant temperature gauge does not indicate normally...................................... 699 E-9 Hydraulic oil temperature gauge does not indicate normally....................................... 700 E-10 Fuel level gauge does not indicate normally..................................................... 703 E-11 Contents of display by machine monitor are different from applicable machine.................... 705 E-12 Machine monitor does not display some items..................................................... 705 E-13 Function switch does not work................................................................... 705 E-14 Auto-decelerator does not operate normally...................................................... 706 E-15 Working mode does not change.................................................................... 707 E-16 Travel speed does not change.................................................................... 708 E-17 Alarm buzzer cannot be stopped.................................................................. 709 E-18 Windshield wiper and window washer do not operate............................................... 710 E-19 Swing holding brake does not operate normally................................................... 714 E-20 Travel alarm does not sound or does not stop sounding........................................... 716 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)........ 717 E-22 While starting switch is in OFF position, service meter is not displayed........................ 730 E-23 Machine monitor cannot be set in service mode................................................... 731 E-24 Monitoring function does not display lever control signal normally.............................. 732 E-25 KOMTRAX system does not operate normally........................................................ 752 500 Troubleshooting of hydraulic and mechanical system (H-mode).......................................... 755 Information contained in troubleshooting table....................................................... 757 System chart for hydraulic and mechanical systems.................................................... 758 H-1 Speed or power of all work equipment, swing, and travel are low.................................. 760 H-2 Engine speed sharply drops or engine stalls...................................................... 761 H-3 No work equipment, travel and swing move......................................................... 762 H-4 Abnormal noise is heard from around hydraulic pump............................................... 762 H-5 Fine control performance or response of work equipment and travel is low......................... 763 H-6 Speed or power of boom is low.................................................................... 764 H-7 Speed or power of arm is low..................................................................... 765 H-8 Speed or power of bucket is low.................................................................. 766 H-9 Speed or power of boom swing is low.............................................................. 767 H-10 Speed or power of blade is low.................................................................. 768 H-11 Work equipment does not move in its single operation............................................ 769 H-12 Hydraulic drift of work equipment is large...................................................... 770 H-13 Time lag of work equipment is large............................................................. 772 H-14 Work equipment loaded more is slower during compound operation.................................. 772 H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE............................. 772 H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel.... 773 H-17 Machine deviates during travel.................................................................. 774 H-18 Travel speed is low............................................................................. 775 H-19 Machine cannot be steered easily or steering power is low....................................... 776 H-20 Travel speed does not change or it is kept low or high.......................................... 777 H-21 Track does not move (only either side).......................................................... 777 H-22 Machine does not swing.......................................................................... 778 H-23 Swing acceleration, swing speed and swing power are low......................................... 779 H-24 Excessive overrun when stopping swing........................................................... 781 H-25 When upper structure stops swinging, it makes large shock....................................... 782 H-26 When upper structure stops swinging, it makes large sound....................................... 782 H-27 Hydraulic drift of swing is large............................................................... 783 H-28 Flow rate in attachment circuit cannot be adjusted.............................................. 784 600 Troubleshooting of engine (S-mode)................................................................... 787 Method of using troubleshooting chart................................................................ 788 S-1 Starting performance is poor..................................................................... 792 S-2 Engine does not start............................................................................ 793 S-3 Engine does not pick up smoothly................................................................. 796 S-4 Engine stops during operations................................................................... 797 S-5 Engine does not rotate smoothly.................................................................. 798 S-6 Engine lacks output (or lacks power)............................................................. 799 S-7 Exhaust smoke is black (incomplete combustion)................................................... 800 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................... 801 S-9 Oil becomes contaminated quickly................................................................. 802 S-10 Fuel consumption is excessive................................................................... 803 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........................... 804 S-12 Oil pressure drops.............................................................................. 805 S-13 Oil level rises (Entry of coolant or fuel)...................................................... 806 S-14 Coolant temperature becomes too high (overheating).............................................. 807 S-15 Abnormal noise is made.......................................................................... 808 S-16 Vibration is excessive.......................................................................... 809 50 Disassembly and assembly.................................................................................. 0 100 General information on disassembly and assembly...................................................... 811 How to read this manual.............................................................................. 812 Coating materials list............................................................................... 814 Special tool list.................................................................................... 817 Sketches of special tools............................................................................ 821 200 Engine and cooling system............................................................................ 827 Removal and installation of fuel supply pump assembly................................................ 828 Removal and installation of fuel injector assembly................................................... 832 Removal and installation of engine front seal........................................................ 836 Removal and installation of engine rear seal......................................................... 837 Removal and installation of cylinder head assembly................................................... 839 Removal and installation of radiator assembly........................................................ 850 Removal and installation of aftercooler assembly..................................................... 853 Removal and installation of hydraulic oil cooler assembly............................................ 855 Removal and installation of engine and hydraulic pump assembly....................................... 858 Removal and installation of fuel tank assembly....................................................... 868 Removal and installation of fuel tank assembly....................................................... 869 300 Power train.......................................................................................... 873 Removal and installation of travel motor and final drive assembly.................................... 875 Disassembly and assembly of travel motor and final drive assembly.................................... 877 Removal and installation of swing motor and swing machinery assembly................................. 915 Disassembly and assembly of swing machinery.......................................................... 917 Removal and installation of swing circle assembly.................................................... 926 400 Undercarriage and frame.............................................................................. 929 Disassembly and assembly of track roller assembly.................................................... 930 Disassembly and assembly of idler assembly........................................................... 933 Disassembly and assembly of recoil spring assembly................................................... 936 Spreading and installation of track shoe assembly.................................................... 938 Removal and installation of sprocket................................................................. 940 Removal and installation of revolving frame assembly................................................. 941 Removal and installation of counterweight assembly................................................... 944 500 Hydraulic system..................................................................................... 949 Removal and installation of center swivel joint assembly............................................. 950 Disassembly and assembly of center swivel joint assembly............................................. 952 Removal and installation of hydraulic tank assembly.................................................. 954 Removal and installation of hydraulic pump assembly.................................................. 957 Removal and installation of control valve assembly................................................... 961 Disassembly and assembly of control valve assembly................................................... 969 Disassembly and assembly of work equipment PPC valve assembly........................................ 975 Disassembly and assembly of travel PPC valve assembly................................................ 977 Removal and installation of boom swing cylinder assembly............................................. 979 Disassembly and assembly of hydraulic cylinder assembly.............................................. 982 600 Work equipment....................................................................................... 989 Removal and installation of work equipment assembly.................................................. 990 Removal and installation of boom swing bracket....................................................... 993 Removal and installation of blade assembly........................................................... 997 700 Cab and its attachments..............................................................................1001 Removal and installation of operator cab assembly....................................................1002 Removal and installation of operator's cab glass (Stuck glass).......................................1007 Removal and installation of front window assembly....................................................1017 Removal and installation of floor frame assembly.....................................................1018 800 Electrical system....................................................................................1025 Removal and installation of air conditioner compressor assembly......................................1026 Removal and Installation of air conditioner condenser assembly.......................................1027 Removal and installation of air conditioner unit assembly............................................1028 Removal and installation of machine monitor assembly.................................................1032 Removal and installation of pump controller assembly.................................................1034 Removal and installation of engine controller assembly...............................................1036 Removal and installation of KOMTRAX terminal assembly................................................1038 90 Diagrams and drawings..................................................................................... 0 100 Hydraulic diagrams and drawings......................................................................1041 Hydraulic circuit diagram............................................................................1043 200 Electrical diagrams and drawings.....................................................................1048 Electrical circuit diagram...........................................................................1050 Electrical circuit diagram of the air conditioner unit...............................................1062 Connector list and stereogram........................................................................1063
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