Komatsu PC88MR-8 Hydraulic Excavator Shop Manual WENBM00020 PDF

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Komatsu PC88MR-8 Hydraulic Excavator Shop Manual WENBM00020 – PDF DOWNLOAD

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Komatsu PC88MR-8 Hydraulic Excavator Shop Manual WENBM00020 – PDF DOWNLOAD 

Language : English
Pages : 1056
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC88MR-8 Hydraulic Excavator Shop Manual WENBM00020 – PDF DOWNLOAD 

SERIAL NUMBERS F80003 and up

How to read the shop manual 
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section 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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
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 instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by 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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC88MR-8 Hydraulic Excavator Shop Manual WENBM00020 – PDF DOWNLOAD

SERIAL NUMBERS F80003 and up

00 Index and foreword 3
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 57
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 andmaintenance standard 67
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 134
Functions and operation by valve 138
430 Hydraulic system, Part 3 169
PPC valve 171
Swing motor 183
Travel motor 193
Center swivel joint 201
Solenoid valve 202
PPC accumulator 209
Anti-drop valve 212
500 Work equipment 219
Work equipment 220
Dimensions of components 222
Work equipment cylinder 228
600 Cab and its attachments 233
Air conditioner 234
700 Electrical system 247
Electrical control system 248
Monitor system 282
KOMTRAX system 296
Sensor 298
20 Standard value table 305
100 Standard service value table 305
Standard value table for engine related parts 306
Standard value table for chassis 307
30 Testing and adjusting 317
110 Testing and adjusting, Part 1 317
Tools for testing, adjusting, and troubleshooting 319
Testing engine speed 324
Testing exhaust temperature 325
Checking exhaust gas color 326
Adjusting valve clearance 327
Testing compression pressure 329
Testing blow-by pressure 331
Testing engine oil pressure 332
Handling fuel system parts 333
Releasing residual pressure from fuel system 333
Testing fuel pressure 334
Testing fuel return rate and fuel leakage 335
Bleeding air from fuel circuit 337
Checking fuel circuit for leakage 339
Testing and adjusting fan belt tension 340
Checking and adjusting air conditioner compressor belt tension 342
Testing swing circle bearing clearance 343
Checking and adjusting track shoe tension 344
Testing and adjusting oil pressure in work equipment and travel circuits 346
Testing and adjusting swing and blade circuit oil pressure 348
Testing control circuit basic pressure 351
Testing and adjusting oil pressure in pump PC control circuit 352
Testing PC-EPC solenoid output pressure 355
Testing LS differential pressure and adjusting LS valve 356
Testing solenoid valve output pressure 358
Testing PPC valve output pressure 359
Adjusting play of work equipment and swing PPC valves 361
Checking parts which cause hydraulic drift of work equipment 362
Testing and adjusting travel deviation 364
Releasing residual pressure from hydraulic circuit 366
Testing oil leakage 367
Bleeding air from each part 370
Adjusting mirrors 372
Testing and adjusting hood catch 373
120 Testing and adjusting, Part 2 377
Special functions of machine monitor 378
130 Testing and adjusting, Part 3 429
Handling voltage circuit of engine controller 430
Preparation work for troubleshooting of electrical system 431
Procedure for testing diodes 436
Pm Clinic service 437
40 Troubleshooting 443
100 Failure code table and fuse locations 443
Failure code table 444
Fuse locations 447
200 General information on troubleshooting 451
Points to remember when troubleshooting 452
Sequence of events in troubleshooting 453
Checks before troubleshooting 454
Classification and procedures for troubleshooting 455
Information in troubleshooting table 456
Phenomena looking like troubles and troubleshooting Nos 458
Connection table for connector pin numbers 461
T- branch box and T- branch adapter table 497
310 Troubleshooting by failure code, Part 1 501
Failure code [989L00] Engine controller lock caution 1 503
Failure code [989M00] Engine controller lock caution 2 504
Failure code [989N00] Engine controller lock caution 3 505
Failure code [AB00KE] Charge voltage low 506
Failure code [B@BAZG] Eng oil press low 508
Failure code [B@BCNS] Eng coolant overheat 509
Failure code [B@HANS] Hyd oil overheat 509
Failure code [CA111] ECM critical internal failure 510
Failure code [CA115] Eng Ne and Bkup speed sensor error 513
Failure code [CA122] Charge air press sensor high error 515
Failure code [CA123] Charge air press sensor low error 517
Failure code [CA131] Throttle sensor high error 518
Failure code [CA132] Throttle sensor low error 520
Failure code [CA144] Coolant temp sensor high error 522
Failure code [CA145] Coolant temp sensor low error 524
Failure code [CA153] Charge air temp sensor high error 526
Failure code [CA154] Charge air temp sensor low error 528
Failure code [CA187] Sensor sup 2 volt low error 529
Failure code [CA221] Ambient air press sensor high error 530
Failure code [CA222] Ambient air press sensor low error 532
Failure code [CA227] Sensor sup 2 volt high error 533
Failure code [CA234] Eng overspeed 534
Failure code [CA238] Ne speed sensor sup volt error 536
Failure code [CA271] IMV/PCV1 short error 538
Failure code [CA272] IMV/PCV1 open error 539
Failure code [CA322] Injector #1 (L #1) system open/short error 540
Failure code [CA324] Injector #3 (L #3) system open/short error 542
Failure code [CA331] Injector #2 (L #2) system open/short error 544
Failure code [CA332] Injector #4 (L #4) system open/short error 546
320 Troubleshooting by failure code, Part 2 549
Failure code [CA351] Inj drive circuit error 551
Failure code [CA352] Sensor sup 1 volt low error 554
Failure code [CA386] Sensor sup 1 volt high error 556
Failure code [CA435] Abnormality in engine oil pressure switch 558
Failure code [CA441] Battery voltage low error 559
Failure code [CA442] Battery voltage high error 560
Failure code [CA449] Rail press very high error 561
Failure code [CA451] Rail press sensor high error 562
Failure code [CA452] Rail press sensor low error 564
Failure code [CA553] Rail press high error 564
Failure code [CA559] Rail press low error 565
Failure code [CA689] Eng Ne speed sensor error 568
Failure code [CA731] Eng Bkup speed sensor phase error 570
Failure code [CA757] All persistent data lost error 571
Failure code [CA778] Eng Bkup speed sensor error 572
Failure code [CA1633] KOMNET datalink timeout error 574
Failure code [CA2185] Throttle sens sup volt high error 576
Failure code [CA2186] Throttle sens sup volt low error 578
Failure code [CA2249] Rail press very low error 579
Failure code [CA2311] Abnormality in IMV solenoid 580
Failure code [D110KB] Battery relay drive short 581
Failure code [D19JKZ] Personal code relay abnormality 583
Failure code [D862KA] GPS antenna discon 586
Failure code [DA22KK] Pump solenoid power low error 587
Failure code [DA25KP] 5 V sensor 1 power abnormality 589
Failure code [DA26KP] 5 V sensor 2 power abnormality 592
330 Troubleshooting by failure code, Part 3 595
Failure code [DA2RMC] CAN discon (Pump controller detected) 596
Failure code [DAFGMC] GPS module error 598
Failure code [DAFRMC] CAN discon (Monitor detected) 600
Failure code [DFB1KZ] Service lever pot 1 abnormality 602
Failure code [DFB2KZ] Service lever pot 2 abnormality 604
Failure code [DFB3L8] Service lever1 potentio error 606
Failure code [DFB4L8] Service lever2 potentio error 608
Failure code [DFB5KZ] Service lever sPot 1 abnormality 610
Failure code [DFB6KZ] Service lever sPot 2 abnormality 612
Failure code [DGH2KB] Hydr oil sensor short 614
Failure code [DHPAMA] Pump press sensor abnormality 616
Failure code [DHS5KX] Travel PPC sensor abnormality 618
Failure code [DHSAMA] Swing RH PPC press sensor abnormality 620
Failure code [DHSBMA] Swing LH PPC press sensor abnormality 622
Failure code [DHX1MA] Overload sensor abnormality 624
Failure code [DV20KB] Travel alarm short circuit 625
Failure code [DW43KA] Travel speed sol discon 626
Failure code [DW43KB] Travel speed sol short 627
Failure code [DW45KA] Swing brake sol discon 628
Failure code [DW45KB] Swing brake sol short 630
Failure code [DWJ0KA] Merge-divider sol discon 632
Failure code [DWJ0KB] Merge-divider sol short 633
340 Troubleshooting by failure code, Part 4 635
Failure code [DXA8KA] PC-EPC sol discon 636
Failure code [DXA8KB] PC-EPC sol short 638
Failure code [DXE7KA] Service current EPC2 open circuit 640
Failure code [DXE7KB] Service current EPC2 short circuit 642
Failure code [DXE8KA] Service current EPC3 open circuit 644
Failure code [DXE8KB] Service current EPC3 short circuit 646
Failure code [DXE9KA] Service current EPC4 open circuit 648
Failure code [DXE9KB] Service current EPC4 short circuit 650
Failure code [DXEAKA] Service current EPC1 open circuit 652
Failure code [DXEAKB] Service current EPC1 short circuit 654
Failure code [DY20KA] Wiper working abnormality 656
Failure code [DY20MA] Wiper parking abnormality 658
Failure code [DY2CKA] Washer drive open circuit 660
Failure code [DY2CKB] Washer drive short circuit 662
Failure code [DY2DKB] Wiper drive (fwd) short circuit 664
Failure code [DY2EKB] Wiper drive (rev) short circuit 666
400 Troubleshooting of electrical system (E-mode) 669
Before carrying out troubleshooting of electrical system 671
Information in troubleshooting table 673
E-1 When starting switch is turned ON, machine monitor displays nothing 674
E-2 Engine does not start (Engine does not turn) 676
E-3 Preheater does not operate 679
E-4 Automatic warm-up system does not operate (in cold season) 681
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked 682
E-6 Precaution lights up while engine is running 684
E-7 Emergency stop item lights up while engine is running 687
E-8 Engine coolant temperature gauge does not indicate normally 688
E-9 Hydraulic oil temperature gauge does not indicate normally 689
E-10 Fuel level gauge does not indicate normally 692
E-11 Contents of display by machine monitor are different from applicable machine 694
E-12 Machine monitor does not display some items 694
E-13 Function switch does not work 694
E-14 Auto-decelerator does not operate normally 695
E-15 Working mode does not change 696
E-16 Travel speed does not change 697
E-17 Alarm buzzer cannot be stopped 698
E-18 Windshield wiper and window washer do not operate 699
E-19 Swing holding brake does not operate normally 703
E-20 Travel alarm does not sound or does not stop sounding 705
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) 706
E-22 While starting switch is in OFF position, service meter is not displayed 719
E-23 Machine monitor cannot be set in service mode 720
E-24 Monitoring function does not display lever control signal normally 721
E-25 KOMTRAX system does not operate normally 741
500 Troubleshooting of hydraulic and mechanical system (H-mode) 743
Information contained in troubleshooting table 745
System chart for hydraulic and mechanical systems 746
H-1 Speed or power of all work equipment, swing, and travel are low 748
H-2 Engine speed sharply drops or engine stalls 749
H-3 No work equipment, travel and swing move 750
H-4 Abnormal noise is heard from around hydraulic pump 750
H-5 Fine control performance or response of work equipment and travel is low 751
H-6 Speed or power of boom is low 752
H-7 Speed or power of arm is low 753
H-8 Speed or power of bucket is low 754
H-9 Speed or power of boom swing is low 755
H-10 Speed or power of blade is low 756
H-11 Work equipment does not move in its single operation 757
H-12 Hydraulic drift of work equipment is large 758
H-13 Time lag of work equipment is large 760
H-14 Work equipment loaded more is slower during compound operation 760
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE 760
H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel 761
H-17 Machine deviates during travel 762
H-18 Travel speed is low 763
H-19 Machine cannot be steered easily or steering power is low 764
H-20 Travel speed does not change or it is kept low or high 765
H-21 Track does not move (only either side) 765
H-22 Machine does not swing 766
H-23 Swing acceleration, swing speed and swing power are low 767
H-24 Excessive overrun when stopping swing 769
H-25 When upper structure stops swinging, it makes large shock 770
H-26 When upper structure stops swinging, it makes large sound 770
H-27 Hydraulic drift of swing is large 771
H-28 Flow rate in attachment circuit cannot be adjusted 772
600 Troubleshooting of engine (S-mode) 775
Method of using troubleshooting chart 776
S-1 Starting performance is poor 780
S-2 Engine does not start 781
S-3 Engine does not pick up smoothly 784
S-4 Engine stops during operations 785
S-5 Engine does not rotate smoothly 786
S-6 Engine lacks output (or lacks power) 787
S-7 Exhaust smoke is black (incomplete combustion) 788
S-8 Oil consumption is excessive (or exhaust smoke is blue) 789
S-9 Oil becomes contaminated quickly 790
S-10 Fuel consumption is excessive 791
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 792
S-12 Oil pressure drops 793
S-13 Oil level rises (Entry of coolant or fuel) 794
S-14 Coolant temperature becomes too high (overheating) 795
S-15 Abnormal noise is made 796
S-16 Vibration is excessive 797
50 Disassembly and assembly 799
100 General information on disassembly and assembly 799
How to read this manual 800
Coating materials list 802
Special tool list 805
Sketches of special tools 809
200 Engine and cooling system 815
Removal and installation of fuel supply pump assembly 816
Removal and installation of fuel injector assembly 820
Removal and installation of engine front seal 824
Removal and installation of engine rear seal 825
Removal and installation of cylinder head assembly 827
Removal and installation of radiator assembly 838
Removal and installation of aftercooler assembly 841
Removal and installation of hydraulic oil cooler assembly 843
Removal and installation of engine and hydraulic pump assembly 846
Removal and installation of engine hood assembly 856
300 Power train 861
Removal and installation of travel motor and final drive assembly 863
Disassembly and assembly of travel motor and final drive assembly 865
Removal and installation of swing motor and swing machinery assembly 903
Disassembly and assembly of swing machinery 905
Removal and installation of swing circle assembly 914
400 Undercarriage and frame 917
Disassembly and assembly of track roller assembly 918
Disassembly and assembly of idler assembly 921
Disassembly and assembly of recoil spring assembly 924
Spreading and installation of track shoe assembly 926
Removal and installation of sprocket 928
Removal and installation of revolving frame assembly 929
Removal and installation of counterweight assembly 932
500 Hydraulic system 937
Removal and installation of center swivel joint assembly 938
Disassembly and assembly of center swivel joint assembly 940
Removal and installation of hydraulic tank assembly 942
Removal and installation of hydraulic pump assembly 945
Removal and installation of control valve assembly 949
Disassembly and assembly of control valve assembly 957
Disassembly and assembly of work equipment PPC valve assembly 963
Disassembly and assembly of travel PPC valve assembly 965
Removal and installation of boom swing cylinder assembly 967
Disassembly and assembly of hydraulic cylinder assembly 970
600 Work equipment 977
Removal and installation of work equipment assembly 978
Removal and installation of boom swing bracket 981
Removal and installation of blade assembly 985
700 Cab and its attachments 989
Removal and installation of operator cab assembly 990
Removal and installation of operator’s cab glass (Stuck glass) 995
Removal and installation of front window assembly 1005
Removal and installation of floor frame assembly 1006
800 Electrical system 1013
Removal and installation of air conditioner compressor assembly 1014
Removal and Installation of air conditioner condenser assembly 1015
Removal and installation of air conditioner unit assembly 1016
Removal and installation of machine monitor assembly 1020
Removal and installation of pump controller assembly 1022
Removal and installation of engine controller assembly 1024
Removal and installation of KOMTRAX terminal assembly 1026
90 Diagrams and drawings 1029
100 Hydraulic diagrams and drawings 1029
Hydraulic circuit diagram 1031
Hydraulic circuit diagram (1/2) 1031
Hydraulic circuit diagram (2/2) 1033
200 Electrical diagrams and drawings 1037
Electrical circuit diagram 1039
Electrical circuit diagram 1041
Electrical circuit diagram 1043
Electrical circuit diagram 1045
Electrical circuit diagram 1047
Electrical circuit diagram 1049
Electrical circuit diagram of the air conditioner unit 1051
Connector list and stereogram 1053

S.V 12/12/24