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PC88MR-10
Komatsu PC88MR-10 Hydraulic Excavator Manuals
Manuals and User Guides for Komatsu PC88MR-10 Hydraulic Excavator. We have
2
Komatsu PC88MR-10 Hydraulic Excavator manuals available for free PDF download: Shop Manual, Operation & Maintenance Manual
Komatsu PC88MR-10 Shop Manual (1435 pages)
HYDRAULIC EXCAVATOR
Brand:
Komatsu
| Category:
Excavators
| Size: 52.82 MB
Table of Contents
Specification
68
Table of Contents
4
Index
5
00 Index and Foreword
15
Foreword, Safety and General Information
15
Important Safety Notice
15
How to Read the Shop Manual
22
Explanation of Terms for Maintenance Standard
24
Handling Equipment of Fuel System Devices
26
Handling of Intake System Parts
27
Handling of Hydraulic Equipment
28
Method of Disconnecting and Connecting of Push-Pull Type Coupler
30
Handling of Electrical Equipment
33
How to Read Electric Wire Code
41
Precautions When Performing Operation
44
Practical Use of KOMTRAX
49
Standard Tightening Torque Table
50
List of Abbreviation
56
Conversion Table
61
01 Specification
67
Table of Contents
68
Specifications
69
Specification Drawing
69
Working Range Drawings
70
Specifications
71
Weight Table
75
Table of Fuel, Coolant, and Lubricants
77
10 Structure and Function
79
Shop Manual Hydraulic Excavator
80
Table of Contents
80
Engine and Cooling System
81
Engine Related Parts
81
Pto
83
Variable Flow Turbocharger
84
EGR System Piping Drawing
88
EGR System Circuit Diagram
90
EGR Valve
91
EGR Cooler
93
KCCV Layout Drawing
95
KCCV Ventilator
98
KDOC Muffler
100
Cooling System
102
Power Train
105
Power Train System
105
Swing Circle
107
Swing Machinery
109
Undercarriage and Frame
111
Track Frame
111
Idler Cushion
113
Hydraulic System
114
Hydraulic Component Layout
114
Valve Control
116
Hydraulic Tank
118
Clss
122
Main Pump
126
Control Valve
138
Swing Motor
186
Travel Motor
197
Work Equipment and Swing PPC Valve
208
Travel PPC Valve
215
Blade PPC Valve
221
Boom Swing PPC Valve
223
Solenoid Valve
225
Multi-Control Valve
229
Anti-Drop Valve for Boom
230
Anti-Drop Valve for Arm
234
Center Swivel Joint
238
Accumulator
239
Work Equipment
241
Work Equipment Shim
242
Bucket Play Adjustment Shim
243
Cab and Its Attachments
244
Cab Mount and Cab Tipping Stopper
244
ROPS Cab
246
Electrical System
248
Electrical Control System
248
Machine Monitor System
292
KOMTRAX System
314
Sensor
316
20 Standard Value Tables
325
Standard Value Tables
326
Table of Contents
326
Standard Service Value Table
327
Standard Value Table for Engine
327
Standard Value Table for Machine
329
Standard Value Table for Electrical System
345
30 Testing and Adjusting
351
Shop Manual Hydraulic Excavator
352
Table of Contents
352
Related Information on Testing and Adjusting
353
Tools for Testing and Adjusting
353
Sketch of Tools for Testing and Adjusting
356
Engine and Cooling System
358
Testing Engine Speed
358
Testing Exhaust Gas Color
359
Testing and Adjusting Valve Clearance
360
Testing Compression Pressure
362
Testing Blowby Pressure
364
Testing Engine Oil Pressure
365
Testing Fuel Pressure
366
Testing Fuel Return Rate and Leakage
367
Bleeding Air from Fuel System
370
Testing Fuel Circuit for Leakage
372
Handling Cylinder Cutout Mode Operation
373
Handling No-Injection Cranking Operation
374
Testing and Adjusting Air Conditioner Compressor Belt Tension
375
Check Fan Belt, Replace
376
Check Auto-Tensioner, Replace
378
Writing Compensation Values at Replacement of Injector and Engine Controller
381
Power Train
385
Testing Swing Circle Bearing Clearance
385
Undercarriage and Frame
386
Testing and Adjusting Track Tension
386
Hydraulic System
387
Releasing Remaining Pressure from Hydraulic Circuit
387
Testing and Adjusting Oil Pressure in Work Equipment and Travel Circuits
392
Testing and Adjusting Swing and Blade Circuit Oil Pressure
395
Testing Oil Pressure of Control Circuit
398
Testing and Adjusting Oil Pressure in Pump PC Control Circuit
399
Testing and Adjusting Oil Pressure in Pump LS Control Circuit
402
Testing Outlet Pressure of Solenoid Valve
405
Testing PPC Valve Outlet Pressure
406
Adjusting Play of Work Equipment and Swing PPC Valves
407
Isolating the Parts Causing Hydraulic Drift in Work Equipment
408
Testing and Adjusting Travel Deviation
409
Testing Oil Leakage
411
Bleeding Air from Hydraulic Circuit
415
Cab and Its Attachments
418
Testing, Cleaning and Lubricating Slide Door Rail and Roller
418
Adjusting Mirrors
419
Testing and Adjusting Hood Catcher
421
Electrical System
423
Special Functions of Machine Monitor
423
KOMTRAX Terminal Start-Up Procedure
471
Adjusting Rearview Camera Angle
475
Handling Voltage Circuit of Engine Controller
477
Handling Battery Disconnect Switch
478
Testing Diodes
479
Pm Clinic
480
Pm Clinic Service
480
40 Troubleshooting
489
Shop Manual Hydraulic Excavator
490
Table of Contents
490
Related Information on Troubleshooting
496
Troubleshooting Points
496
Sequence of Events in Troubleshooting
498
Checks before Troubleshooting
500
Inspection Procedure before Troubleshooting
502
Preparation for Troubleshooting of Electrical System
519
Classification and Procedures for Troubleshooting
524
Symptom and Troubleshooting Numbers
527
Information in Troubleshooting Table
530
Troubleshooting Method for Open Circuit in Wiring Harness of Pressure Sensor System
532
Connector List and Layout
534
Connector Contact Identification
543
T-Branch Box and T-Branch Adapter Table
582
Fuse Location Table
587
Failure Codes Table
589
Troubleshooting by Failure Code (Display of Code)
596
Failure Code [879AKA] A/C Recirc Air Temp Sens Open Circuit
596
Failure Code [879AKB] A/C Recirc Air Temp Sens Short
597
Failure Code [879BKA] A/C Fresh Air Temp Sens Open Circuit
598
Failure Code [879BKB] A/C Fresh Air Temp Sens Short Circuit
599
Failure Code [879CKA] Ventilating Sensor Open Circuit
600
Failure Code [879CKB] Ventilating Sensor Short Circuit
601
Failure Code [879DKZ] Sunlight Sensor Open or Short Circuit
602
Failure Code [879EMC] Ventilation Damper Malfunction
603
Failure Code [879FMC] Air MIX Damper Malfunction
604
Failure Code [879GKX] Refrigerant Press Input Sig out of Range
605
Failure Code [989L00] Engine Controller Lock Caution 1
606
Failure Code [989M00] Engine Controller Lock Caution 2
607
Failure Code [989N00] Engine Controller Lock Caution 3
608
Failure Code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3
609
Failure Code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1
610
Failure Code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2
611
Failure Code [AB00KE] Charge Voltage Low
612
Failure Code [B@BAZG] Eng Oil Press Low
614
Failure Code [B@BCNS] Eng Water Overheat
615
Failure Code [CA115] Eng Ne and Bkup Speed Sens Error
616
Failure Code [CA122] Charge Air Pressure Sensor High Error
617
Failure Code [CA123] Charge Air Pressure Sensor Low Error
619
Failure Code [CA131] Throttle Sensor High Error
621
Failure Code [CA132] Throttle Sensor Low Error
623
Failure Code [CA144] Coolant Temperature Sensor High Error
625
Failure Code [CA145] Coolant Temperature Sensor Low Error
627
Failure Code [CA153] Charge Air Temperature Sensor High Error
629
Failure Code [CA154] Charge Air Temperature Sensor Low Error
631
Failure Code [CA187] Sensor 2 Supply Voltage Low Error
633
Failure Code [CA221] Ambient Pressure Sensor High Error
635
Failure Code [CA222] Ambient Pressure Sensor Low Error
637
Failure Code [CA227] Sensor 2 Supply Voltage High Error
639
Failure Code [CA234] Engine Overspeed
640
Failure Code [CA238] NE Speed Sensor Supply Voltage Error
641
Failure Code [CA239] NE Speed Sensor Supply Voltage High Error
642
Failure Code [CA271] PCV1 Short Circuit Error
643
Failure Code [CA272] PCV1 Open Circuit Error
644
Failure Code [CA322] Injector #1 (L#1) Open or Short Circuit
645
Failure Code [CA324] Injector #3 (L#3) Open or Short Circuit
647
Failure Code [CA331] Injector #2 (L#2) Open or Short Circuit
649
Failure Code [CA332] Injector #4 (L#4) Open or Short Circuit
651
Failure Code [CA343] Engine Controller Internal Failure
653
Failure Code [CA351] Injectors Drive Circuit Error
654
Failure Code [CA352] Sensor1 Supply Voltage Low Error
655
Failure Code [CA356] MAF Sensor High Error
657
Failure Code [CA357] MAF Sensor Low Error
659
Failure Code [CA386] Sensor1 Supply Voltage High Error
661
Failure Code [CA435] Engine Oil Pressure SW Error
662
Failure Code [CA441] Battery Voltage Low Error
663
Failure Code [CA442] Battery Voltage High Error
665
Failure Code [CA449] Common Rail Pressure High Error 2
666
Failure Code [CA451] Common Rail Pressure Sensor High Error
667
Failure Code [CA452] Common Rail Pressure Sensor Low Error
669
Failure Code [CA466] KVGT Motor Driver Position Error
671
Failure Code [CA515] Rail Pressure Sensor Sup Volt High Error
673
Failure Code [CA516] Rail Pressure Sensor Sup Volt Low Error
675
Failure Code [CA553] Common Rail Pressure High Error 1
677
Failure Code [CA555] Crankcase Pressure High Error 1
678
Failure Code [CA556] Crankcase Pressure High Error 2
679
Failure Code [CA559] Common Rail Pressure Low Error 1
680
Failure Code [CA689] Engine NE Speed Sensor Error
683
Failure Code [CA691] Intake Air Temperature Sensor High Error
685
Failure Code [CA692] Intake Air Temperature Sensor Low Error
687
Failure Code [CA697] Engine con Internal Temp Sens High Error
689
Failure Code [CA698] Engine con Internal Temp Sens Low Error
690
Failure Code [CA731] Engine Backup Speed Sensor Phase Error
691
Failure Code [CA778] Engine Backup Speed Sensor Error
693
Failure Code [CA1117] Engine Controller Partial Data Lost Error
697
Failure Code [CA1695] Sensor 5 Supply Voltage High Error
698
Failure Code [CA1696] Sensor 5 Supply Voltage Low Error
699
Failure Code [CA1843] Crankcase Pressure Sensor High Error
700
Failure Code [CA1844] Crankcase Pressure Sensor Low Error
702
Failure Code [CA1896] EGR Valve Stuck Error
704
Failure Code [CA1942] Crankcase Pressure Sensor in Range Error
705
Failure Code [CA1961] Egr_Motor Driver IC over Temp Error
706
Failure Code [CA2185] Throttle Sensor Supply Voltage High Error
707
Failure Code [CA2186] Throttle Sensor Supply Voltage Low Error
709
Failure Code [CA2249] Common Rail Pressure Low Error 2
711
Failure Code [CA2272] EGR Valve Position Sensor Low Error
712
Failure Code [CA2311] IMV Solenoid Error
714
Failure Code [CA2349] EGR Valve Solenoid Open Circuit Error
715
Failure Code [CA2353] EGR Valve Solenoid Short Circuit Error
717
Failure Code [CA2357] EGR Valve Servo Error
719
Failure Code [CA2765] Injector Trim Data Mismatch
720
Failure Code [CA3419] MAF Sensor Supply Voltage High Error
721
Failure Code [CA3421] MAF Sensor Supply Voltage Low Error
723
Failure Code [CA3724] EGR/KVGT Motor Driver Power Low Error
725
Failure Code [CA3918] KVGT Stuck Error
727
Failure Code [CA3919] KVGT Motor Driver IC over Temp Error
728
Failure Code [CA3921] KVGT Servo Error 2
729
Failure Code [CA3922] KVGT Motor Driver Open Error
730
Failure Code [CA3923] KVGT Motor Driver Short Error
732
Failure Code [D110KB] Battery Relay Output Short Circuit
734
Failure Code [D19JKZ] Personal Code Relay Open or Short
736
Failure Code [D811MC] KOMTRAX Malfunction
739
Failure Code [D862KA] GPS Antenna Open Circuit
740
Failure Code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
741
Failure Code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
743
Failure Code [D8AQKR] CAN 2 Defective Communication (KOMTRAX)
744
Failure Code [DA20MC] Pump Controller Malfunction
746
Failure Code [DA22KK] Pump con Solenoid Power Volt Low Error
747
Failure Code [DA25KP] 5V Sensor 1 Power Voltage Low Error
749
Failure Code [DA29KQ] Model Selection Sig Mismatch (Pump Con)
751
Failure Code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
753
Failure Code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
755
Failure Code [DA2QKR] CAN 2 Defective Communication (Pump Con)
756
Failure Code [DA2RKR] CAN 1 Defective Communication (Pump Con)
758
Failure Code [DAF0MB] Monitor ROM Abnormality
759
Failure Code [DAF0MC] Monitor Malfunction
760
Failure Code [DAF8KB] Camera Power Supply Short Circuit
761
Failure Code [DAF9KQ] Model Selection Signal Mismatch (Monitor)
762
Failure Code [DAFGMC] GPS Module Malfunction
763
Failure Code [DAFLKA] Operating Lamp Open Circuit (Monitor)
764
Failure Code [DAFLKB] Operating Lamp Short Circuit (Monitor)
766
Failure Code [DAFQKR] CAN 2 Defective Communication (Monitor)
767
Failure Code [DAZ9KQ] Model Selection Sig Mismatch (A/C)
768
Failure Code [DAZQKR] CAN2 Defective Communication (A/C ECU)
769
Failure Code [DB2QKR] CAN2 Defective Communication (Engine Con)
773
Failure Code [DB2RKR] CAN1 Defective Communication (Engine Con)
777
Failure Code [DDNRKA] WE Lever Lock SW Open Circuit
781
Failure Code [DDNRKY] WE Lever Lock SW Short Circuit
783
Failure Code [DDNS00] Lock Lever Auto Lock Release SW on
785
Failure Code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault
787
Failure Code [DHPAMA] Front Pump Press Sens Defective Function
789
Failure Code [DHS3MA] Arm in PPC Press Sensor Def Function
791
Failure Code [DHS4MA] Bucket CURL PPC Press Sens Def Function
793
Failure Code [DHS5MA] Travel PPC Sensor Abnormality
795
Failure Code [DHS8MA] Boom Raise PPC Press Sens Def Function
797
Failure Code [DHS9MA] Boom Lower PPC Press Sens Def Function
799
Failure Code [DHSAMA] Swing Right PPC Press Sens Def Function
801
Failure Code [DHSBMA] Swing Left PPC Press Sensor Def Function
803
Failure Code [DHSCMA] Arm out PPC Press Sens Def Function
805
Failure Code [DHSDMA] Bucket DUMP PPC Press Sens Def Function
807
Failure Code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality
809
Failure Code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality
811
Failure Code [DKULKA] PPC Lock Relay Open Circuit
813
Failure Code [DKULKB] PPC Lock Relay Short Circuit
815
Failure Code [DKULKY] PPC Lock Relay Hot Short Circuit
817
Failure Code [DV20KB] Travel Alarm Short Circuit
819
Failure Code [DW43KA] Travel Speed Solenoid Open Circuit
821
Failure Code [DW43KB] Travel Speed Solenoid Short Circuit
823
Failure Code [DW43KY] Travel Speed Sol Hot Short Circuit
825
Failure Code [DW45KA] Swing Parking Brake Solenoid Open Circuit
826
Failure Code [DW45KB] Swing Parking Brake Solenoid Short Circuit
829
Failure Code [DW45KY] Swing Brake Sol Hot Short Circuit
831
Failure Code [DW4CKY] PPC Lock Sol Hot Short Circuit
833
Failure Code [DWJ0KA] Merge-Divider Sol Open Circuit
835
Failure Code [DWJ0KB] Merge-Divider Sol Short Circuit
837
Failure Code [DWJ0KY] Merge-Divider Sol Short Circuit
839
Failure Code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit
840
Failure Code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit
842
Failure Code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit
844
Failure Code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit
846
Circuit
846
Failure Code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit
850
Failure Code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit
852
Failure Code [DXEAKY] Service Current EPC5 Hot Short Circuit
854
Failure Code [DY20KA] Wiper Motor Open Circuit
856
Failure Code [DY20MA] Wiper Motor Defective Function
858
Failure Code [DY2CKB] Washer Motor Short Circuit
860
Failure Code [DY2DKB] Wiper Motor (Normal) Short Circuit
862
Failure Code [DY2EKB] Wiper Motor (Reverse) Short Circuit
864
Troubleshooting of Electrical System (E-Mode)
866
Engine Does Not Start (Engine Does Not Crank)
866
E-2 Manual Preheating System Does Not Work
872
While Preheating Is Working, Preheating Monitor Does Not Light up
875
When Starting Switch Is Turned to on Position, Machine Monitor Displays Nothing
877
Engine Coolant Temperature Monitor Lights up in White While Engine Is Running
880
Hydraulic Oil Temperature Monitor Lights up in White While Engine Is Running
881
E-7 Charge Level Monitor Lights up While Engine Is Running
882
E-8 Fuel Level Monitor Lights up in Red While Engine Is Running
883
Engine Coolant Temperature Monitor Lights up in Red While Engine Is Running
884
Hydraulic Oil Temperature Monitor Lights up in Red While Engine Is Running
885
Engine Oil Pressure Monitor Lights up in Red While Engine Is Running
886
Fuel Gauge Display Does Not Move from Minimum or Maximum
887
Fuel Gauge Indicates Incorrect Amount (Indicates Neither Full nor Empty)
888
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
889
Engine Coolant Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Full nor Empty)
890
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum
891
Hydraulic Oil Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Full nor Empty)
893
E-18 some Areas of Machine Monitor Screen Are Not Displayed
894
E-19 Function Switch Does Not Work
895
Automatic Warm-Up System Does Not Operate (in Cold Season)
896
Auto-Deceleration Monitor Does Not Light Up, or Does Not Go Out, While Auto-Deceleration Switch Is Operated
897
Auto-Deceleration Function Does Not Operate or Is Not Canceled While Lever Is Operated
898
Working Mode Selection Screen Is Not Displayed While Working Mode Selector Switch Is Operated
900
Setting of Engine and Hydraulic Pump Is Not Changed While Working Mode Is Changed
901
Travel Speed Monitor Does Not Change When Travel Speed Switch Is Operated
902
Travel Speed Does Not Change While Travel Speed Selection Is Changed
903
E-27 Alarm Buzzer Does Not Stop Sounding
904
Service Meter Is Not Displayed, While Starting Switch Is in off Position
905
E-29 Service Mode Cannot be Selected
906
E-30 any of Work Equipment, Swing and Travel Does Not Work
907
E-31 any of Work Equipment, Swing and Travel Cannot be Locked
909
Upper Structure Does Not Swing While Swing Parking Brake Cancel Switch Is Set to CANCEL Position
911
Swing Brake Does Not Operate While Swing Parking Brake Cancel Switch Is Set to NORMAL Position
913
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch Is in Release Position
915
E-35 Alarm Does Not Sound During Travel
917
E-36 Alarm Does Not Stop Sounding While Machine Is Stopped
918
E-37 Horn Does Not Sound
919
E-38 Horn Does Not Stop Sounding
921
Wiper Monitor Does Not Light Up, or Does Not Go Out, While Wiper Switch Is Operated
922
E-40 Wiper Does Not Operate While Wiper Switch Is Operated
923
Window Washer Does Not Operate While Window Washer Switch Is Operated
925
Boom LOWER Is Not Displayed Correctly with Monitoring Function
926
E-43 Arm out Is Not Displayed Correctly with Monitoring Function
927
E-44 Arm in Is Not Displayed Correctly with Monitoring Function
928
Boom RAISE Is Not Displayed Correctly with Monitoring Function
929
Bucket CURL Is Not Displayed Correctly with Monitoring Function
930
Bucket DUMP Is Not Displayed Correctly with Monitoring Function
931
Boom Swing Left Is Not Displayed Correctly with Monitoring Function
932
Boom Swing Right Is Not Displayed Correctly with Monitoring Function
933
E-50 Swing Is Not Displayed Correctly with Monitoring Function
934
E-51 Travel Is Not Displayed Correctly with Monitoring Function
935
Blade RAISE on Is Not Displayed Correctly with Monitoring Function
936
Blade LOWER on Is Not Displayed Correctly with Monitoring Function
938
E-54 KOMTRAX System Does Not Operate Normally
940
Troubleshooting of Hydraulic and Mechanical System (H-Mode)
942
Information Described in Troubleshooting Table (H-Mode)
942
System Chart of Hydraulic and Mechanical Systems
943
Failure Mode and Cause Table
945
All of Work Equipments, Swing and Travel Operations Lack Speed or Power
953
H-2 Engine Speed Drops Significantly or Engine Stalls
955
H-3 any of Work Equipment, Swing and Travel Does Not Work
956
H-4 Unusual Sound Is Heard from Around Hydraulic Pump
957
H-5 Fine Control Performance or Response Is Poor
958
H-6 Boom Speed or Power Is Low
959
H-7 Arm Speed or Power Is Low
962
H-8 Bucket Speed or Power Is Low
964
H-9 Boom Swing Speed or Power Is Low
966
H-10 Blade Speed or Power Is Low
968
H-11 Work Equipment Does Not Move in Single Operation
970
H-12 Hydraulic Drift of Boom Is Large
971
H-13 Hydraulic Drift of Arm Is Large
972
H-14 Hydraulic Drift of Bucket Is Large
973
H-15 Hydraulic Drift of Blade Is Large
974
H-16 Time Lag of Work Equipment Is Large
975
In Combined Operation of Work Equipment , Equipment Having Heavier Load Moves Slower
977
In Combined Operation of Swing and Boom RAISE, Boom Rising Speed Is Low
978
In Combined Operation of Work Equipment or Swing and Travel, Travel Speed Drops Largely
979
H-20 Machine Does Not Travel Straight
981
H-21 Travel Speed Is Slow
983
H-22 Machine Is Hard to Steer or Travel Power Is Low
985
Travel Speed Does Not Change, or Travel Speed Is too Slow or Fast
988
H-24 One of Tracks Does Not Run
989
H-25 Upper Structure Does Not Swing to the Right or Left
991
H-26 Upper Structure Swing Only to the Right or Left
992
Swing Acceleration or Swing Speed Is Low in both Directions (Right and Left)
993
Swing Acceleration Performance Is Poor or Swing Speed Is Slow in Only One Direction
994
Upper Structure Overruns Excessively When It Stops Swinging (both Right and Left)
995
Upper Structure Overruns Excessively When It Stops Swinging (Either Right or Left)
996
H-31 Shock Is Large When Upper Structure Stops Swinging
997
Large Unusual Noise Is Heard When Upper Structure Stops Swinging
998
Swing Drift on a Slope Is Large While Swing Parking Brake Is Applied
999
Swing Drift on a Slope Is Large While Swing Parking Brake Is Released
1000
H-35 Oil Flow in Attachment Circuit Cannot be Controlled
1001
Troubleshooting of Engine (S-Mode)
1002
Information Mentioned in Troubleshooting Table (S Mode)
1002
Engine Does Not Crank When Starting Switch Is Turned to START Position
1003
S-2 Engine Cranks but no Exhaust Smoke Comes out
1004
Fuel Is Being Injected but Engine Does Not Start
1005
S-4 Engine Startability Is Poor
1006
S-5 Engine Does Not Pick up Smoothly
1008
S-6 Engine Stops During Operation
1010
S-7 Engine Runs Rough or Is Unstable
1012
S-8 Engine Lacks Power
1013
S-9 Exhaust Smoke Is Black
1015
S-10 Engine Oil Consumption Is Excessive
1017
S-11 Oil Becomes Contaminated Quickly
1018
S-12 Fuel Consumption Is Excessive
1019
Oil Is in Coolant (or Coolant Spurts or Coolant Level Goes Down)
1020
S-14 Oil Pressure Drops
1021
S-15 Fuel Mixes into Engine Oil
1022
Water Mixes into Engine Oil (Milky)
1023
Coolant Temperature Rises too High (Overheating)
1024
S-18 Unusual Noise Is Heard
1025
S-19 Vibration Is Excessive
1026
S-20 Air Cannot be Bled from Fuel Circuit
1027
50 Disassembly and Assembly
1029
Shop Manual Hydraulic Excavator
1030
Table of Contents
1030
Related Information on Disassembly and Assembly
1032
How to Read this Manual
1032
Coating Materials List
1034
Special Tools List
1038
Sketches of Special Tools
1043
Engine and Cooling System
1045
Removal and Installation of Supply Pump Assembly
1045
Removal and Installation of Injector Assembly
1048
Removal and Installation of Cylinder Head Assembly
1055
Removal and Installation of Radiator Assembly
1067
Removal and Installation of Hydraulic Oil Cooler Assembly
1071
Removal and Installation of Aftercooler Assembly
1074
Removal and Installation of Engine and Main Pump Assembly
1077
Removal and Installation of Engine Front Oil Seal
1085
Removal and Installation of Engine Rear Oil Seal
1086
Removal and Installation of Fuel Cooler Assembly
1088
Removal and Installation of Fuel Tank Assembly
1089
Removal and Installation of Engine Hood Assembly
1091
Removal and Installation of KDOC Muffler
1092
Removal and Installation of KCCV Ventilator
1095
Removal and Installation of Air Cleaner Assembly
1097
Removal and Installation of EGR (Exhaust Gas Recirculation) Cooler Assembly
1099
Removal and Installation of EGR (Exhaust Gas Recirculation) Valve Assembly
1101
Removal and Installation of Fan Belt
1102
Power Train System
1104
Removal and Installation of Travel Motor and Final Drive Assembly
1104
Disassembly and Assembly of Travel Motor and Final Drive Assembly
1106
Removal and Installation of Swing Motor and Swing Machinery Assembly
1139
Disassembly and Assembly of Swing Machinery Assembly
1141
Removal and Installation of Swing Circle Assembly
1149
Undercarriage and Frame
1150
Separation and Connection of Track
1150
Removal and Installation of Sprocket
1151
Removal and Installation of Idler and Idler Cushion Assembly
1152
Disassembly and Assembly of Idler Assembly
1153
Disassembly and Assembly of Idler Cushion Assembly
1156
Disassembly and Assembly of Track Roller Assembly
1159
Removal and Installation of Revolving Frame Assembly
1162
Removal and Installation of Counterweight Assembly
1164
Hydraulic System
1166
Removal and Installation of Center Swivel Joint Assembly
1166
Disassembly and Assembly of Center Swivel Joint Assembly
1168
Removal and Installation of Hydraulic Tank Assembly
1169
Removal and Installation of Main Pump Assembly
1172
Removal and Installation of Control Valve Assembly
1176
Disassembly and Assembly of Control Valve Assembly
1180
Disassembly and Assembly of Work Equipment PPC Valve Assembly
1183
Disassembly and Assembly of Travel PPC Valve Assembly
1185
Disassembly and Assembly of Work Equipment Cylinder Assembly
1186
Work Equipment
1190
Removal and Installation of Work Equipment Assembly
1190
Removal and Installation of Boom Swing Bracket
1193
Removal and Installation of Anti-Drop Valve for Boom Assembly
1194
Removal and Installation of Anti-Drop Valve for Arm Assembly
1197
Disassembly and Assembly of Anti-Drop Valve Assembly
1200
Removal and Installation of Blade Assembly
1201
Cab and Its Attachments
1203
Removal and Installation of Operator's Cab Assembly
1203
Removal and Installation of Operator's Cab Door
1207
Removal and Installation of Operator's Cab Glass (Adhered Glass)
1210
Removal and Installation of Front Window Assembly
1221
Removal and Installation of Floor Frame Assembly
1222
Removal and Installation of Air Conditioner Unit Assembly
1227
Removal and Installation of Air Conditioner Compressor Assembly
1232
Removal and Installation of Air Conditioner Condenser Assembly
1234
Removal and Installation of Operator's Seat
1236
Removal and Installation of Seat Belt
1237
Removal and Installation of Front Wiper Assembly
1238
Electrical System
1245
Removal and Installation of Starting Motor Assembly
1245
Removal and Installation of Engine Controller Assembly
1246
Removal and Installation of Pump Controller Assembly
1247
Removal and Installation of Machine Monitor Assembly
1248
Removal and Installation of Mass Air Flow and Temperature Sensor
1250
Removal and Installation of KOMTRAX Terminal Assembly
1251
60 Maintenance Standard
1253
Shop Manual Hydraulic Excavator
1254
60 Maintenance Standard
1254
Table of Contents
1254
Engine and Cooling System
1255
Engine Mount
1255
Pto
1256
Cooling System
1257
Power Train System
1259
Swing Circle
1259
Swing Machinery
1261
Sprocket
1263
Track Frame
1264
Undercarriage and Frame
1264
Idler Cushion
1265
Idler
1266
Track Roller
1267
Carrier Roller
1268
Track Shoe
1269
Hydraulic System
1275
Hydraulic Tank
1275
Main Pump
1276
Control Valve
1280
Swing Motor
1289
Travel Motor
1291
PPC Valve
1292
Work Equipment and Swing PPC Valve
1292
Travel PPC Valve
1295
Blade PPC Valve
1297
Boom Swing PPC Valve
1299
Solenoid Valve
1301
Anti-Drop Valve for Boom
1303
Anti-Drop Valve for Arm
1305
Center Swivel Joint
1307
Cab and Its Attachments
1308
Cab Mount and Cab Tipping Stopper
1308
Work Equipment
1309
Boom Cylinder
1320
Arm Cylinder
1321
Bucket Cylinder
1322
Boom Swing Cylinder
1323
Blade Cylinder
1324
80 Appendix
1325
Shop Manual Hydraulic Excavator
1326
80 Appendix
1326
Air Conditioner Components
1327
Precautions for Refrigerant
1327
Air Conditioner Component
1328
Configuration and Function of Refrigeration Cycle
1331
Outline of Refrigeration Cycle
1332
Air Conditioner Unit
1334
Dual Pressure Switch
1339
Air Conditioner Controller
1340
Compressor
1341
Condenser
1342
Sunlight Sensor
1344
Outer Temperature Sensor (Outside Air Temperature Sensor)
1345
Procedure for Testing and Troubleshooting
1346
Circuit Diagram and Arrangement of Connector Pins
1348
System Diagram
1350
Table of Contents
1326
Input and Output Signals of the Air Conditioner Controller
1351
Air Conditioner Unit
1353
Parts and Connectors Layout
1355
Testing Air Leakage (Duct)
1361
Testing with Self-Diagnosis Function
1363
Testing Vent (Mode) Changeover
1366
Testing FRESH/RECIRC Air Changeover
1367
Testing Sunlight Sensor
1368
Testing (Dual) Pressure Switch for Refrigerant
1369
Testing Relays
1371
Troubleshooting Chart 1
1372
Troubleshooting Chart 2
1373
Information in Troubleshooting Table
1376
Failure Code List Related to Air Conditioner
1377
Failure Code [879AKA] A/C Recirc Air Temp Sens Open Circuit
1378
Failure Code [879AKB] A/C Recirc Air Temp Sens Short
1379
Failure Code [879BKA] A/C Fresh Air Temp Sens Open Circuit
1380
Failure Code [879BKB] A/C Fresh Air Temp Sens Short Circuit
1382
Failure Code [879CKA] Ventilating Sensor Open Circuit
1384
Failure Code [879CKB] Ventilating Sensor Short Circuit
1385
Failure Code [879DKZ] Sunlight Sensor Open or Short Circuit
1386
Failure Code [879EMC] Ventilation Damper Malfunction
1388
Failure Code [879FMC] Air MIX Damper Malfunction
1389
Failure Code [879GKX] Refrigerant Press Input Sig out of Range
1390
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
1391
Troubleshooting for Compressor and Refrigerant System (Air Is Not Cooled)
1393
Abnormal)
1396
Troubleshooting for Blower Motor System
1396
A-4 Troubleshooting for FRESH/RECIRC Air Changeover
1398
Troubleshooting with Gauge Pressure
1400
Connection of Service Tool
1403
Precautions for Disconnecting and Connecting Refrigerant Piping
1405
Handling of Compressor Oil
1407
90 Diagrams and Drawings
1409
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Komatsu PC88MR-10 Operation & Maintenance Manual (446 pages)
HYDRAULIC EXCAVATOR, SERIAL NUMBERS F10236 and up/7001 and up
Brand:
Komatsu
| Category:
Excavators
| Size: 22.32 MB
Table of Contents
Table of Contents
17
Safety Information
5
Safety Labels
6
Noise
7
Vibration Levels
8
Vibration - Operating Condition
8
Guide to Reduce Vibration Levels on Machine
9
Introduction
10
Demolition Work
10
Main Use of Machine
10
Directions of Machine
11
Visibility from Operator's Seat
12
Product Information
13
Location of Engine Number Plate
13
Location of Product Identification Number (Pin)/Machine Serial No. Plate
13
Fluorinated Greenhouse Gases
14
Service Meter Location
14
Your Machine Serial Numbers and Distributor
14
Serial Plate
15
Declaration of Conformity
16
Table of Contents
17
Safety Labels
24
Location of Safety Labels
25
Contents of Safety Labels
27
General Precautions Common to Operation and Maintenance
38
Ensure Safe Operation
38
Inspect Machine
38
Keep Machine Clean
38
Precautions before Starting Operation
38
Precautions for Safety-Related Equipment
38
Preparations for Safe Operation
38
Understand the Machine
38
Wear Well-Fitting Clothes and Protective Equipment
38
If any Problem Is Found
39
Precautions for Inside Operator's Compartment
39
Provide Fire Extinguisher and First Aid Kit
39
Actions if Fire Occurs
40
Precautions to Prevent Fire
40
Prevent Fire
40
Lifting of Personnel Prohibited
42
No Jumping on or off Machine
42
No People on Attachments
42
Precautions When Getting on or off Machine
42
Use Handrails and Steps When Getting on or off Machine
42
Electromagnetic Interference
43
Emergency Exit from Operator's Cab
43
Precautions When Leaving Machine
43
Precautions When Standing up from Operator's Seat
43
Actions in the Event of Damage to Safety Structures
44
Do Not Get Caught in Work Equipment
44
Protection against Falling, Flying or Intruding Objects
44
Unauthorized Modification
44
Precautions Related to Attachments and Options
45
Precautions Related to Cab Glass
45
Precautions When Running Engine Inside Building
45
Precautions for Operation
46
Do Not Go Close to High-Voltage Cables
46
Investigate and Confirm Jobsite Conditions
46
Precautions for Jobsite
46
Precautions When Working on Loose Ground
46
Beware of Asbestos Dust
47
Check Signs and Signalman's Signals
47
Ensure Good Visibility
47
Checks and Adjustment before Starting Engine
49
Start Engine
49
Use Warning Tags
49
In Cold Weather
50
Precautions When Starting Engine
50
Start Engine with Jumper Cables
50
Checks before Operation
51
Precautions for Operation
51
Precautions When Traveling in Forward or Reverse and Swinging
51
Precautions When Traveling
52
Precautions When Travelling on Slopes
53
Precautions When Operating on Slopes
54
Prohibited Operations
54
Precautions When Operating on Snow or Frozen Surfaces
55
Precautions When Parking Machine
55
Precautions for Transportation
57
Precautions When Loading and Unloading
57
Precautions for Towing and Being Towed
58
Towing and Being Towed
58
Lifting Operation by Using Bucket with Hook
59
Precautions for Lifting Operations
59
Lifting Operation by Using Lifting Device (Optional Equipment)
60
Precautions for Lifting Operations
60
Precautions for Maintenance
62
Appoint Leader When Working with Others
62
Display Warning Tag During Inspection and Maintenance
62
Keep Work Place Clean and Tidy
62
Only Authorized Personnel
62
Precautions before Starting Inspection and Maintenance
62
Select Suitable Place for Inspection and Maintenance
62
Stop Engine before Carrying out Inspection and Maintenance
62
Two Workers for Maintenance When Engine Is Running
63
Precautions for Working at High Places
64
Precautions When Installing, Removing, or Storing Attachments
64
Precautions When Working on Machine
64
Precautions When Working under Machine or Work Equipment
64
Use Proper Tools
65
Handle Battery
66
Precautions for Check and Maintenance
66
Precautions for Welding
66
Turn Battery Disconnect Switch to off Position
66
Precautions for High-Temperature Coolant
67
Precautions for High-Temperature Oil
67
Precautions When Using Hammer
67
Handle High-Pressure Hoses and Piping
68
Precautions for High-Pressure Fuel
68
Precautions for High-Pressure Oil
68
Precautions for High-Temperature Parts
68
Do Not Disassemble Recoil Spring
69
Precautions for High Voltage
69
Precautions for High-Pressure Grease When Adjusting Track Tension
69
Precautions for Noise
69
Handle Accumulator and Gas Spring
70
Maintenance of Air Conditioner
70
Method for Selecting Window Washer Fluid
70
Periodic Replacement of Defined Life Parts
70
Precautions for Compressed Air
70
Precautions for Disposing of Waste Materials
70
Operation
73
General View
74
Machine Equipment Name
74
Cab Equipment Names
76
Controls and Gauges Names
77
Explanation of Components
81
Explanation of Machine Monitor Equipment (Version with Rear Camera)
81
Explanation of Machine Monitor Equipment
83
Switches
151
Control Levers and Pedals
158
Other Equipment
163
Machine Operations and Controls
181
Checks and Adjustment before Starting Engine
181
Method for Starting Engine
204
Method for Operations and Checks after Starting Engine
208
Method for Stopping Engine
218
Method for Starting Machine (Travel Forward and Reverse) and Stopping Machine
219
Method for Steering Machine
222
Method for Operating Work Equipment
224
Method for Swinging Machine
224
Handle Working Mode
226
Prohibited Operations
228
Precautions for Operation
233
Precautions for Working on Slope
235
Method for Escaping from Mud
237
Recommended Applications
238
Method for Lifting Objects with Lifting Device
240
Method for Replacing and Inverting Bucket
242
Method for Parking Machine
245
Method for Checking after Finishing Work
247
Lock
248
Handle Air Conditioner
255
Explanation of Air Conditioner Equipment
256
Method for Operating Air Conditioner
260
Handle Radio
267
Stow Antenna
268
Handle Road Liners and Rubber Shoes
269
Precautions When Using Road Liners and Rubber Shoes
269
Recommended Use of Road Liners and Rubber Shoes
269
Warranty of Road Liners and Rubber Shoes
269
Transportation
273
Precautions for Transporting Machine
273
Select Transportation Method
273
Loading and Unloading with Trailer
274
Method for Lifting Machine
279
Cold Weather Operation
281
Cold Weather Operation Information
281
After Cold Weather Season
282
Precautions after Daily Work Completion in Cold Weather
282
Precautions for Long-Term Storage
283
Maintenance During Long-Term Storage
283
Preparation for Long-Term Storage
283
Starting Machine after Long-Term Storage
283
Troubles and Actions
285
Actions When Running out of Fuel
285
Phenomena that Are Not Failures
285
Precautions for Towing Machine
286
Precautions for Severe Job Condition
287
Precautions for Discharged Battery
288
Other Trouble
293
Maintenance
299
Precautions for Maintenance
300
Always Use Clean Washer Fluid
300
Check Drained Oil and Used Filter
300
Check Service Meter Reading
300
Do Not Drop Things Inside Machine
300
Fresh and Clean Lubricants
300
Komatsu Genuine Lubricants
300
Komatsu Genuine Replacement Parts
300
Precautions for Refilling Oil or Fuel
300
Welding Instructions
300
Avoid Mixing Oil
301
Bleed Air from Hydraulic Circuit
301
Checks after Inspection and Maintenance
301
Close Engine Hood Securely
301
Fuel and Lubricants to Match the Ambient Temperature
301
Lock Inspection Covers
301
Precautions When Installing Hydraulic Hoses
301
Outline of Maintenance
302
Handle Oil, Fuel, Coolant, and Performing Oil Clinic
302
Handle Electrical Components
306
Standard Tightening Torque for Bolts and Nuts
307
Maintenance Schedule
309
Maintenance Schedule Table
309
Maintenance Interval for Hydraulic Breaker
311
Maintenance Interval When Diesel Fuel Mixed with Bio-Fuel Is Used
311
Maintenance Procedure
312
When Required
312
Method for Checking, Cleaning and Replacing Air Cleaner
312
Method for Cleaning Inside of Cooling System
316
Method for Checking Looseness and Tightening Track Shoe Bolts
320
Method for Checking and Adjusting Track Tension
321
Method for Checking Looseness and Tightening Road Liner Shoe Bolts
321
Method for Checking Road Liner
323
Method for Checking Rubber Shoes
323
Method for Replacing Road Liner
323
Method for Checking and Adjusting Rubber Shoes Track Tension
325
Method for Replacing Rubber Shoes
326
Method for Changing Shoes
329
Method for Replacing Bucket Teeth
329
Method for Adjusting Bucket Clearance
331
Method for Checking Window Washer Fluid Level, Adding Fluid
331
Method for Checking and Maintenance Air Conditioner
332
Method for Checking, Cleaning and Lubricating Slide Door Rail and Roller
334
Method for Checking Stopper Clearance in Opening Front Door Is up
335
Method for Replacing Additional Filter Element for Breaker
335
Method for Washing Washable Floor
336
Method for Bleeding Air from Hydraulic Circuit
339
Checks before Starting
343
Every 100 Hours Maintenance
344
Method for Lubricating Work Equipment
344
Method for Checking Oil Level in Swing Machinery Case, Adding Oil
344
Every 250 Hours Maintenance
346
Method for Checking Oil Level in Final Drive Case, Adding Oil
346
Method for Checking Battery Electrolyte Level
346
Method for Checking Gas Spring
339
Method for Checking and Adjusting Air Conditioner Compressor Belt Tension
349
Every 500 Hours Maintenance
351
Method for Lubricating
351
Method for Replacing Fuel Prefilter Cartridge
354
Method for Checking Swing Pinion Grease Level, Add Grease
356
Method for Checking and Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Air Conditioner Condenser Fins
357
Method for Lubricating Swing Circle
357
Method for Cleaning Air Conditioner Fresh/Recirc Air Filters
359
Method for Replacing Hydraulic Tank Breather Element
360
Every 1000 Hours Maintenance
361
Method for Replacing Hydraulic Oil Filter Element
361
Method for Change Oil in Swing Machinery Case
363
Method for Changing Oil in Final Drive Case
363
Method for Checking Oil Level in Pto Gear Case, Adding Oil
364
Method for Replacing Fuel Main Filter Cartridge
365
Method for Checking All Tightening Points of Engine Intake Pipe Clamps
367
Method for Checking Fan Belt Tension and Replacing Fan Belt
367
Every 2000 Hours Maintenance
368
Method for Checking and Releasing Nitrogen Gas Charge Pressure in Accumula- Tor (for Control Circuit)
368
Method for Checking Alternator and Starting Motor
371
Method for Checking and Adjusting Engine Valve Clearance
371
Method for Replacing Kccv Filter Element
371
Every 4000 Hours Maintenance
375
Replace Defined Life Parts
375
Method for Checking Water Pump
375
Method for Replacing Accumulator (for Control Circuit)
376
Method for Checking for Looseness of Engine High-Pressure Piping Clamp, Hard- Ening of Rubber
377
Every 5000 Hours Maintenance
378
Method for Changing Oil in Hydraulic Tank, Cleaning Hydraulic Tank Strainer
378
Specifications
381
Explanation of Lift Capacity Chart
384
Attachments and Options
387
Precautions for Using Attachment and Options
388
Precautions When Removing and Installing
388
Precautions When Selecting
388
Precautions When Using
388
Read the Operation and Maintenance Manual Thoroughly
388
Quick Coupler System
390
Handling Quick Coupler
390
2-Piece Boom
393
2-Piece Boom Components
393
2-Piece Boom Control Pedal
393
Method for Lubricating 2-Piece Boom
394
Specifications
395
Explanation of Lift Capacity Chart
397
Handle Bucket with Hook
399
Precautions for Operation
399
Handle Machine Ready for Installation of Attachment
400
Explanation of Components
400
Hydraulic Circuit
402
Method for Removing and Installing Attachment
403
Method for Operating Attachment
409
Long-Term Storage
412
Specifications
412
HANDLE MACHINE READY for POWERTILT (3Rd LINE)
413
Explanation of Components
413
Method for Operating Powertilt
414
Attachments and Options
420
Install Attachment
420
Track Shoes Selection
422
Recommended Attachment Operations
423
Hydraulic Breaker
423
Replacement Parts
429
Periodic Replacement of Defined Life Parts
430
Defined Life Parts List
430
Consumable Parts
431
Consumable Parts List
431
Recommended Fuel, Coolant, and Lubricant
432
Lubrication Chart
433
Method for Using Fuel, Coolant and Lubricants According to Ambient Temperature
435
Recommended Brands and Qualities Other than Komatsu Genuine Oils
436
Index
437
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