Komatsu Hydraulic Excavators PC88MR Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC88MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC88MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 4,973 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
Cover...1
00 Index and foreword ...3
Index ...4
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
Table of contents ...80
Engine and cooling system ...81
Engine related parts ...81
PTO ...83
VFT ...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
Center swivel joint ...230
Accumulator ...231
Work equipment ...233
Work equipment ...233
Work equipment shim ...234
Bucket play adjustment shim ...235
Cab and its attachments ...236
Cab mount and cab tipping stopper ...236
ROPS cab ...238
Electrical system ...240
Electrical control system ...240
Machine monitor system ...285
KOMTRAX system ...307
KOMTRAX terminal ...307
Sensor ...309
20 Standard value tables ...317
Table of contents ...318
Standard service value table ...319
Standard value table for engine ...319
Standard value table for machine ...321
Standard value table for electrical system ...337
30 Testing and adjusting ...343
Table of contents ...344
Related information on testing and adjusting ...345
Tools for testing and adjusting ...345
Sketch of tools for testing and adjusting ...348
Engine and cooling system ...350
Testing engine speed ...350
Testing exhaust gas color ...351
Testing and adjusting valve clearance ...352
Testing compression pressure ...354
Testing blowby pressure ...356
Testing engine oil pressure ...357
Testing fuel pressure ...358
Testing fuel return rate and leakage ...359
Bleeding air from fuel system ...362
Testing fuel circuit for leakage ...364
Handling cylinder cutout mode operation ...365
Handling no-injection cranking operation ...366
Testing and adjusting air conditioner compressor belt tension ...367
Replacing fan belt ...368
Writing compensation values at replacement of injector and engine controller ...370
Power train ...374
Testing swing circle bearing clearance ...374
Undercarriage and frame ...375
Testing and adjusting track tension ...375
Hydraulic system ...376
Releasing remaining pressure from hydraulic circuit ...376
Testing and adjusting oil pressure in work equipment and travel circuits ...378
Testing and adjusting swing and blade circuit oil pressure ...381
Testing oil pressure of control circuit ...384
Testing and adjusting oil pressure in pump PC control circuit ...385
Testing and adjusting oil pressure in pump LS control circuit ...388
Testing outlet pressure of solenoid valve ...391
Testing PPC valve outlet pressure ...392
Adjusting play of work equipment and swing PPC valves ...393
Isolating the parts causing hydraulic drift in work equipment ...394
Testing and adjusting travel deviation ...395
Testing oil leakage ...397
Bleeding air from hydraulic circuit ...401
Cab and its attachments ...404
Testing, cleaning and lubricating slide door rail and roller ...404
Adjusting mirrors ...405
Testing and adjusting hood catcher ...407
Electrical system ...409
Special functions of machine monitor ...409
KOMTRAX terminal start-up procedure ...457
Adjusting rearview camera angle ...461
Handling voltage circuit of engine controller ...463
Handling battery disconnect switch ...464
Testing diodes ...465
Pm clinic ...466
Pm Clinic service ...466
40 Troubleshooting ...475
Table of contents ...476
Related information on troubleshooting ...482
Troubleshooting points ...482
Sequence of events in troubleshooting ...484
Checks before troubleshooting ...486
Inspection procedure before troubleshooting ...488
Preparation for troubleshooting of electrical system ...505
Classification and procedures for troubleshooting ...510
Symptom and troubleshooting numbers ...513
Information in troubleshooting table ...516
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...518
Connector list and layout ...520
Connector contact identification ...529
T-branch box and T-branch adapter table ...567
Fuse location table ...572
Failure codes table ...574
Troubleshooting by failure code (Display of code) ...580
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit ...580
Failure code [879AKB] A/C Recirc Air Temp Sens Short ...581
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit ...582
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit ...583
Failure code [879CKA] Ventilating Sensor Open Circuit ...584
Failure code [879CKB] Ventilating Sensor Short Circuit ...585
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...586
Failure code [879EMC] Ventilation Damper Malfunction ...587
Failure code [879FMC] Air Mix Damper Malfunction ...588
Failure code [879GKX] Refrigerant Press Input Sig Out of Range ...589
Failure code [989L00] Engine Controller Lock Caution 1 ...590
Failure code [989M00] Engine Controller Lock Caution 2 ...591
Failure code [989N00] Engine Controller Lock Caution 3 ...592
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 ...593
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ...594
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 ...595
Failure code [AB00KE] Charge Voltage Low ...596
Failure code [B@BAZG] Eng Oil Press Low ...598
Failure code [B@BCNS] Eng Water Overheat ...599
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...600
Failure code [CA122] Charge Air Pressure Sensor High Error ...601
Failure code [CA123] Charge Air Pressure Sensor Low Error ...603
Failure code [CA131] Throttle Sensor High Error ...605
Failure code [CA132] Throttle Sensor Low Error ...607
Failure code [CA144] Coolant Temperature Sensor High Error ...609
Failure code [CA145] Coolant Temperature Sensor Low Error ...611
Failure code [CA153] Charge Air Temperature Sensor High Error ...613
Failure code [CA154] Charge Air Temperature Sensor Low Error ...615
Failure code [CA187] Sensor 2 Supply Voltage Low Error ...617
Failure code [CA221] Ambient Pressure Sensor High Error ...619
Failure code [CA222] Ambient Pressure Sensor Low Error ...621
Failure code [CA227] Sensor 2 Supply Voltage High Error ...623
Failure code [CA234] Engine Overspeed ...624
Failure code [CA238] NE Speed Sensor Supply Voltage Error ...625
Failure code [CA239] NE Speed Sensor Supply Voltage High Error ...626
Failure code [CA271] PCV1 Short Circuit Error ...627
Failure code [CA272] PCV1 Open Circuit Error ...628
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit ...629
Failure code [CA324] Injector #3 (L#3) Open or Short Circuit ...631
Failure code [CA331] Injector #2 (L#2) Open or Short Circuit ...633
Failure code [CA332] Injector #4 (L#4) Open or Short Circuit ...635
Failure code [CA343] Engine Controller Internal Failure ...637
Failure code [CA351] Injectors Drive Circuit Error ...638
Failure code [CA352] Sensor1 Supply Voltage Low Error ...639
Failure code [CA356] MAF Sensor High Error ...641
Failure code [CA357] MAF Sensor Low Error ...643
Failure code [CA386] Sensor1 Supply Voltage High Error ...645
Failure code [CA435] Engine Oil Pressure SW Error ...646
CEBM007301 - PC88MR-8 sn A90001-up...0
CONTENTS...2
REVISED PAGES...3
SAFETY...19
Safety Notice...19
Important Safety Notice...19
General Precautions...19
Preparations For Work...19
Precautions During Work...19
GENERAL...22
HOW TO READ THE SHOP MANUAL...23
Volumes...23
Distribution And Updating...23
Filing Method...23
Revised Edition Mark...23
Revisions...23
Symbols...23
HOISTING INSTRUCTIONS...24
Hoisting...24
Wire Ropes...24
PUSH PULL COUPLER...25
Type 1...25
Disconnection...25
Connection...25
Type 2...26
Disconnection...26
Connection...26
Type 3...27
Disconnection...27
Connection...27
EXPLANATION OF MAINTENANCE STANDARD TERMS...28
STANDARD TIGHTENING TORQUE...30
Bolts And Nuts...30
Tightening Torque Of Hose Nuts...31
Tightening Torque Of Split Flange Bolts...31
Tightening Torque For Flared Nuts...31
Tightening Torques For O-ring Boss Piping Joints...32
COVER...1
INTRODUCTION...3
FOREWORD...4
SAFETY INFORMATION...5
Signal Words...5
Other Signal Words...5
Safety Labels...6
