Komatsu Excavator PC88MR-11 service & repair manual

Description Komatsu Excavator PC88MR-11 service & repair manual

Komatsu Hydraulic Excavator PC88MR-11 pdf workshop service & repair manual

Serial numbers:
C40001 and up
10001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
ABBREVIATION LIST

SPECIFICATIONS
SPECIFICATION DRAWING
WORKING RANGE DRAWINGS
WEIGHT TABLE
FUEL, COOLANT, LUBRICANTS

STRUCTURE AND FUNCTION
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTO-DECELERATION SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM
OVERHEAT PREVENTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
MACHINE MONITOR SYSTEM
KOMTRAX SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
ENGINE AND PUMP COMBINED CONTROL SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
PPC LOCK SYSTEM
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
SWING CONTROL SYSTEM DIAGRAM
COMPONENT PARTS OF SWING SYSTEM
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM
COMPONENT PARTS OF TRAVEL SYSTEM
UNDERCARRIAGE AND FRAME
LAYOUT DRAWING OF UNDERCARRIAGE
IDLER CUSHION
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
BUCKET CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB MOUNT
TAKE WIRING HARNESS OUT OF CAB

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: PC88MR-11
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: PC88MR-11
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
VISUAL CHECK INSIDE OF EGR VALVE
CLEAN INSIDE OF EGR VALVE
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL SYSTEM FOR LEAKAGE
CYLINDER CUT-OUT MODE OPERATION
NO-INJECTION CRANKING OPERATION
CHECK FAN BELT
TEST AUTO-TENSIONER
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS
TEST AND ADJUST OIL PRESSURE IN SWING AND BLADE CIRCUITS
TEST OIL PRESSURE OF CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TEST OUTLET PRESSURE IN SOLENOID VALVE
TEST OUTLET PRESSURE IN PPC VALVE
TEST AND ADJUST TRAVEL DEVIATION
TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
TEST OIL LEAKAGE
BLEED AIR FROM HYDRAULIC SYSTEM
CAB RELATED PARTS
ADJUST MIRRORS
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
START UP KOMTRAX SYSTEM
ADJUST REARVIEW CAMERA ANGLE
ADJUST RIGHTVIEW CAMERA ANGLE
SET REGION OF Bluetooth COMPATIBLE RADIO
ENGINE CONTROLLER VOLTAGE CIRCUIT
BATTERY DISCONNECT SWITCH
TEST DIODES
Pm-CLINIC
Pm CLINIC SERVICE

TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
CONNECTOR LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
PREPARATION
DRAIN AND ADD COOLANT
DRAIN AND ADD HYDRAULIC OIL
DRAIN AND ADD FUEL
COLLECT AND REFILL REFRIGERANT
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL EGR VALVE ASSEMBLY
REMOVE AND INSTALL EGR COOLER ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL FAN BELT
REMOVE AND INSTALL AUTO-TENSIONER
REMOVE AND INSTALL EXPANSION TANK ASSEMBLY
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL KDOC ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
UNDERCARRIAGE AND FRAME
SEPARATE AND CONNECT TRACK ASSEMBLY
REMOVE AND INSTALL SPROCKET
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL MAIN PUMP ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL BLADE ASSEMBLY
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
REMOVE AND INSTALL BOOM SWING BRACKET
REMOVE AND INSTALL BOOM ANTI-DROP VALVE ASSEMBLY
REMOVE AND INSTALL ARM ANTI-DROP VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING CYLINDER ASSEMBLY
CAB RELATED PARTS
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY
REMOVE AND INSTALL OPERATORS CAB DOOR
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL OPERATORS SEAT
REMOVE AND INSTALL SEATBELT
REMOVE AND INSTALL FRONT WIPER ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF PTO
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE
MAINTENANCE STANDARD OF SWING MACHINERY
MAINTENANCE STANDARD OF SPROCKET
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER
MAINTENANCE STANDARD OF CARRIER ROLLER
MAINTENANCE STANDARD OF TRACK SHOE
MAINTENANCE STANDARD OF TRIPLE SHOE
MAINTENANCE STANDARD FOR RUBBER SHOE
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF PC-EPC VALVE
MAINTENANCE STANDARD OF SWING MOTOR
MAINTENANCE STANDARD OF TRAVEL MOTOR
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF ANTI-DROP VALVE OF BOOM
MAINTENANCE STANDARD OF ANTI-DROP VALVE OF ARM
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
MAINTENANCE STANDARD OF BLADE PPC VALVE
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE
MAINTENANCE STANDARD OF TRAVEL PPC VALVE
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)
MAINTENANCE STANDARD OF SOLENOID VALVE
MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT)
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
MAINTENANCE STANDARD OF BOOM CYLINDER
MAINTENANCE STANDARD OF ARM CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER
MAINTENANCE STANDARD OF BOOM SWING CYLINDER
MAINTENANCE STANDARD OF BLADE CYLINDER

APPENDIX
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
AIR CONDITIONER CONTROLLER
COMPRESSOR
CONDENSER
RECEIVER DRIER
SENSORS FOR AIR CONDITIONER SYSTEM
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TESTING AIR LEAKAGE (DUCT)
METHOD FOR TESTING AIR LEAKAGE (DUCT)
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
TEST VENT (MODE) CHANGEOVER
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST SUNLIGHT SENSOR
METHOD FOR TESTING SUNLIGHT SENSOR
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING CHART
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
TROUBLESHOOTING USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL

CIRCUIT DIAGRAMS
HOW TO READ THE CODES FOR ELECTRIC CABLE
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE OPERATION)
HYDRAULIC CIRCUIT DIAGRAM (AT LEFT SWING OPERATION)
HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE AND LEFT SWING OPERATION
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM

Engine SAA3D95E-1 workshop service repair manual