Komatsu PC88MR-11 Compact Hydraulic Excavator Shop Manual SEN06843-04 – PDF DOWNLOAD

Komatsu PC88MR-11 Compact Hydraulic Excavator Shop Manual SEN06843-04 – PDF DOWNLOAD

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Komatsu PC88MR-11 Compact Hydraulic Excavator Shop Manual SEN06843-04 – PDF DOWNLOAD

Language : English
Pages : 2204
Downloadable : Yes
File Type : PDF
Size: 71.3 MB

TABLE OF CONTENTS:

Komatsu PC88MR-11 Compact Hydraulic Excavator Shop Manual SEN06843-04 – PDF DOWNLOAD

00 INDEX AND FOREWORD 00-1
FOREWORD, SAFETY, BASIC INFORMATION 00-15
HOW TO READ THE SHOP MANUAL 00-15
SAFETY NOTICE FOR OPERATION 00-17
PRECAUTIONS TO PREVENT FIRE 00-25
ACTIONS IF FIRE OCCURS 00-27
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00-28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-42
PRACTICAL USE OF KOMTRAX 00-43
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-48
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-52
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-53
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-56
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-58
HOW TO READ ELECTRICAL WIRE CODE 00-59
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-63
STANDARD TIGHTENING TORQUE TABLE 00-66
CONVERSION TABLE 00-73
ABBREVIATION LIST 00-78
01 SPECIFICATIONS 01-1
CONTENTS 01-2
SPECIFICATIONS 01-3
SPECIFICATION DRAWING 01-3
WORKING RANGE DRAWINGS 01-4
SPECIFICATIONS 01-5
WEIGHT TABLE 01-9
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 01-11
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
BOOT-UP SYSTEM 10-5
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-5
SYSTEM OPERATING LAMP SYSTEM 10-6
BATTERY DISCONNECT SWITCH 10-8
ENGINE SYSTEM 10-9
LAYOUT DRAWING OF ENGINE SYSTEM 10-9
ENGINE CONTROL SYSTEM 10-11
AUTO-DECELERATION SYSTEM 10-14
ENGINE AUTOMATIC WARM-UP SYSTEM 10-16
OVERHEAT PREVENTION SYSTEM 10-18
TURBOCHARGER PROTECTION SYSTEM 10-19
AUTOMATIC IDLE STOP SYSTEM 10-20
COMPONENT PARTS OF ENGINE SYSTEM 10-23
COOLING SYSTEM 10-38
LAYOUT DRAWING OF COOLING SYSTEM 10-38
CONTROL SYSTEM 10-40
LAYOUT DRAWING OF CONTROL SYSTEM 10-40
MACHINE MONITOR SYSTEM 10-42
KOMTRAX SYSTEM 10-44
COMPONENT PARTS OF CONTROL SYSTEM 10-45
INDEX 00 INDEX AND FOREWORD
00-2 PC88MR-11
HYDRAULIC SYSTEM 10-76
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-76
CLSS 10-79
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10-82
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-86
WORK EQUIPMENT SYSTEM 10-167
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-167
PPC LOCK SYSTEM 10-169
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10-170
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10-172
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-174
SWING SYSTEM 10-206
LAYOUT DRAWING OF SWING SYSTEM 10-206
SWING CONTROL SYSTEM DIAGRAM 10-208
COMPONENT PARTS OF SWING SYSTEM 10-210
TRAVEL SYSTEM 10-223
LAYOUT DRAWING OF TRAVEL SYSTEM 10-223
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM 10-225
COMPONENT PARTS OF TRAVEL SYSTEM 10-228
UNDERCARRIAGE AND FRAME 10-242
LAYOUT DRAWING OF UNDERCARRIAGE 10-242
IDLER CUSHION 10-244
WORK EQUIPMENT 10-245
STRUCTURE OF WORK EQUIPMENT 10-245
FUNCTION OF WORK EQUIPMENT 10-246
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10-247
BUCKET CLEARANCE ADJUSTMENT SHIM 10-248
CAB AND ITS ATTACHMENTS 10-249
ROPS CAB 10-249
CAB MOUNT 10-250
TAKE WIRING HARNESS OUT OF CAB 10-252
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
STANDARD VALUE TABLE FOR ENGINE 20-3
STANDARD VALUE TABLE FOR ENGINE: PC88MR-11 20-3
STANDARD VALUE TABLE FOR MACHINE 20-5
STANDARD VALUE TABLE FOR MACHINE: PC88MR-11 20-5
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 20-17
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING 30-5
TOOLS FOR TESTING AND ADJUSTING 30-5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30-10
ENGINE AND COOLING SYSTEM 30-12
TEST ENGINE SPEED 30-12
TEST EXHAUST GAS COLOR 30-16
TEST AND ADJUST VALVE CLEARANCE 30-19
TEST COMPRESSION PRESSURE 30-21
TEST BLOWBY PRESSURE 30-24
TEST ENGINE OIL PRESSURE 30-26
VISUAL CHECK INSIDE OF EGR VALVE 30-28
CLEAN INSIDE OF EGR VALVE 30-30
TEST FUEL PRESSURE 30-33
TEST FUEL RETURN RATE AND LEAKAGE 30-35
BLEED AIR FROM FUEL SYSTEM 30-40
TEST FUEL SYSTEM FOR LEAKAGE 30-42
CYLINDER CUT-OUT MODE OPERATION 30-44
NO-INJECTION CRANKING OPERATION 30-45
00 INDEX AND FOREWORD INDEX
PC88MR-11 00-3
CHECK FAN BELT 30-46
TEST AUTO-TENSIONER 30-47
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 30-49
POWER TRAIN 30-55
TEST SWING CIRCLE BEARING CLEARANCE 30-55
UNDERCARRIAGE AND FRAME 30-56
TEST AND ADJUST TRACK TENSION 30-56
HYDRAULIC SYSTEM 30-58
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-58
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS 30-63
TEST AND ADJUST OIL PRESSURE IN SWING AND BLADE CIRCUITS 30-73
TEST OIL PRESSURE OF CONTROL CIRCUIT 30-77
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30-79
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30-85
TEST OUTLET PRESSURE IN SOLENOID VALVE 30-91
TEST OUTLET PRESSURE IN PPC VALVE 30-94
TEST AND ADJUST TRAVEL DEVIATION 30-97
TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT 30-100
TEST OIL LEAKAGE 30-102
BLEED AIR FROM HYDRAULIC SYSTEM 30-109
CAB RELATED PARTS 30-115
ADJUST MIRRORS 30-115
ELECTRICAL SYSTEM 30-117
SET AND OPERATE MACHINE MONITOR 30-117
START UP KOMTRAX SYSTEM 30-186
ADJUST REARVIEW CAMERA ANGLE 30-193
ADJUST RIGHTVIEW CAMERA ANGLE 30-196
ENGINE CONTROLLER VOLTAGE CIRCUIT 30-199
BATTERY DISCONNECT SWITCH 30-200
TEST DIODES 30-201
Pm-CLINIC 30-202
Pm CLINIC SERVICE 30-202
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
RELATED INFORMATION ON TROUBLESHOOTING 40-9
GENERAL TROUBLESHOOTING POINTS 40-9
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-10
CHECKS BEFORE TROUBLESHOOTING 40-12
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-14
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-16
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 40-40
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-48
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40-51
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-56
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM 40-58
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE 40-61
CONNECTOR LAYOUT 40-66
CONNECTOR CONTACT IDENTIFICATION 40-72
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-114
FUSE LOCATION TABLE 40-120
FAILURE CODES TABLE 40-122
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-130
FAILURE CODE [879AKA] 40-130
FAILURE CODE [879AKB] 40-131
FAILURE CODE [879BKA] 40-132
FAILURE CODE [879BKB] 40-134
FAILURE CODE [879CKA] 40-136
INDEX 00 INDEX AND FOREWORD
00-4 PC88MR-11
FAILURE CODE [879CKB] 40-137
FAILURE CODE [879DKZ] 40-138
FAILURE CODE [879EMC] 40-140
FAILURE CODE [879FMC] 40-141
FAILURE CODE [879GKX] 40-142
FAILURE CODE [989L00] 40-144
FAILURE CODE [989M00] 40-145
FAILURE CODE [989N00] 40-146
FAILURE CODE [A900FR] 40-147
FAILURE CODE [A900N6] 40-148
FAILURE CODE [A900NY] 40-149
FAILURE CODE [AA10NX] 40-150
FAILURE CODE [AB00KE] 40-152
FAILURE CODE [B@BAZG] 40-154
FAILURE CODE [B@BCNS] 40-155
FAILURE CODE [B@BCQA] 40-156
FAILURE CODE [B@BCZK] 40-158
FAILURE CODE [B@HANS] 40-160
FAILURE CODE [CA115] 40-162
FAILURE CODE [CA122] 40-163
FAILURE CODE [CA123] 40-165
FAILURE CODE [CA131] 40-167
FAILURE CODE [CA132] 40-169
FAILURE CODE [CA144] 40-171
FAILURE CODE [CA145] 40-173
FAILURE CODE [CA153] 40-175
FAILURE CODE [CA154] 40-178
FAILURE CODE [CA187] 40-181
FAILURE CODE [CA221] 40-183
FAILURE CODE [CA222] 40-185
FAILURE CODE [CA227] 40-187
FAILURE CODE [CA234] 40-188
FAILURE CODE [CA238] 40-189
FAILURE CODE [CA239] 40-191
FAILURE CODE [CA271] 40-193
FAILURE CODE [CA272] 40-195
FAILURE CODE [CA322] 40-197
FAILURE CODE [CA324] 40-200
FAILURE CODE [CA331] 40-203
FAILURE CODE [CA343] 40-206
FAILURE CODE [CA351] 40-207
FAILURE CODE [CA352] 40-208
FAILURE CODE [CA356] 40-210
FAILURE CODE [CA357] 40-212
FAILURE CODE [CA386] 40-215
FAILURE CODE [CA435] 40-216
FAILURE CODE [CA441] 40-218
FAILURE CODE [CA442] 40-220
FAILURE CODE [CA449] 40-221
FAILURE CODE [CA451] 40-222
FAILURE CODE [CA452] 40-224
FAILURE CODE [CA515] 40-226
FAILURE CODE [CA516] 40-228
FAILURE CODE [CA553] 40-230
FAILURE CODE [CA559] 40-231
FAILURE CODE [CA689] 40-235
FAILURE CODE [CA691] 40-237
FAILURE CODE [CA692] 40-239
00 INDEX AND FOREWORD INDEX
PC88MR-11 00-5
FAILURE CODE [CA697] 40-241
FAILURE CODE [CA698] 40-242
FAILURE CODE [CA731] 40-243
FAILURE CODE [CA778] 40-244
FAILURE CODE [CA1117] 40-247
FAILURE CODE [CA1896] 40-248
FAILURE CODE [CA1961] 40-250
FAILURE CODE [CA2185] 40-251
FAILURE CODE [CA2186] 40-253
FAILURE CODE [CA2249] 40-255
FAILURE CODE [CA2272] 40-256
FAILURE CODE [CA2311] 40-259
FAILURE CODE [CA2349] 40-260
FAILURE CODE [CA2353] 40-262
FAILURE CODE [CA2357] 40-264
FAILURE CODE [CA2765] 40-265
FAILURE CODE [CA2973] 40-266
FAILURE CODE [CA3419] 40-267
FAILURE CODE [CA3421] 40-269
FAILURE CODE [CA3724] 40-271
FAILURE CODE [CA4264] 40-272
FAILURE CODE [CA4952] 40-274
FAILURE CODE [D110KB] 40-276
FAILURE CODE [D19JKZ] 40-278
FAILURE CODE [D811MC] 40-280
FAILURE CODE [D862KA] 40-281
FAILURE CODE [D8ALKA] 40-282
FAILURE CODE [D8ALKB] 40-284
FAILURE CODE [D8AQKR] 40-286
FAILURE CODE [D8G1KT] 40-291
FAILURE CODE [D8G6KT] 40-292
FAILURE CODE [DA20MC] 40-293
FAILURE CODE [DA22KK] 40-294
FAILURE CODE [DA25KP] 40-297
FAILURE CODE [DA29KQ] 40-300
FAILURE CODE [DA2LKA] 40-302
FAILURE CODE [DA2LKB] 40-304
FAILURE CODE [DA2QKR] 40-306
FAILURE CODE [DA2RKR] 40-312
FAILURE CODE [DAF0MB] 40-317
FAILURE CODE [DAF0MC] 40-318
FAILURE CODE [DAF8KB] 40-319
FAILURE CODE [DAF9KQ] 40-321
FAILURE CODE [DAFGMC] 40-322
FAILURE CODE [DAFLKA] 40-323
FAILURE CODE [DAFLKB] 40-325
FAILURE CODE [DAFQKR] 40-327
FAILURE CODE [DAZ9KQ] 40-333
FAILURE CODE [DAZQKR] 40-334
FAILURE CODE [DB2QKR] 40-338
FAILURE CODE [DB2RKR] 40-344
FAILURE CODE [DDNRKA] 40-349
FAILURE CODE [DDNRKY] 40-352
FAILURE CODE [DDNS00] 40-354
FAILURE CODE [DFB1KZ] 40-356
FAILURE CODE [DFB3L8] 40-358
FAILURE CODE [DFB5KZ] 40-360
FAILURE CODE [DGH2KA] 40-362
INDEX 00 INDEX AND FOREWORD
00-6 PC88MR-11
FAILURE CODE [DGH2KB] 40-364
FAILURE CODE [DHA4KA] 40-365
FAILURE CODE [DHPAMA] 40-367
FAILURE CODE [DHS3MA] 40-369
FAILURE CODE [DHS4MA] 40-371
FAILURE CODE [DHS5MA] 40-373
FAILURE CODE [DHS8MA] 40-375
FAILURE CODE [DHS9MA] 40-377
FAILURE CODE [DHSAMA] 40-379
FAILURE CODE [DHSBMA] 40-381
FAILURE CODE [DHSCMA] 40-383
FAILURE CODE [DHSDMA] 40-385
FAILURE CODE [DHSPMA] 40-387
FAILURE CODE [DHSQMA] 40-389
FAILURE CODE [DKULKA] 40-391
FAILURE CODE [DKULKB] 40-393
FAILURE CODE [DKULKY] 40-395
FAILURE CODE [DLM5KA] 40-397
FAILURE CODE [DLM5MB] 40-399
FAILURE CODE [DV20KB] 40-401
FAILURE CODE [DW43KA] 40-403
FAILURE CODE [DW43KB] 40-405
FAILURE CODE [DW43KY] 40-407
FAILURE CODE [DW45KA] 40-408
FAILURE CODE [DW45KB] 40-411
FAILURE CODE [DW45KY] 40-414
FAILURE CODE [DW4CKY] 40-416
FAILURE CODE [DWA2KA] 40-418
FAILURE CODE [DWA2KB] 40-420
FAILURE CODE [DWA2KY] 40-422
FAILURE CODE [DWJ0KA] 40-423
FAILURE CODE [DWJ0KB] 40-425
FAILURE CODE [DWJ0KY] 40-427
FAILURE CODE [DWN5KA] 40-428
FAILURE CODE [DWN5KB] 40-430
FAILURE CODE [DWN5KY] 40-432
FAILURE CODE [DXA8KA] 40-434
FAILURE CODE [DXA8KB] 40-436
FAILURE CODE [DXE7KA] 40-438
FAILURE CODE [DXE7KB] 40-440
FAILURE CODE [DXE7KY] 40-442
FAILURE CODE [DXEAKA] 40-443
FAILURE CODE [DXEAKB] 40-445
FAILURE CODE [DXEAKY] 40-447
FAILURE CODE [DY20KA] 40-448
FAILURE CODE [DY20MA] 40-450
FAILURE CODE [DY2CKB] 40-452
FAILURE CODE [DY2DKB] 40-454
FAILURE CODE [DY2EKB] 40-456
FAILURE CODE [F313KA] 40-458
FAILURE CODE [F313KB] 40-459
FAILURE CODE [F318KB] 40-460
FAILURE CODE [F318KY] 40-461
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-462
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-462
E-2 MANUAL PREHEATING SYSTEM DOES NOT OPERATE 40-468
E-3 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP
40-471
00 INDEX AND FOREWORD INDEX
PC88MR-11 00-7
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-473
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN
OPERATION 40-476
E-6 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION
40-477
E-7 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 40-478
E-8 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 40-479
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40-480
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40-481
E-11 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40-482
E-12 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40-483
E-13 FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL 40-485
E-14 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM40-486
E-15 COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 40-487
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
40-488
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE
40-490
E-18 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN 40-491
E-19 FUNCTION SWITCH DOES NOT OPERATE 40-492
E-20 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) 40-493
E-21 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION
SWITCH IS OPERATED 40-494
E-22 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER
OPERATION 40-495
E-23 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS
OPERATED 40-496
E-24 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS
CHANGED 40-497
E-25 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED
40-498
E-26 TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU CHANGE TRAVEL SPEED 40-499
E-27 ALARM BUZZER CANNOT BE STOPPED 40-500
E-28 SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION 40-501
E-29 MACHINE DOES NOT CHANGE TO SERVICE MODE 40-502
E-30 ALL WORK EQUIPMENT, SWING, TRAVEL DO NOT OPERATE 40-503
E-31 ALL WORK EQUIPMENT, SWING, TRAVEL CANNOT BE LOCKED 40-506
E-32 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED
40-508
E-33 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON 40-510
E-34 WHEN LOCK LEVER AUTOMATIC CANCEL SWITCH IS OPERATED, WORK EQUIPMENT
DOES NOT OPERATE 40-512
E-35 TRAVEL ALARM DOES NOT SOUND 40-514
E-36 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS 40-516
E-37 HORN DOES NOT MAKE SOUND 40-517
E-38 HORN DOES NOT STOP SOUNDING 40-519
E-39 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED
40-520
E-40 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 40-521
E-41 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED
40-523
E-42 BOOM RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-524
E-43 BOOM LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-525
E-44 ARM OUT IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-526
INDEX 00 INDEX AND FOREWORD
00-8 PC88MR-11
E-45 ARM IN IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-527
E-46 BUCKET DUMP IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-528
E-47 BUCKET CURL IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-529
E-48 BOOM SWING LEFT IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-530
E-49 BOOM SWING RIGHT IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-531
E-50 SWING IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-532
E-51 TRAVEL IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-533
E-52 BLADE RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-534
E-53 BLADE LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 40-536
E-54 KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY 40-538
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-539
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-539
FAILURE MODE AND CAUSE TABLE 40-540
H-1 ANY WORK EQUIPMENT, SWING OR TRAVEL DOES NOT WORK 40-552
H-2 ALL WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW 40-553
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS BAD 40-555
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 40-556
H-5 ENGINE SPEED FALLS LARGELY OR ENGINE STOPS 40-557
H-6 BOOM SPEED OR POWER IS LOW 40-559
H-7 ARM SPEED OR POWER IS LOW 40-563
H-8 BUCKET SPEED OR POWER IS LOW 40-566
H-9 BLADE SPEED OR POWER IS LOW 40-569
H-10 BOOM SWING SPEED OR POWER IS LOW 40-571
H-11 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40-574
H-12 HYDRAULIC DRIFT OF BOOM IS LARGE 40-575
H-13 HYDRAULIC DRIFT OF ARM IS LARGE 40-576
H-14 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-577
H-15 HYDRAULIC DRIFT OF BLADE IS LARGE 40-578
H-16 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES 40-579
H-17 TIME LAG OF WORK EQUIPMENT IS LARGE 40-580
H-18 ATTACHMENT CIRCUIT CANNOT BE CHANGED 40-582
H-19 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 40-583
H-20 IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER
LOAD MOVES SLOWER 40-584
H-21 IN COMBINED OPERATION OF WORK EQUIPMENT OR SWING AND TRAVEL, TRAVEL
SPEED FALLS LARGELY 40-585
H-22 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW
40-587
H-23 MACHINE DOES NOT TRAVEL STRAIGHT 40-588
H-24 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 40-591
H-25 TRAVEL SPEED IS SLOW 40-594
H-26 ONE OF TRACKS DOES NOT RUN 40-597
H-27 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 40-599
H-28 MACHINE DOES NOT SWING TO RIGHT OR LEFT 40-600
H-29 MACHINE SWINGS ONLY IN ONE DIRECTION 40-602
H-30 SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND
LEFT 40-603
H-31 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 40-604
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION
(RIGHT AND LEFT) 40-605
H-33 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION
(ONLY ONE DIRECTION) 40-606
H-34 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION 40-607
H-35 LARGE UNUSUAL NOISE IS MADE WHEN UPPER STRUCTURE STOPS SWING OPERATION
40-608
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 40-609
00 INDEX AND FOREWORD INDEX
PC88MR-11 00-9
H-37 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40-610
H-38 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT ROTATE) 40-611
H-39 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40-612
TROUBLESHOOTING OF ENGINE (S-MODE) 40-613
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-613
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-614
S-2 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT 40-615
S-3 FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT
DOES NOT START) 40-616
S-4 ENGINE STARTABILITY IS UNSATISFACTORY 40-617
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-619
S-6 ENGINE STOPS DURING OPERATION 40-621
S-7 ENGINE RUNNING IS UNSTABLE 40-623
S-8 OUTPUT IS NOT SUFFICIENT (POWER IS LOW) 40-624
S-9 EXHAUST IS BLACK 40-626
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-628
S-11 ENGINE OIL BECOMES CONTAMINATED QUICKLY 40-629
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-630
S-13 OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES
DOWN) 40-631
S-14 ENGINE OIL PRESSURE FALLS 40-632
S-15 FUEL MIXES INTO ENGINE OIL 40-633
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-634
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT) 40-635
S-18 THERE IS AN UNUSUAL NOISE 40-636
S-19 VIBRATION IS EXCESSIVE 40-638
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-639
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-6
HOW TO READ THIS MANUAL 50-6
COATING MATERIALS LIST 50-8
SPECIAL TOOLS LIST 50-12
SKETCHES OF SPECIAL TOOLS 50-29
PREPARATION 50-32
DRAIN AND ADD COOLANT 50-32
DRAIN AND ADD HYDRAULIC OIL 50-35
DRAIN AND ADD FUEL 50-39
COLLECT AND REFILL REFRIGERANT 50-42
ENGINE AND COOLING SYSTEM 50-44
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-44
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-64
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-76
REMOVE AND INSTALL EGR VALVE ASSEMBLY 50-147
REMOVE AND INSTALL EGR COOLER ASSEMBLY 50-152
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 50-165
REMOVE AND INSTALL FAN BELT 50-171
REMOVE AND INSTALL AUTO-TENSIONER 50-176
REMOVE AND INSTALL EXPANSION TANK ASSEMBLY 50-178
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-188
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-195
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 50-214
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 50-220
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 50-270
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-275
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 50-282
INDEX 00 INDEX AND FOREWORD
00-10 PC88MR-11
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 50-285
REMOVE AND INSTALL KDOC ASSEMBLY 50-291
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-301
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-312
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-317
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-322
POWER TRAIN 50-327
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-327
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-335
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50-383
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 50-394
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 50-406
UNDERCARRIAGE AND FRAME 50-408
SEPARATE AND CONNECT TRACK ASSEMBLY 50-408
REMOVE AND INSTALL SPROCKET 50-411
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 50-413
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-415
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 50-419
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-422
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 50-427
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-440
HYDRAULIC SYSTEM 50-450
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 50-450
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 50-462
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-464
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 50-473
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 50-492
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 50-538
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50-543
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50-546
WORK EQUIPMENT 50-549
REMOVE AND INSTALL BLADE ASSEMBLY 50-549
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-555
REMOVE AND INSTALL BOOM SWING BRACKET 50-566
REMOVE AND INSTALL BOOM ANTI-DROP VALVE ASSEMBLY 50-574
REMOVE AND INSTALL ARM ANTI-DROP VALVE ASSEMBLY 50-581
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 50-587
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY 50-588
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY 50-593
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY 50-599
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY 50-604
DISASSEMBLE AND ASSEMBLE SWING CYLINDER ASSEMBLY 50-609
CAB RELATED PARTS 50-615
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 50-615
REMOVE AND INSTALL OPERATOR’S CAB DOOR 50-647
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 50-652
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 50-663
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 50-667
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-687
REMOVE AND INSTALL OPERATOR’S SEAT 50-714
REMOVE AND INSTALL SEATBELT 50-719
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 50-721
ELECTRICAL SYSTEM 50-734
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-734
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 50-740
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-745
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-756
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER 50-759
00 INDEX AND FOREWORD INDEX
PC88MR-11 00-11
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ENGINE AND COOLING SYSTEM 60-3
MAINTENANCE STANDARD OF ENGINE MOUNT 60-3
MAINTENANCE STANDARD OF PTO 60-4
MAINTENANCE STANDARD OF COOLING SYSTEM 60-5
POWER TRAIN 60-6
MAINTENANCE STANDARD OF SWING CIRCLE 60-6
MAINTENANCE STANDARD OF SWING MACHINERY 60-8
MAINTENANCE STANDARD OF SPROCKET 60-10
UNDERCARRIAGE AND FRAME 60-11
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 60-11
MAINTENANCE STANDARD OF IDLER 60-13
MAINTENANCE STANDARD OF TRACK ROLLER 60-15
MAINTENANCE STANDARD OF CARRIER ROLLER 60-16
MAINTENANCE STANDARD OF TRACK SHOE 60-17
MAINTENANCE STANDARD OF TRIPLE SHOE 60-20
MAINTENANCE STANDARD FOR RUBBER SHOE 60-21
HYDRAULIC SYSTEM 60-22
MAINTENANCE STANDARD OF HYDRAULIC TANK 60-22
MAINTENANCE STANDARD OF MAIN PUMP 60-23
MAINTENANCE STANDARD OF PC-EPC VALVE 60-26
MAINTENANCE STANDARD OF SWING MOTOR 60-27
MAINTENANCE STANDARD OF TRAVEL MOTOR 60-29
MAINTENANCE STANDARD OF CONTROL VALVE 60-30
MAINTENANCE STANDARD OF ANTI-DROP VALVE OF BOOM 60-41
MAINTENANCE STANDARD OF ANTI-DROP VALVE OF ARM 60-43
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60-45
MAINTENANCE STANDARD OF BLADE PPC VALVE 60-48
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 60-50
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60-52
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 60-55
MAINTENANCE STANDARD OF SOLENOID VALVE 60-58
MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE 60-59
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE
CIRCUIT) 60-60
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60-61
WORK EQUIPMENT 60-62
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-62
MAINTENANCE STANDARD OF BOOM CYLINDER 60-72
MAINTENANCE STANDARD OF ARM CYLINDER 60-73
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-74
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 60-75
MAINTENANCE STANDARD OF BLADE CYLINDER 60-76
80 APPENDIX 80-1
CONTENTS 80-2
AIR CONDITIONER SYSTEM 80-4
PRECAUTIONS FOR REFRIGERANT 80-4
AIR CONDITIONER COMPONENT 80-5
SPECIFICATIONS OF AIR CONDITIONER 80-7
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-8
OUTLINE OF REFRIGERATION CYCLE 80-9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-11
AIR CONDITIONER UNIT 80-11
COMPONENT PARTS OF AIR CONDITIONER UNIT 80-14
AIR CONDITIONER CONTROLLER 80-19
COMPRESSOR 80-20
CONDENSER 80-21
INDEX 00 INDEX AND FOREWORD
00-12 PC88MR-11
RECEIVER DRIER 80-22
SENSORS FOR AIR CONDITIONER SYSTEM 80-23
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
80-25
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80-27
AIR CONDITIONER SYSTEM DIAGRAM 80-29
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80-30
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
80-32
TESTING AIR LEAKAGE (DUCT) 80-38
METHOD FOR TESTING AIR LEAKAGE (DUCT) 80-38
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 80-39
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR 80-40
TEST VENT (MODE) CHANGEOVER 80-41
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80-41
TESTING FRESH/RECIRC AIR CHANGEOVER 80-42
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80-42
TEST SUNLIGHT SENSOR 80-43
METHOD FOR TESTING SUNLIGHT SENSOR 80-43
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-44
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-44
TEST RELAYS 80-46
METHOD FOR TESTING RELAYS 80-46
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-47
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-48
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-51
FAILURE CODE [879AKA] 80-53
FAILURE CODE [879AKB] 80-54
FAILURE CODE [879BKA] 80-55
FAILURE CODE [879BKB] 80-57
FAILURE CODE [879CKA] 80-59
FAILURE CODE [879CKB] 80-60
FAILURE CODE [879DKZ] 80-61
FAILURE CODE [879EMC] 80-63
FAILURE CODE [879FMC] 80-64
FAILURE CODE [879GKX] 80-65
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-67
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
80-69
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-72
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-74
TROUBLESHOOTING USING GAUGE PRESSURE 80-76
CONNECTION OF SERVICE TOOL 80-79
METHOD FOR CONNECTING SERVICE TOOL 80-79
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-81
HANDLE COMPRESSOR OIL 80-83
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
HOW TO READ THE CODES FOR ELECTRIC CABLE 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-7
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-7
HYDRAULIC CIRCUIT DIAGRAM 90-11
HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE OPERATION) 90-13
HYDRAULIC CIRCUIT DIAGRAM (AT LEFT SWING OPERATION) 90-15
00 INDEX AND FOREWORD INDEX
PC88MR-11 00-13
HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE AND LEFT SWING OPERATION) 90-17
ELECTRICAL CIRCUIT DIAGRAM 90-19
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 90-19
ELECTRICAL CIRCUIT DIAGRAM (1/8) 90-23
ELECTRICAL CIRCUIT DIAGRAM (2/8) 90-25
ELECTRICAL CIRCUIT DIAGRAM (3/8) 90-27
ELECTRICAL CIRCUIT DIAGRAM (4/8) 90-29
ELECTRICAL CIRCUIT DIAGRAM (5/8) 90-31
ELECTRICAL CIRCUIT DIAGRAM (6/8) 90-33
ELECTRICAL CIRCUIT DIAGRAM (7/8) 90-35
ELECTRICAL CIRCUIT DIAGRAM (8/8) 90-37
INDEX 1

DESCRIPTION:

Komatsu PC88MR-11 Compact Hydraulic Excavator Shop Manual SEN06843-04 – PDF DOWNLOAD

SERIAL NUMBERS 10001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD:
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL: