Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC80MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC80MR 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.
WEBM008601 – Hydraulic Excavator PC80MR-3 Shop Manual.pdf
Total Pages: 302 pages
File Format: PDF
Language: English
CEAM021202 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…4
FOREWORD…5
SAFETY INFORMATION…6
Signal Words…6
Other Signal Words…6
Safety Labels…7
Safety Label Using Words…7
Safety Label Using Pictogram…7
INTRODUCTION…8
Directional Reference of Machine…8
Visibility from Operator’s Seat…8
BREAKING IN THE MACHINE…9
PRODUCT INFORMATION…10
Product Identification Number (PIN) – Machine Serial No. Plate…10
EPA* Regulations, Engine Serial Number Plate and its Location…10
Service Meter Location…11
Your Machine Serial Numbers and Distributor…11
TABLE OF CONTENTS…12
SAFETY…24
SAFETY AND WARNING DECALS…25
Location of Safety Decals…26
GENERAL SAFETY RULES AND PRECAUTIONS…33
General Safety Rules…33
General Safety at Job Site…34
Working on Loose Ground…34
Safety Features…35
Personal Protective Equipment…35
Fire and Explosion Prevention…36
Fire Caused by Fuel or Oil…36
Fire Caused by Accumulation of Flammable Material…36
Fire Coming From Electric Wiring…37
Fire Coming From Hydraulic Line…37
Windshield Washer Fluid…37
Action if Fire Occurs…37
Fire Extinguisher and First Aid Kit…37
Fire Prevention and Suppression…38
Fire Prevention Steps…38
Fixed Fire Detection System…38
Fixed Fire Suppression System…38
Fire Prevention Procedures…38
Dust Hazard Precautions…39
Keep Operator’s Cab Clean…39
Unauthorized Modifications…39
Leaving Operator’s Compartment…40
Mounting and Dismounting…41
Crush or Pinch Point Dangers…41
Inside Operator’s Compartment…42
Precautions When Using ROPS…42
Protection Against Falling or Flying Objects…43
Precautions for Attachments…44
Quick Coupler Attachment…44
Large Attachments…44
PRECAUTIONS BEFORE STARTING OPERATIONS…45
Pre-Operational Checks…45
Seat Belt Inspection…46
Starting Your Work Operations…47
Work Site Hazards…47
Avoiding Dangerous Situations…48
Working Clearances…52
Operations on Slopes…53
Operating on Snow or Icy Surfaces…53
Asbestos Hazard Alert…53
RULES FOR ROAD TRAVEL…54
Precautions When Traveling…54
Traveling with Carriage Reversed…54
Travel on Slopes…55
Parking the Machine…57
PRECAUTIONS DURING MAINTENANCE OPERATIONS…58
Warning Tags…58
Equipment Storage…58
Working Under the Machine…59
Using Drop Lamps…59
Keeping the Machine Clean…59
Performing General Maintenance Procedures…60
Running the Engine During Maintenance…61
Proper Tools…61
Engine System High-Voltage…61
Welding, Grinding or Cutting…62
Adjusting Track Tension…62
DO NOT Disassemble Recoil Springs…62
When Using Hammer…62
Refueling the Machine…63
Cooling System Precautions…63
Battery Precautions…64
Starting the Machine…65
High-Pressure Hoses…65
Handling High-Pressure Hoses…65
Precaution for High Fuel Pressure…66
High Temperatures Areas…66
Disposal of Waste Materials…66
Accumulator…67
Critical Parts…67
TRANSPORTING THE MACHINE…68
Loading and Unloading a Trailer…68
Loading the Machine…69
Securing the Machine…71
TOWING…72
Safety Rules for Towing…72
OPERATION…74
MACHINE VIEW ILLUSTRATIONS…75
Overall Machine View…75
Controls and Gauges…76
Machine Monitor…77
DETAILED CONTROLS AND GAUGES…78
Monitoring System…78
Basic Operation of Machine Monitor…79
Starting Engine When Situation is Normal…79
Stopping Engine When Situation is Normal…80
If There Is Abnormality When Starting Engine…81
If Any Abnormality Occurs During Operation…81
Emergency Monitors…83
Engine Coolant Temperature Monitor…83
Hydraulic Oil Temperature Monitor…83
Engine Oil Pressure Monitor…84
Caution Monitors…85
Engine Coolant Temperature Monitor…85
Hydraulic Oil Temperature Monitor…86
Fuel Level Monitor…86
Charge Level Monitor…86
Basic Check Monitors…87
Maintenance Interval Monitor…87
Meter Display Portion…88
Pilot Display…88
Engine Pre-heating Monitor…88
Swing Lock Monitor…89
Wiper Monitor…89
Auto-deceleration Monitor…89
Working Mode Monitor…89
Travel Speed Monitor…90
Air Conditioner Monitor…90
Message Monitor…90
Idle Stop Guidance…90
Gauges and Meter…91
Engine Coolant Temperature Gauge…91
Hydraulic Oil Temperature Gauge…92
Fuel Gauge…92
Service Meter, Clock…93
ECO Gauge…94
Monitor Switches Portion…95
Working Mode Selector Switch…95
Auto-deceleration Switch…98
Travel Speed Selector Switch…99
Wiper Switch…100
Window Washer Switch…101
Buzzer Cancel Switch…101
Function Switches…102
Air Conditioner Switch…102
Handling Function Switches…103
Service Meter/Clock Display Selector Switch…104
Maintenance Selector Switch…105
Operations on Maintenance List Screen…106
Operations on Maintenance Interval Reset Screen…107
User Mode Selector Switch…108
Breaker/Attachment Setting…110
Message Display…123
Adjusting Screen…125
Clock Adjustment…128
Language Selection…134
Adjusting Economy Mode…136
Switches…138
Ignition Switch…138
Fuel Control Dial…139
Cigarette Lighter…139
1st-Line Attachment Proportional Switch…140
Breaker Operation Switch…140
Horn Switch…140
Room Lamp Switch…140
Emergency Pump Drive Switch…141
Swing Parking Brake Release Switch…141
Revolving Warning Lamp Switch (If Equipped)…141
Lamp Switch…142
Quick Coupler Switches…142
Control Levers and Pedals…143
Lock Lever…144
Travel Levers…145
Work Equipment Control Lever…146
Blade Control Lever…147
Swing Lock Cover…147
Boom Swing Control Pedal…147
SUN ROOF…148
WINDSHIELD…149
Opening…149
Closing…153
Removing Lower Windshield…155
SLIDING DOOR…156
EMERGENCY ESCAPE HAMMER…157
COVER WITH LOCK…158
Opening and Closing Covers with Lock…158
Opening the Cover…158
Locking the Cover…158
ENGINE HOOD…159
MUD COVER…161
BATTERY INSPECTION COVER…162
AIR CONDITIONER CONTROLS…163
Air Conditioner Control Panel…163
OFF Switch…163
Fan Switch…164
Temperature Control Switch…164
Vent Selector Switch…165
Auto Switch…166
FRESH/RECIRC Selector Switch…166
Display Monitor…166
Air Conditioner Switch…167
Sunlight Sensor…167
Method of Operation…168
Automatic Operation…168
Stopping Automatic Operation…169
Manual Operation…169
Stopping Manual Operation…171
Operation with Cold Air to Face and Warm Air to Feet…171
Defroster Operation…173
Use Air Conditioner with Care…175
Ventilation…175
Temperature Control…175
Inspection and maintenance of Air Conditioner Equipped Machine…175
RADIO…177
Control Panel…177
Power Switch, Volume Control Knob, Balance Control Knob…177
Sel Button…177
FM/AM Selection Button (AM/FM)…177
Display Selection Button (TIME)…177
AS/PS button…178
Preset Station Buttons (1, 2, 3, 4, 5, 6)…178
Display…178
Time Reset Button…178
Tuning Button (TUNING)…178
Controls of Radio…179
Method of Setting with Preset Button…179
Method of Tuning…179
Method of Operating Mode…179
Setting Correct Time…180
Antenna…180
Use Radio with Care…180
FUSE…181
Fuse Capacities and Circuit Names…181
Fusible Link…182
AUXILIARY ELECTRIC POWER…183
CONTROLLERS…184
OPERATION MANUAL STORAGE…185
CUP HOLDER…185
TOOL BOX…185
GREASE PUMP HOLDER…185
ASHTRAY…186
FIRE EXTINGUISHER (IF EQUIPPED)…186
MACHINE OPERATIONS AND CONTROLS…187
Before Starting Engine…187
Walk-Around Checks…187
Checks Before Starting…188
Check Coolant Level, Add Coolant…188
Check Oil Level in Engine Oil Pan, Add Oil…189
Check Fuel Level, Add Fuel…191
Check Oil Level in Hydraulic Tank, Add Oil…193
Check Dust Indicator…194
Check for Water and Sediment in Water Separator, Drain Water…195
Check Electric Wiring…197
Check Working Lamp Switch…197
Check Function of Horn…197
Adjustments…198
Seat Adjustment…198
Rear View Mirrors…199
Wind-in Type Seat Belt…201
Operations Before Starting Engine…202
STARTING ENGINE…205
Normal Starting…205
Starting Engine in Cold Weather…207
Turbo protect function…209
Breaking-in the New Machine…209
AFTER STARTING ENGINE…210
Checking Engine Startability and Noise…210
Checking Engine Acceleration and Deceleration…210
Engine Warm Up…211
Hydraulic Equipment Warm Up…213
Operation After Completion of Warm-Up Operation…219
STOPPING THE ENGINE…221
MACHINE OPERATION…222
Preparations for Moving the Machine…222
Moving Machine Forward…223
Moving Machine Backward…224
Stopping Machine…225
STEERING THE MACHINE…226
Steering…226
Steering the Machine When Stopped…226
Changing Direction of the Machine…227
Counter-rotation Turn (Spin Turn)…227
SWINGING…228
WORK EQUIPMENT CONTROLS AND OPERATIONS…229
WORKING MODE…231
PROHIBITED OPERATIONS…233
Operations Using Swing Force…233
Operations Using Travel Force…233
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends…233
Operations Using Bucket Dropping Force…234
Operations Using Machine Dropping Force…234
Digging Hard Rocky Ground…234
Prohibition of Lifting Operation…235
Sudden Lever or Pedal Shifting High Speed Travel…235
Support Blade on Both Sides…235
GENERAL OPERATION INFORMATION…236
Traveling…236
High Speed Travel…236
Folding in Work Equipment…236
Avoid Hitting Blade…237
Blade During Backhoe Operations…237
Permissible Water Depth…237
TRAVELING ON SLOPES…238
Traveling Downhill…239
Engine Stopped on Slope…239
Cab Doors on Slope…239
ESCAPE FROM MUD…240
Track on One Side Stuck…240
Tracks on Both Sides Stuck…240
RECOMMENDED APPLICATIONS…241
Backhoe Work…241
Shovel Work…241
Ditching Work…241
Loading Work…242
Refill and Finishing Work…242
Side Ditching Work…242
BUCKET REPLACEMENT AND INVERSION…243
Replacement…243
Inversion…244
PARKING MACHINE…247
MACHINE INSPECTION AFTER DAILY WORK…249
Before Stopping Engine…249
After Stopping Engine…249
LOCKING…249
ROAD LINERS AND RUBBER SHOES…250
Road Liners and Rubber Shoes Information…250
Warranty for Road Liners and Rubber Shoes…250
Using Road Liners and Rubber Shoes…251
Prohibited Works…251
Long Life Operations…251
MACHINE READY FOR ATTACHMENT…255
Locations…255
Selector Valve…255
1st-Line Attachment Proportional Switch…256
Breaker Operation Switch…256
Breaker Circuit Additional Oil Filter…256
Accumulator (For Low Pressure)…256
Hydraulic Circuit…257
Hydraulic Circuit Connection…257
Attachment Removal And Installation…259
Attachment Installation…259
Attachment Removal…261
Attachment Operations…263
When Using Breaker…263
When Using General Attachment Such As Crusher…265
Long Term Storage…265
Hydraulic Specifications…265
TRANSPORTATION…265
Transportation Procedure…265
Loading and Unloading with Trailer…266
Loading…267
Securing Machine…268
Unloading…269
LIFTING MACHINE…272
COLD WEATHER OPERATION…273
Fuel and Lubricants…273
Cooling System Coolant…273
Battery…274
After Daily Work Completion…275
After Cold Weather Season…275
LONG TERM STORAGE…276
Before Storage…276
During Storage…276
After Storage…276
Starting Machine After Long-term Storage…276
TROUBLES AND ACTIONS…277
Running Out of Fuel…277
Phenomena That Are Not Failures…277
Towing the Machine…278
Severe Job Condition…278
Discharged Battery…279
Battery Removal and Installation…280
Battery Charges…281
Starting Engine with Booster Cables…282
Connecting and Disconnecting Booster Cables…282
Booster Cable Connection…283
Starting the Engine…283
Booster Cable Disconnection…283
TROUBLESHOOTING…285
Electrical System…285
Chassis…286
Engine…287
Electronic Control System…289
Point of Contact to Telephone when Error Occurs…289
MAINTENANCE…290
GUIDES TO MAINTENANCE…291
Check Service Meter…291
Komatsu Genuine Replacement Parts…291
Komatsu Genuine Oils…291
Always Use Clean Washer Fluid…291
Always Use Clean Oil and Grease…291
Checking Foreign Materials in Drained Oil and on Filters…291
Fueling…291
Welding Instructions…291
Do Not Drop Things Inside Machine:…291
Dusty Work Sites…292
Avoid Mixing Oil…292
Locking Inspection Covers…292
Bleeding Air From Hydraulic Circuit…292
Precautions When Installing Hydraulic Hoses…292
Checks After Inspection and Maintenance…292
OUTLINES OF SERVICE…293
Handling Oil, Fuel, Coolant, and Performing Oil Clinic…293
Oil…293
Fuel…293
Coolant and Water for Dilution…294
Grease…294
Performing KOWA (Komatsu Oil Wear Analysis)…295
Storing Oil and Fuel…296
Filters…296
Outline of Electric System…296
WEAR PARTS LIST…297
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…298
USE OF FUEL, COOLANT AND LUBRICANTS…299
Selection According to Ambient Temperature…299
Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil…300
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…301
Torque List…301
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…303
Safety Critical Parts…303
REGULAR SCHEDULED MAINTENANCE…305
Maintenance Schedule Chart…305
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…306
WHEN REQUIRED…307
Check, Clean and Replace Air Cleaner Element…307
Checking…307
Cleaning Outer Element…307
Replacing Element…309
Clean Inside of Cooling System…311
Mixing Rate of Water and Antifreeze…312
Check and Tighten Track Shoe Bolts…314
Method for Further Tightening of Steel Shoe…314
Method for Further Tightening of Road Liner…314
Order for tightening…314
Check and Adjust Track Tension…315
Checking…315
Adjustment…315
Increasing Track Tension…315
Loosening Track Tension…316
Check Road Liners or Rubber Shoes…317
Lug Height…317
Rubber Shoe Steel Code Cuts…317
Rubber Shoe Core Separations…318
Rubber Shoe Tension…318
Rubber Shoe Cracks…318
Check and Adjust Rubber Shoe Tension…319
Checking…319
Adjustment…319
Increasing Track Tension…319
Loosening Track Tension…320
Replace Road Liners…320
Replace Rubber Shoes…321
Rubber Shoes Removal…321
Rubber Shoes Installation…322
Change Steel Shoes or Road Liner to Rubber Shoes…323
Changing from Steel Shoes or Road Liners to Rubber Shoes…323
Changing from Rubber Shoes to Steel Shoes or Road Liners…323
Replace Bucket Teeth (Vertical Pin Type)…324
Replace Bucket Teeth (Horizontal Pin Type)…327
Adjust Bucket Clearance…329
Check Window Washer Fluid Level, Add Fluid…330
Check and Maintenance of Air Conditioner…331
Check Level of Refrigerant (Gas)…331
Inspection During Off Season…331
Inspection and Maintenance Items…331
Check, Clean and Lubricate Cab Slide Door Rail and Roller…332
Checking…332
Cleaning…332
Greasing…332
Replace Breaker Circuit Additional Oil Filter Element…333
Wash Washable Floor…334
Method of Washing…334
Method of Setting Machine at Angle…335
Check Gas Spring…337
Bleeding Air From Hydraulic System…338
CHECK BEFORE STARTING…341
EVERY 100 HOURS MAINTENANCE…342
Lubricating…342
Check Swing Machinery Case Oil, Add Oil…343
EVERY 250 HOURS MAINTENANCE…344
Check Oil Level in Final Drive Case, Add Oil…344
Check Level of Battery Electrolyte…344
When Checking Electrolyte Level from Side of Battery…345
When it is Impossible to Check Electrolyte Level from Side of Battery…346
When it is Possible to Use Indicator to Check Electrolyte Level…346
Check and Adjust Cooling Fan Belt Tension…347
Checking…347
Adjustment…348
Check Air Conditioner Compressor Belt Tension, Adjust…349
Checking…349
Adjustment…350
EVERY 500 HOURS MAINTENANCE…351
Lubricating…351
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge…353
Replace Fuel Pre-Filter Cartridge…354
Check Swing Pinion Grease Level, Add Grease…356
Lubricate Swing Circle…356
Clean and Inspect Radiator Fins, Oil Cooler Fins, After Cooler Fins, Fuel Cooler Fins, and Air Conditioner Condenser Fins…357
Clean Air Conditioner Fresh/Recirc Filters…358
Cleaning Recirculated Air Filter…358
Cleaning Fresh Air Filter…358
Replace Breather Element In Hydraulic Tank…359
EVERY 1000 HOURS MAINTENANCE…360
Change Oil in Swing Machinery Case…360
Change Oil in Final Drive Case…361
Replace Hydraulic Oil Filter Element…362
Replace Fuel Main Filter Cartridge…364
Check All Tightening Points of Engine Exhaust Pipe Clamps…366
Check Oil Level in PTO Gear Case, Add Oil…366
EVERY 2000 HOURS MAINTENANCE…367
Check Alternator, Starting Motor…367
Check Engine Valve Clearance, Adjust…367
Checking Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit)…367
Function of Accumulator…367
Checking Function of Accumulator…368
Method of Releasing Pressure In Hydraulic Circuit…370
EVERY 4000 HOURS MAINTENANCE…371
Check Water Pump…371
Replace Accumulator (For Control Circuit)…371
EVERY 5000 HOURS MAINTENANCE…372
Change Oil in Hydraulic Tank, Clean Strainer…372
SPECIFICATIONS…376
SPECIFICATIONS…377
OPTIONS, ATTACHMENTS…380
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…381
Safety First…381
Attachment Installation…382
BUCKET WITH HOOK…383
Hook Condition…383
Prohibited Operations…383
Operations with Care…383
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…384
Control Pattern Change Procedure…384
Machine Control Patterns…385
HYDRAULIC QUICK COUPLER PIPING…386
Locations…386
Operation…387
To Release a Bucket or Attachment…387
To Pick Up a New Bucket or Attachment…387
POWER ANGLE BLADE…388
Blade Control Lever…388
Lifting Control…388
Angling Control…388
Maintenance…389
When Required…389
Every 500 Hours Service…389
Wear Parts List…390
Specifications…390
ATTACHMENT GUIDE…391
Attachment Combinations…391
Track Shoes Selection…392
RECOMMENDED ATTACHMENT OPERATIONS…393
Hydraulic Breaker…393
Main Applications…393
Prohibited Works…395
Greasing…398
Crusher…399
Main Applications…399
Prohibited Works…399
HANDLING MACHINES EQUIPPED WITH KOMTRAX…403
Basic Precautions…403
CEBM007301 – Hydraulic Excavator PC88MR-8 Shop Manual…404
CEBM007301 – PC88MR-8 sn A90001-up…0
CONTENTS…405
REVISED PAGES…406
SAFETY…422
Safety Notice…422
Important Safety Notice…422
General Precautions…422
Preparations For Work…422
Precautions During Work…422
GENERAL…425
HOW TO READ THE SHOP MANUAL…426
Volumes…426
Distribution And Updating…426
Filing Method…426
Revised Edition Mark…426
Revisions…426
Symbols…426
HOISTING INSTRUCTIONS…427
Hoisting…427
Wire Ropes…427
PUSH PULL COUPLER…428
Type 1…428
Disconnection…428
Connection…428
Type 2…429
Disconnection…429
Connection…429
Type 3…430
Disconnection…430
Connection…430
EXPLANATION OF MAINTENANCE STANDARD TERMS…431
STANDARD TIGHTENING TORQUE…433
Bolts And Nuts…433
Tightening Torque Of Hose Nuts…434
Tightening Torque Of Split Flange Bolts…434
Tightening Torque For Flared Nuts…434
Tightening Torques For O-ring Boss Piping Joints…435
Table Of Tightening Torques For O-ring Boss Plugs…435
Torque Table For Hoses (Taper Seal Type And Face Seal Type)…435
ELECTRIC WIRE CODE…436
Classification By Thickness…436
Classification By Color And Code…436
How To Read Electric Wire Code…437
CONVERSION TABLES…440
Method Of Using The Conversion Table…440
COATING MATERIALS…446
01 GENERAL…448
SPECIFICATIONS DIMENSION DRAWING…449
Working Range Diagram…450
Specifications…451
Weight Table…455
TABLE FOR FUEL, COOLANT AND LUBRICANTS…457
Selection According to Ambient Temperature…457
Mixing Rate of Water and Antifreeze…458
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…460
ENGINE AND COOLING SYSTEM…465
Engine Mount…465
Cooling System…467
Power Take Off (PTO)…469
POWER TRAIN…470
Power Train…470
Swing Circle…471
Swing Machinery…473
UNDERCARRIAGE AND FRAME…475
Track Frame…475
Idler Cushion…476
Idler…477
Track Roller…479
Carrier Roller…480
Sprocket…481
Track Shoe…483
City Pad Shoe, Road Liner, Triple Grouser Shoe…483
City Pad Shoe, Triple Grouser Shoe…486
Road Liner…487
HYDRAULIC SYSTEM…489
Hydraulic Equipment Layout Drawing…489
Valve Control…490
Hydraulic Tank and Filter…491
Oil Filler Cap Breather…492
Hydraulic Pump…493
Model: LPD45+45…493
Operation of Pump…498
Servo Valve…499
Control of Delivery…501
LS Valve…502
PC Valve…502
Action of Spring…503
When Pump Pressure (PAVE) is Low…503
When Pump Pressure (PAVE) is High…503
When Swing Gear Pump Pressure Increases or Decreases…503
When PC-EPC Valve Operates…503
When Load is Light…504
When Load is Heavy…505
When Balanced…506
Control Valve…507
10-Spool Valve (EU Specification)…507
Sectional Views…509
9-Spool Valve (North America Specification)…521
CLSS…523
Outline of CLSS…523
Features…523
Composition…523
Basic principle…524
Pump swash plate angle control…524
LS differential pressure (rPLS) and pump swash plate angle…524
Pressure compensation control…525
Functions and Operation by Valve…527
Hydraulic Circuit Diagram and the Name of Valves…527
9-Spool Valve (North America Specification)…528
Unload Valve…529
Merge-Divider Valve…539
Introduction of LS Pressure…541
Travel Valve…542
LS Bypass Valve…543
LS Select Valve…545
Boom RAISE Merge Valve…547
Pressure compensation valve…550
Boom hydraulic drift prevention valve…551
Boom regeneration circuit…554
Travel junction valve…557
Travel LS Bleed Circuit and Travel Junction Valve…561
PPC Valve…565
Work Equipment and Swing PPC Valve…565
Travel PPC Valve…571
Blade and Boom Swing PPC Valve…575
Swing Motor…577
Brake Valve…581
Modulating Relief Valve…583
Swing Holding Brake…584
Reverse Prevention Valve…585
Travel Motor…588
Center Swivel Joint…596
Solenoid Valve…597
4-Spool Solenoid Valve…597
Check Valve…598
Solenoid Valve…599
EPC Valve…601
PPC Accumulator…604
Anti-Drop Valve…606
Multi-Control Valve…611
WORK EQUIPMENT…612
Dimensions of Components…615
Arm…615
Bucket…619
Work Equipment Cylinder…621
Boom Cylinder…621
Arm Cylinder…621
Bucket Cylinder…621
Boom Swing Cylinder…622
Blade Cylinder…622
AIR CONDITIONER…625
Air Conditioner Piping Diagram…625
Refrigerant Circuit Diagram…627
Air Conditioner Unit…629
Air Conditioner Controller…632
Compressor…633
Condenser…634
Receiver…635
Sensors…636
Sunlight Sensor…636
Ambient Air Temperature Sensor…636
ELECTRICAL SYSTEM…637
Electrical Control System…637
Machine Control System Diagram…637
Engine Control Function…639
Engine and Pump Mutual Control Function…641
Auto-Deceleration Function…645
Engine Automatic Warm-Up Function…647
Turbocharger Protection Function…649
Swing Control Function…651
Travel Control Function…653
PPC Lock Function…655
Oil Flow Adjuster Function for Attachment…656
System Components…657
Engine Controller…657
Pump Controller…659
Fuel control dial…661
Resistor…662
Engine Oil Pressure Switch…663
PPC Oil Pressure Switch…664
Monitor System…665
Machine monitor…667
Display…669
Switches…673
Operator Mode Function…677
Service Mode Function…679
KOMTRAX System…680
KOMTRAX terminal…681
Input and Output Signals…681
Sensor…682
Atmospheric Pressure Sensor…682
Boost Pressure and Temperature Sensor…682
Coolant Temperature Sensor…683
Crankshaft Speed Sensor…683
Camshaft Speed Sensor…683
Common Rail Pressure Sensor…684
Hydraulic Oil Temperature Sensor…684
Fuel Level Sensor…685
Pump Oil Pressure Sensor…686
Boom Cylinder Bottom Oil Pressure Sensor…686
PPC Oil Pressure Sensor…687
20 STANDARD VALUE TABLES…688
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…689
STANDARD VALUE TABLE FOR CHASSIS…690
30 TESTING AND ADJUSTING…698
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…701
ENGINE SPEED…706
EXHAUST TEMPERATURE…707
EXHAUST GAS COLOR…709
VALVE CLEARANCE…711
COMPRESSION PRESSURE…713
BLOW-BY PRESSURE…715
ENGINE OIL PRESSURE…717
HANDLING FUEL SYSTEM PARTS…719
Releasing Residual Pressure From Fuel System…719
Testing Fuel Pressure…720
Testing Fuel Return Rate And Fuel Leakage…721
Bleeding Air From Fuel Circuit…723
Checking Fuel Circuit for Leakage…725
ALTERNATOR BELT TENSION…727
Testing…727
Adjusting…728
AIR CONDITIONER COMPRESSOR BELT TENSION…729
Checking…729
Adjusting…729
SWING CIRCLE BEARING CLEARANCE…730
TRACK SHOE TENSION…731
Checking…731
Adjusting…731
Increasing tension…731
Decreasing tension…732
OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS…733
Testing…733
Adjusting…735
SWING AND BLADE CIRCUIT OIL PRESSURE…737
Testing…737
CONTROL CIRCUIT BASIC PRESSURE…741
OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…743
PC-EPC SOLENOID OUTPUT PRESSURE…746
LS DIFFERENTIAL PRESSURE AND LS VALVE…747
Testing LS Differential Pressure…747
Adjusting LS Valve…748
SOLENOID VALVE OUTPUT PRESSURE…749
PPC VALVE OUTPUT PRESSURE…751
PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…753
PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT…755
TRAVEL DEVIATION…757
Inspection…757
Adjusting…758
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…759
OIL LEAKAGE…761
Bleeding Air from Each Part…765
MIRRORS…767
SPECIAL FUNCTIONS OF MACHINE MONITOR…769
Upper Section of Machine Monitor (Display Section)…770
Upper Section of Machine Monitor (Switch Section)…770
Lower Section of Machine Monitor (Switch Section)…770
Ordinary and Special Functions of Machine Monitor…771
Operator Mode (Outline)…772
Service Mode…785
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…823
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…824
Machine Monitor…824
Engine Controller…825
Pump Controller…825
KOMTRAX Communication Module…826
Engine Ne Speed Sensor (Crank Sensor)…826
Engine Bkup Speed Sensor (Cam Sensor)…826
Engine Oil Pressure Switch (Oil Pressure Switch)…826
Boost Pressure and Temperature Sensor (Boost Press and Imt)…827
Supply Pump IMV Solenoid (Fuel Regulator)…827
Common Rail Pressure Sensor (Fuel Rail Press)…828
Engine Coolant Temperature Sensor (Coolant Temp)…828
PROCEDURE FOR TESTING DIODES…829
When Using Digital Circuit Tester…829
When Using Analog Circuit Tester…830
PM CLINIC SERVICE…831
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge…831
Check sheet (PC88MR-8)…832
Engine…832
Work equipment speed…832
Hydraulic drift of work equipment…832
Hydraulic circuit…833
* Gauge changing work: Change hoses of gauges [3] and [4]…833
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5]…834
40 TROUBLESHOOTING…836
GENERAL INFORMATION ON TROUBLESHOOTING…841
Points to Remember When Troubleshooting…841
Sequence of Events in Troubleshooting…843
Checks Before Troubleshooting…844
Classification and Procedures for Troubleshooting…845
Procedure for Troubleshooting…845
Phenomena Looking Like Troubles and Troubleshooting Nos…847
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…850
T-ADAPTER TABLE…873
FAILURE CODE TABLE…877
FUSE LOCATIONS…879
TROUBLESHOOTING BY FAILURE CODE…882
Failure Code [989L00] Engine Controller Lock Caution 1…882
Failure Code [989M00] Engine Controller Lock Caution 2…883
Failure Code [989N00] Engine Controller Lock Caution 3…884
Failure Code [AB00KE] Charge Voltage Low…885
Failure Code [B@BAZG] Eng Oil Press. Low…887
Failure Code [B@BCNS] Eng Coolant Overheat…887
Failure Code [B@HANS] Hyd. Oil Overheat…888
Failure Code [CA111] ECM Critical Internal Failure…889
Failure Code [CA115] Eng. Ne and Bkup Speed Sensor Error…892
Failure Code [CA122] Charge Air Press Sensor High Error…893
Failure Code [CA123] Charge Air Press Sensor Low Error…895
Failure Code [CA131] Throttle Sensor High Error…897
Failure Code [CA132] Throttle Sensor Low Error…899
Failure Code [CA144] Coolant Temp. Sensor High Error…901
Failure Code [CA145] Coolant Temp. Sensor Low Error…903
Failure Code [CA153] Charge Air Temp. Sensor High Error…905
Failure Code [CA154] Charge Air Temp. Sensor Low Error…907
Failure Code [CA187] Sensor Sup. 2 Volt. Low Error…908
Failure Code [CA221] Ambient Air Press. Sensor High Error…909
Failure Code [CA227] Sensor Sup. 2 Volt. High Error…912
Failure Code [CA234] Eng. Overspeed…913
Failure Code [CA238] Ne Speed Sensor Sup. Volt. Error…915
Failure Code [CA272] IMV/PCV1 Open Error…919
Failure Code [CA322] Injector #1 (L #1) System Open/Short Error…921
Failure Code [CA324] Injector #3 (L #3) System Open/Short Error…923
Failure Code [CA331] Injector #2 (L #2) System Open/Short Error…925
Failure Code [CA332] Injector #4 (L #4) System Open/Short Error…927
Failure Code [CA351] Inj. Drive Circuit Error…929
Failure Code [CA352] Sensor Sup. 1 Volt. Low Error…932
Failure Code [CA386] Sensor Sup. 1 Volt. High Error…933
Failure Code [CA435] Abnormality in Engine Oil Pressure Switch…935
Failure Code [CA441] Battery Voltage Low Error…936
Failure Code [CA442] Battery Voltage High Error…937
Failure Code [CA449] Rail Press. Very High Error…938
Failure Code [CA451] Rail Press. Sensor High Error…939
Failure Code [CA452] Rail Press. Sensor Low Error…941
Failure Code [CA553] Rail Press. High Error…941
Failure Code [CA559] Rail Press. Low Error…942
Failure Code [CA731] Eng. Bkup Speed Sensor Phase Error…947
Failure Code [CA757] All Persistent Data Lost Error…948
Failure Code [CA778] Eng. Bkup Speed Sensor Error…949
Failure Code [CA1633] KOMNET Datalink Timeout Error…951
Failure Code [CA2185] Throttle Sens. Sup. Volt. High Error…953
Failure Code [CA2186] Throttle Sens. Sup. Volt. Low Error…955
Failure Code [CA2249] Rail Press. Very Low Error…956
Failure Code [CA2311] Abnormality in IMV Solenoid…957
Failure Code [D110KB] Battery Relay Drive Short…959
Failure Code [D19JKZ] Personal Code Relay Abnormality…961
Failure Code [D862KA] GPS Antenna Discon…963
Failure Code [DA22KK] Pump Solenoid Power Low Error…965
Failure Code [DA25KP] 5 V Sensor 1 Power Abnormality…967
Failure Code [DA26KP] 5 V Sensor 2 Power Abnormality…970
Failure Code [DA2RMC] CAN Discon (Pump Controller Detected)…971
Failure Code [DAFGMC] GPS Module Error…973
Failure Code [DAFRMC] CAN Discon (Monitor Detected)…975
Failure Code [DFB1KZ] Service Lever Pot. 1 Abnormality…977
Failure Code [DFB2KZ] Service Lever Pot. 2 Abnormality…979
Failure Code [DFB3L8] Service Lever 1 Potentio Error…981
Failure Code [DFB4L8] Service Lever 2 Potentio Error…983
Failure Code [DFB5KZ] Service Lever sPot. 1 Abnormality…985
Failure Code [DFB6KZ] Service Lever sPot. 2 Abnormality…987
Failure Code [DGH2KB] Hydr Oil Sensor Short…989
Failure Code [DHPAMA] Pump Press Sensor Abnormality…991
Failure Code [DHS5KX] Travel PPC Sensor Abnormality…993
Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality…995
Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality…997
Failure Code [DHX1MA] Overload Sensor Abnormality…999
Failure Code [DV20KB] Travel Alarm Short Circuit…1001
Failure Code [DW43KA] Travel Speed Sol Discon…1003
Failure Code [DW43KB] Travel Speed Sol Short…1004
Failure Code [DW45KA] Swing Brake Sol Discon…1005
Failure Code [DW45KB] Swing Brake Sol Short…1007
Failure Code [DWJ0KA] Merge-Divider Sol Discon…1009
Failure Code [DWJ0KB] Merge-Divider Sol Short…1010
Failure Code [DXA8KA] PC-EPC Sol Discon…1011
Failure Code [DXA8KB] PC-EPC Sol Short…1013
Failure Code [DXE7KA] Service Current EPC2 Open Circuit…1015
Failure Code [DXE7KB] Service Current EPC2 Short Circuit…1017
Failure Code [DXE8KA] Service Current EPC3 Open Circuit…1019
Failure Code [DXE8KB] Service Current EPC3 Short Circuit…1021
Failure Code [DXE9KA] Service Current EPC4 Open Circuit…1023
Failure Code [DXE9KB] Service Current EPC4 Short Circuit…1025
Failure Code [DXEAKA] Service Current EPC1 Open Circuit…1027
Failure Code [DXEAKB] Service Current EPC1 Short Circuit…1029
Failure Code [DY20KA] Wiper Working Abnormality…1031
Failure Code [DY20MA] Wiper Parking Abnormality…1033
Failure Code [DY2CKA] Washer Drive Open Circuit…1035
Failure Code [DY2CKB] Washer Drive Short Circuit…1037
Failure Code [DY2DKB] Wiper Drive (FWD) Short Circuit…1039
Failure Code [DY2EKB] Wiper Drive (REV) Short Circuit…1041
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1043
Before Carrying Out Troubleshooting of Electrical System…1043
Connection table of fuse box…1043
Locations of fusible links…1044
Location of fuse box and fuse numbers…1044
Information in Troubleshooting Table…1045
E-1 When Starting Switch is Turned On, Machine Monitor Displays Nothing…1047
E-2 Engine Does Not Start (Engine Does Not Turn)…1049
E-3 Preheater Does Not Operate…1052
E-5 All Work Equipment, Swing, and Travel Mechanism Does Not Move or Cannot Be Locked…1055
E-6 Precaution Lights Up While Engine Is Running…1057
E-7 Emergency Stop Item Lights Up While Engine Is Running…1060
E-8 Engine Coolant Temperature Gauge Does Not Indicate Normally…1061
E-9 Hydraulic oil temperature gauge does not indicate normally…1063
E-10 Fuel Level Gauge Does Not Indicate Normally…1066
E-11 Contents of Display by Machine Monitor are Different From Applicable Machine…1068
E-12 Machine Monitor Does Not Display Some Items…1068
E-13 Function Switch Does Not Work…1068
E-14 Auto-decelerator Does Not Operate Normally…1069
E-15 Working Mode Does Not Change…1070
E-16 Travel Speed Does Not Change…1071
E-17 Alarm Buzzer Cannot Be Stopped…1072
E-18 Windshield Wiper And Window Washer Do Not Operate…1073
E-19 Swing Holding Brake Does Not Operate Normally…1077
E-20 Travel Alarm Does Not Sound Or Does Not Stop Sounding…1079
E-21 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)…1080
E-22 While Starting Switch is in Off Position, Service Meter is not Displayed…1093
E-25 Komtrax System Does Not Operate Normally…1115
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1118
Information Contained in Troubleshooting Table…1118
System Chart for Hydraulic and Mechanical Systems…1120
H-1 Speed or Power of all Work Equipment, Swing, and Travel are Low…1122
H-2 Engine Speed Sharply Drops or Engine Stalls…1123
H-3 No Work Equipment, Travel and Swing Move…1124
H-4 Abnormal Noise is Heard from Around Hydraulic Pump…1124
H-5 Fine Control Performance or Response of Work Equipment and Travel is Low…1125
H-6 Speed or Power of Boom is Low…1126
H-7 Speed or Power of Arm is Low…1127
H-8 Speed or Power of Bucket is Low…1128
H-9 Speed or Power of Boom Swing is Low…1129
H-10 Speed or Power of Blade is Low…1130
H-11 Work Equipment Does Not Move in its Single Operation…1131
H-12 Hydraulic Drift of Work Equipment is Large…1132
H-13 Time Lag of Work Equipment is Large…1134
H-14 Work Equipment Loaded More is Slower During Compound Operation…1134
H-15 Boom RAISE Speed is Low in Compound Operation of Swing + Boom Raise…1134
H-16 Travel Speed Lowers Significantly During Compound Operation of Work Equipment/Swing + Travel…1135
H-17 Machine Deviates During Travel…1136
H-18 Travel Speed is Low…1137
H-19 Machine Cannot be Steered Easily or Steering Power is Low…1138
H-20 Travel Speed Does Not Change or it is Kept Low or High…1139
H-21 Track Does Not Move (Only Either Side)…1139
H-22 Machine Does Not Swing…1140
H-23 Swing Acceleration, Swing Speed and Swing Power are Low…1142
H-24 Excessive Overrun when Stopping Swing…1144
H-25 When Upper Structure Stops Swinging, it Makes Large Shock…1145
H-26 When Upper Structure Stops Swinging, it Makes Large Sound…1145
H-27 Hydraulic Drift of Swing is Large…1146
H-28 Flow Rate in Attachment Circuit Cannot Be Adjusted…1147
50 DISASSEMBLY AND ASSEMBLY…1148
HOW TO READ THIS MANUAL…1153
Removal and Installation of Assemblies…1153
Special Tools…1153
Removal…1153
Installation…1153
Disassembly and Assembly of Assemblies…1154
Special Tools…1154
Disassembly…1154
Assembly…1155
COATING MATERIALS LIST…1157
SPECIAL TOOLS LIST…1161
SKETCHES OF SPECIAL TOOLS…1165
CONNECTOR REPAIR PROCEDURES…1170
Stripping Insulation…1170
Wire Inspection…1170
Contact Terminal Removal (HD30 Type)…1171
Crimping Contact Terminal (HD30 Type)…1172
Insertion of Contact Terminal (HD30 Type)…1173
Contact Terminal Removal (DT Type)…1174
Crimping Contact Terminal (DT Type)…1175
Insertion of Contact Terminal (DT Type)…1176
ENGINE AND COOLING SYSTEM…1177
Fuel Supply Pump Assembly…1177
Removal…1177
Installation…1181
Fuel Injector Assembly…1183
Removal…1183
Installation…1187
Engine Front Seal…1189
Removal…1189
Installation…1190
Engine Rear Seal…1191
Removal…1191
Installation…1193
Cylinder Head Assembly…1194
Removal…1194
Installation…1204
Radiator Assembly…1209
Removal…1209
Installation…1212
Aftercooler Assembly…1213
Removal…1213
Installation…1216
Hydraulic Oil Cooler Assembly…1217
Removal…1217
Installation…1220
Engine and Hydraulic Pump Assembly…1221
Removal…1221
Installation…1233
Fuel Tank Assembly…1237
Removal…1237
Installation…1239
POWER TRAIN…1241
Travel Motor and Final Drive Assembly…1241
Removal…1241
Installation…1242
Swing Motor and Swing Machinery Assembly…1243
Installation…1244
Swing Machinery…1245
Disassembly…1245
Assembly…1251
Swing Circle Assembly…1257
Removal…1257
Installation…1258
UNDERCARRIAGE AND FRAME…1259
Track Roller Assembly…1259
Disassembly…1259
Assembly…1261
Idler Assembly…1265
Disassembly…1265
Assembly…1266
Recoil Spring Assembly…1269
Disassembly…1269
Assembly…1271
Track Shoe Assembly…1273
Spreading…1273
Installation…1274
Sprocket…1275
Removal…1275
Installation…1275
Revolving Frame Assembly…1277
Removal…1277
Installation…1279
Counterweight Assembly…1281
Removal…1281
Installation…1286
HYDRAULIC SYSTEM…1287
Center Swivel Joint Assembly…1287
Removal…1287
Installation…1288
Disassembly…1289
Assembly…1290
Hydraulic Tank Assembly…1291
Removal…1291
Installation…1294
Hydraulic Pump Assembly…1295
Removal…1295
Installation…1300
Control Valve Assembly…1301
Removal…1301
Disassembly…1311
Assembly…1311
Work Equipment PPC Valve Assembly…1319
Disassembly…1319
Assembly…1319
Travel PPC Valve Assembly…1321
Assembly…1321
Boom Swing Cylinder Assembly…1323
Removal…1323
Installation…1326
Hydraulic Cylinder Assembly…1327
Disassembly…1328
Assembly…1331
WORK EQUIPMENT…1335
Work Equipment Assembly (Machine With Boom Hydraulic Drift Prevention Valve)…1335
Removal…1335
Installation…1338
Boom Swing Bracket…1339
Removal…1339
Installation…1342
Blade Assembly…1343
Removal…1343
Installation…1344
CAB AND ITS ATTACHMENTS…1345
Operator Cab Assembly…1345
Removal…1345
Installation…1351
Operator’s Cab Glass (Stuck glass)…1353
Removal…1354
Installation…1355
Front Window Assembly…1364
Removal…1364
Installation…1364
Floor Frame Assembly…1365
Removal…1365
Installation…1372
Air Conditioner Compressor Assembly…1373
Removal…1373
Installation…1374
Air Conditioner Condenser Assembly…1375
Removal…1375
Installation…1375
Air Conditioner Unit Assembly…1377
Removal…1377
Installation…1382
ELECTRICAL SYSTEM…1383
Machine Monitor Assembly…1383
Removal…1383
Installation…1384
Pump Controller Assembly…1385
Removal…1385
Installation…1387
Engine Controller Assembly…1389
Removal…1389
Installation…1392
KOMTRAX Terminal Assembly…1393
Removal…1393
Installation…1393
90 DIAGRAMS AND SCHEMATICS…1394
HYDRAULIC SYSTEM…1396
Hydraulic Circuit Diagram…1396
ELECTRICAL SYSTEM…0
Electrical Circuit Diagram (2/6)…1398
Electrical Circuit Diagram (3/6)…1399
Electrical Circuit Diagram (4/6)…1400
Electrical Circuit Diagram (5/6)…1401
Electrical Circuit Diagram (6/6)…1402
Electrical Circuit Diagram for Air Conditioner…1403
Connector List and Stereogram…1404
SEN04329-11 – Hydraulic Excavator PC88MR-8 Shop Manual…1405
COVER…1405
00 Index and foreword…0
100 Index…1407
Composition of shop manual…1408
Table of contents…1410
200 Foreword and general information…1419
Safety notice…1420
How to read the shop manual…1425
Explanation of terms for maintenance standard…1427
Handling of electric equipment and hydraulic component…1429
Handling of connectors newly used for engines…1438
How to read electric wire code…1441
Precautions when carrying out operation…1444
Method of disassembling and connecting push-pull type coupler…1447
Standard tightening torque table…1450
Conversion table…1454
01 Specification…0
100 Specification and technical data…1461
Specification dimension drawing…1462
Working range diagram…1463
Specifications…1464
Weight table…1467
Table of fuel, coolant and lubricants…1469
10 Structure, function and maintenance standard…0
100 Engine and cooling system…1471
Engine mount…1472
PTO…1473
Cooling system…1474
200 Power train…1477
Power train…1478
Swing circle…1480
Swing machinery…1482
300 Undercarriage and frame…1485
Track frame…1486
Idler cushion…1487
Idler…1488
Track roller…1489
Carrier roller…1490
Sprocket…1491
Track shoe…1492
410 Hydraulic system, Part 1…1499
Hydraulic equipment layout drawing…1500
Valve control…1502
Hydraulic tank and filter…1504
Hydraulic pump…1506
420 Hydraulic system, Part 2…1521
Control valve…1523
CLSS…1540
Functions and operation by valve…1544
430 Hydraulic system, Part 3…1575
PPC valve…1577
Swing motor…1589
Travel motor…1599
Center swivel joint…1607
Solenoid valve…1608
PPC accumulator…1615
Anti-drop valve…1618
Multi-control valve…1623
500 Work equipment…1625
Work equipment…1626
Dimensions of components…1628
Work equipment cylinder…1634
600 Cab and its attachments…1639
Air conditioner…1640
700 Electrical system…1653
Electrical control system…1654
Monitor system…1688
KOMTRAX system…1702
Sensor…1653
20 Standard value table…0
100 Standard service value table…1711
Standard value table for engine related parts…1712
Standard value table for chassis…1713
30 Testing and adjusting…0
110 Testing and adjusting, Part 1…1723
Tools for testing, adjusting, and troubleshooting…1725
Testing engine speed…1730
Testing exhaust temperature…1731
Checking exhaust gas color…1732
Adjusting valve clearance…1733
Testing compression pressure…1735
Testing blow-by pressure…1737
Testing engine oil pressure…1738
Handling fuel system parts…1739
Releasing residual pressure from fuel system…1739
Testing fuel pressure…1740
Testing fuel return rate and fuel leakage…1741
Bleeding air from fuel circuit…1743
Checking fuel circuit for leakage…1745
Testing and adjusting alternator belt tension…1746
Checking and adjusting air conditioner compressor belt tension…1748
Testing swing circle bearing clearance…1749
Checking and adjusting track shoe tension…1750
Testing and adjusting oil pressure in work equipment and travel circuits…1752
Testing and adjusting swing and blade circuit oil pressure…1754
Testing control circuit basic pressure…1757
Testing and adjusting oil pressure in pump PC control circuit…1758
Testing PC-EPC solenoid output pressure…1761
Testing LS differential pressure and adjusting LS valve…1762
Testing solenoid valve output pressure…1764
Testing PPC valve output pressure…1765
Adjusting play of work equipment and swing PPC valves…1767
Checking parts which cause hydraulic drift of work equipment…1768
Testing and adjusting travel deviation…1770
Releasing residual pressure from hydraulic circuit…1772
Testing oil leakage…1773
Bleeding air from each part…1776
Adjusting mirrors…1778
Testing and adjusting hood catch…1779
120 Testing and adjusting, Part 2…1783
Special functions of machine monitor…1784
130 Testing and adjusting, Part 3…1835
Handling voltage circuit of engine controller…1836
Preparation work for troubleshooting of electrical system…1837
Procedure for testing diodes…1842
Pm Clinic service…1843
40 Troubleshooting…0
100 Failure code table and fuse locations…1849
Failure code table…1850
Fuse locations…1853
200 General information on troubleshooting…1857
Points to remember when troubleshooting…1858
Sequence of events in troubleshooting…1859
Checks before troubleshooting…1860
Classification and procedures for troubleshooting…1861
Information in troubleshooting table…1862
Phenomena looking like troubles and troubleshooting Nos…1864
Connection table for connector pin numbers…1867
T- branch box and T- branch adapter table…1903
310 Troubleshooting by failure code, Part 1…1907
Failure code [989L00] Engine controller lock caution 1…1909
Failure code [989M00] Engine controller lock caution 2…1910
Failure code [989N00] Engine controller lock caution 3…1911
Failure code [AB00KE] Charge voltage low…1912
Failure code [B@BAZG] Eng oil press. low…1915
Failure code [B@BCNS] Eng coolant overheat…1916
Failure code [B@HANS] Hydr. oil overheat…1916
Failure code [CA111] ECM critical internal failure…1917
Failure code [CA115] Eng. Ne and Bkup speed sensor error…1920
Failure code [CA122] Charge air press sensor high error…1922
Failure code [CA123] Charge air press sensor low error…1924
Failure code [CA131] Throttle sensor high error…1926
Failure code [CA132] Throttle sensor low error…1928
Failure code [CA144] Coolant temp. sensor high error…1930
Failure code [CA145] Coolant temp. sensor low error…1932
Failure code [CA153] Charge air temp. sensor high error…1934
Failure code [CA154] Charge air temp. sensor low error…1936
Failure code [CA187] Sensor sup. 2 volt. low error…1937
Failure code [CA221] Ambient air press. sensor high error…1938
Failure code [CA222] Ambient air press. sensor low error…1940
Failure code [CA227] Sensor sup. 2 volt. high error…1941
Failure code [CA234] Eng. overspeed…1942
Failure code [CA238] Ne speed sensor sup. volt. error…1944
Failure code [CA271] IMV/PCV1 short error…1946
Failure code [CA272] IMV/PCV1 open error…1947
Failure code [CA322] Injector #1 (L #1) system open/short error…1948
Failure code [CA324] Injector #3 (L #3) system open/short error…1950
Failure code [CA331] Injector #2 (L #2) system open/short error…1952
Failure code [CA332] Injector #4 (L #4) system open/short error…1954
320 Troubleshooting by failure code, Part 2…1957
Failure code [CA351] Inj. drive circuit error…1959
Failure code [CA352] Sensor sup. 1 volt. low error…1962
Failure code [CA435] Abnormality in engine oil pressure switch…1966
Failure code [CA441] Battery voltage low error…1967
Failure code [CA442] Battery voltage high error…1968
Failure code [CA449] Rail press. very high error…1969
Failure code [CA451] Rail press. sensor high error…1970
Failure code [CA452] Rail press. sensor low error…1972
Failure code [CA553] Rail press. high error…1972
Failure code [CA559] Rail press. low error…1973
Failure code [CA689] Eng. Ne speed sensor error…1976
Failure code [CA731] Eng. Bkup speed sensor phase error…1978
Failure code [CA757] All persistent data lost error…1979
Failure code [CA778] Eng. Bkup speed sensor error…1980
Failure code [CA1633] KOMNET datalink timeout error…1982
Failure code [CA2185] Throttle sens. sup. volt. high error…1984
Failure code [CA2186] Throttle sens. sup. volt. low error…1986
Failure code [CA2249] Rail press. very low error…1987
Failure code [CA2311] Abnormality in IMV solenoid…1988
Failure code [D110KB] Battery relay drive short…1989
Failure code [D19JKZ] Personal code relay abnormality…1993
Failure code [D862KA] GPS antenna discon…1996
Failure code [DA22KK] Pump solenoid power low error…1997
Failure code [DA25KP] 5 V sensor 1 power abnormality…1999
Failure code [DA26KP] 5 V sensor 2 power abnormality…2002
330 Troubleshooting by failure code, Part 3…2005
Failure code [DA2RMC] CAN discon (Pump controller detected)…2006
Failure code [DAFGMC] GPS module error…2008
Failure code [DAFRMC] CAN discon (Monitor detected)…2010
Failure code [DFB1KZ] Service lever pot. 1 abnormality…2012
Failure code [DFB2KZ] Service lever pot. 2 abnormality…2014
Failure code [DFB3L8] Service lever1 potentio error…2016
Failure code [DFB4L8] Service lever2 potentio error…2018
Failure code [DFB5KZ] Service lever sPot. 1 abnormality…2020
Failure code [DFB6KZ] Service lever sPot. 2 abnormality…2022
Failure code [DGH2KB] Hydr oil sensor short…2024
Failure code [DHPAMA] Pump press sensor abnormality…2026
Failure code [DHS5KX] Travel PPC sensor abnormality…2028
Failure code [DHSAMA] Swing RH PPC press sensor abnormality…2030
Failure code [DHSBMA] Swing LH PPC press sensor abnormality…2032
Failure code [DHX1MA] Overload sensor abnormality…2034
Failure code [DV20KB] Travel alarm short circuit…2035
Failure code [DW43KA] Travel speed sol discon…2036
Failure code [DW43KB] Travel speed sol short…2037
Failure code [DW45KA] Swing brake sol discon…2038
Failure code [DW45KB] Swing brake sol short…2040
Failure code [DWJ0KA] Merge-divider sol discon…2042
Failure code [DWJ0KB] Merge-divider sol short…2043
340 Troubleshooting by failure code, Part 4…2045
Failure code [DXA8KA] PC-EPC sol discon…2046
Failure code [DXA8KB] PC-EPC sol short…2048
Failure code [DXE7KA] Service current EPC2 open circuit…2050
Failure code [DXE7KB] Service current EPC2 short circuit…2052
Failure code [DXE8KA] Service current EPC3 open circuit…2054
Failure code [DXE8KB] Service current EPC3 short circuit…2056
Failure code [DXE9KA] Service current EPC4 open circuit…2058
Failure code [DXE9KB] Service current EPC4 short circuit…2060
Failure code [DXEAKA] Service current EPC1 open circuit…2062
Failure code [DXEAKB] Service current EPC1 short circuit…2064
Failure code [DY20KA] Wiper working abnormality…2066
Failure code [DY20MA] Wiper parking abnormality…2068
Failure code [DY2CKA] Washer drive open circuit…2070
Failure code [DY2CKB] Washer drive short circuit…2072
Failure code [DY2DKB] Wiper drive (fwd) short circuit…2074
Failure code [DY2EKB] Wiper drive (rev) short circuit…2076
400 Troubleshooting of electrical system (E-mode)…2079
Before carrying out troubleshooting of electrical system…2081
Information in troubleshooting table…2084
E-1 When starting switch is turned ON, machine monitor displays nothing…2086
E-2 Engine does not start (Engine does not turn)…2088
E-3 Preheater does not operate…2092
E-4 Automatic warm-up system does not operate (in cold season)…2095
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked…2096
E-6 Precaution lights up while engine is running…2098
E-7 Emergency stop item lights up while engine is running…2102
E-8 Engine coolant temperature gauge does not indicate normally…2103
E-9 Hydraulic oil temperature gauge does not indicate normally…2104
E-10 Fuel level gauge does not indicate normally…2107
E-11 Contents of display by machine monitor are different from applicable machine…2109
E-12 Machine monitor does not display some items…2109
E-13 Function switch does not work…2109
E-14 Auto-decelerator does not operate normally…2110
E-15 Working mode does not change…2111
E-16 Travel speed does not change…2112
E-17 Alarm buzzer cannot be stopped…2113
E-18 Windshield wiper and window washer do not operate…2114
E-19 Swing holding brake does not operate normally…2118
E-20 Travel alarm does not sound or does not stop sounding…2120
E-21 Air conditioner does not operate normally (including air conditioner abnormality record)…2121
E-22 While starting switch is in OFF position, service meter is not displayed…2134
E-23 Machine monitor cannot be set in service mode…2135
E-24 Monitoring function does not display lever control signal normally…2136
E-25 KOMTRAX system does not operate normally…2156
500 Troubleshooting of hydraulic and mechanical system (H-mode)…2159
Information contained in troubleshooting table…2161
System chart for hydraulic and mechanical systems…2162
H-1 Speed or power of all work equipment, swing, and travel are low…2164
H-2 Engine speed sharply drops or engine stalls…2165
H-3 No work equipment, travel and swing move…2166
H-4 Abnormal noise is heard from around hydraulic pump…2166
H-5 Fine control performance or response of work equipment and travel is low…2167
H-6 Speed or power of boom is low…2168
H-7 Speed or power of arm is low…2169
H-8 Speed or power of bucket is low…2170
H-9 Speed or power of boom swing is low…2171
H-10 Speed or power of blade is low…2172
H-11 Work equipment does not move in its single operation…2173
H-12 Hydraulic drift of work equipment is large…2174
H-13 Time lag of work equipment is large…2176
H-14 Work equipment loaded more is slower during compound operation…2176
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE…2176
H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel…2177
H-17 Machine deviates during travel…2178
H-18 Travel speed is low…2179
H-19 Machine cannot be steered easily or steering power is low…2180
H-20 Travel speed does not change or it is kept low or high…2181
H-21 Track does not move (only either side)…2181
H-22 Machine does not swing…2182
H-23 Swing acceleration, swing speed and swing power are low…2183
H-24 Excessive overrun when stopping swing…2185
H-25 When upper structure stops swinging, it makes large shock…2186
H-26 When upper structure stops swinging, it makes large sound…2186
H-27 Hydraulic drift of swing is large…2187
H-28 Flow rate in attachment circuit cannot be adjusted…2188
600 Troubleshooting of engine (S-mode)…2191
Method of using troubleshooting chart…2192
S-1 Starting performance is poor…2196
S-2 Engine does not start…2197
S-3 Engine does not pick up smoothly…2200
S-4 Engine stops during operations…2201
S-5 Engine does not rotate smoothly…2202
S-6 Engine lacks output (or lacks power)…2203
S-7 Exhaust smoke is black (incomplete combustion)…2204
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2205
S-9 Oil becomes contaminated quickly…2206
S-10 Fuel consumption is excessive…2207
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2208
S-12 Oil pressure drops…2209
S-13 Oil level rises (Entry of coolant or fuel)…2210
S-14 Coolant temperature becomes too high (overheating)…2211
S-15 Abnormal noise is made…2212
S-16 Vibration is excessive…2213
50 Disassembly and assembly…0
100 General information on disassembly and assembly…2215
How to read this manual…2216
Coating materials list…2218
Special tool list…2221
Sketches of special tools…2225
200 Engine and cooling system…2231
Removal and installation of fuel supply pump assembly…2232
Removal and installation of fuel injector assembly…2236
Removal and installation of engine front seal…2240
Removal and installation of engine rear seal…2241
Removal and installation of cylinder head assembly…2243
Removal and installation of radiator assembly…2254
Removal and installation of aftercooler assembly…2257
Removal and installation of hydraulic oil cooler assembly…2259
Removal and installation of engine and hydraulic pump assembly…2262
Removal and installation of fuel tank assembly…2272
Removal and installation of fuel tank assembly…2273
300 Power train…2277
Removal and installation of travel motor and final drive assembly…2279
Disassembly and assembly of travel motor and final drive assembly…2281
Removal and installation of swing motor and swing machinery assembly…2319
Disassembly and assembly of swing machinery…2321
Removal and installation of swing circle assembly…2330
400 Undercarriage and frame…2333
Disassembly and assembly of track roller assembly…2334
Disassembly and assembly of idler assembly…2337
Disassembly and assembly of recoil spring assembly…2340
Spreading and installation of track shoe assembly…2342
Removal and installation of sprocket…2344
Removal and installation of revolving frame assembly…2345
Removal and installation of counterweight assembly…2348
500 Hydraulic system…2353
Removal and installation of center swivel joint assembly…2354
Disassembly and assembly of center swivel joint assembly…2356
Removal and installation of hydraulic tank assembly…2358
Removal and installation of hydraulic pump assembly…2361
Removal and installation of control valve assembly…2365
Disassembly and assembly of control valve assembly…2373
Disassembly and assembly of work equipment PPC valve assembly…2379
Disassembly and assembly of travel PPC valve assembly…2381
Removal and installation of boom swing cylinder assembly…2383
Disassembly and assembly of hydraulic cylinder assembly…2386
600 Work equipment…2393
Removal and installation of work equipment assembly…2394
Removal and installation of boom swing bracket…2397
Removal and installation of blade assembly…2401
700 Cab and its attachments…2405
Removal and installation of operator cab assembly…2406
Removal and installation of operator’s cab glass (Stuck glass)…2411
Removal and installation of front window assembly…2421
Removal and installation of floor frame assembly…2422
800 Electrical system…2429
Removal and installation of air conditioner compressor assembly…2430
Removal and Installation of air conditioner condenser assembly…2431
Removal and installation of air conditioner unit assembly…2432
Removal and installation of machine monitor assembly…2436
Removal and installation of pump controller assembly…2438
Removal and installation of engine controller assembly…2440
Removal and installation of KOMTRAX terminal assembly…2442
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…2445
Hydraulic circuit diagram…2447
200 Electrical diagrams and drawings…2452
Electrical circuit diagram…2454
Electrical circuit diagram of the air conditioner unit…2466
Connector list and stereogram…2467
SEN06467-02 – Hydraulic Excavator PC88MR-10 Shop Manual…2470
Cover…2470
00 Index and foreword …2472
Index …2473
Foreword, safety and general information …2484
Important safety notice …2484
How to read the shop manual …2491
Explanation of terms for maintenance standard …2493
Handling equipment of fuel system devices …2495
Handling of intake system parts …2496
Handling of hydraulic equipment …2497
Method of disconnecting and connecting of push-pull type coupler …2499
Handling of electrical equipment …2502
How to read electric wire code …2510
Precautions when performing operation …2513
Practical use of KOMTRAX …2518
Standard tightening torque table …2519
List of abbreviation …2525
Conversion table …2530
01 Specification …2536
Table of contents …2537
Specifications …2538
Specification drawing …2538
Working range drawings …2539
Specifications …2540
Weight table …2544
Table of fuel, coolant, and lubricants …2546
10 Structure and function …2548
Table of contents …2549
Engine and cooling system …2550
Engine related parts …2550
PTO …2552
VFT …2553
EGR system piping drawing …2557
EGR system circuit diagram …2559
EGR valve …2560
EGR cooler …2562
KCCV layout drawing …2564
KCCV ventilator …2567
KDOC muffler …2569
Cooling system …2571
Power train …2574
Power train system …2574
Swing circle …2576
Swing machinery …2578
Undercarriage and frame …2580
Track frame …2580
Idler cushion …2582
Hydraulic system …2583
Hydraulic component layout …2583
Valve control …2585
Hydraulic tank …2587
CLSS …2591
Main pump …2595
Control valve …2607
Swing motor …2655
Travel motor …2666
Work equipment and swing PPC valve …2677
Travel PPC valve …2684
Blade PPC valve …2690
Boom swing PPC valve …2692
Solenoid valve …2694
Multi-control valve …2698
Center swivel joint …2699
Accumulator …2700
Work equipment …2702
Work equipment …2702
Work equipment shim …2703
Bucket play adjustment shim …2704
Cab and its attachments …2705
Cab mount and cab tipping stopper …2705
ROPS cab …2707
Electrical system …2709
Electrical control system …2709
Machine monitor system …2754
KOMTRAX system …2776
KOMTRAX terminal …2776
Sensor …2778
20 Standard value tables …2786
Table of contents …2787
Standard service value table …2788
Standard value table for engine …2788
Standard value table for machine …2790
Standard value table for electrical system …2806
30 Testing and adjusting …2812
Table of contents …2813
Related information on testing and adjusting …2814
Tools for testing and adjusting …2814
Sketch of tools for testing and adjusting …2817
Engine and cooling system …2819
Testing engine speed …2819
Testing exhaust gas color …2820
Testing and adjusting valve clearance …2821
Testing compression pressure …2823
Testing blowby pressure …2825
Testing engine oil pressure …2826
Testing fuel pressure …2827
Testing fuel return rate and leakage …2828
Bleeding air from fuel system …2831
Testing fuel circuit for leakage …2833
Handling cylinder cutout mode operation …2834
Handling no-injection cranking operation …2835
Testing and adjusting air conditioner compressor belt tension …2836
Replacing fan belt …2837
Writing compensation values at replacement of injector and engine controller …2839
Power train …2843
Testing swing circle bearing clearance …2843
Undercarriage and frame …2844
Testing and adjusting track tension …2844
Hydraulic system …2845
Releasing remaining pressure from hydraulic circuit …2845
Testing and adjusting oil pressure in work equipment and travel circuits …2847
Testing and adjusting swing and blade circuit oil pressure …2850
Testing oil pressure of control circuit …2853
Testing and adjusting oil pressure in pump PC control circuit …2854
Testing and adjusting oil pressure in pump LS control circuit …2857
Testing outlet pressure of solenoid valve …2860
Testing PPC valve outlet pressure …2861
Adjusting play of work equipment and swing PPC valves …2862
Isolating the parts causing hydraulic drift in work equipment …2863
Testing and adjusting travel deviation …2864
Testing oil leakage …2866
Bleeding air from hydraulic circuit …2870
Cab and its attachments …2873
Testing, cleaning and lubricating slide door rail and roller …2873
Adjusting mirrors …2874
Testing and adjusting hood catcher …2876
Electrical system …2878
Special functions of machine monitor …2878
KOMTRAX terminal start-up procedure …2926
Adjusting rearview camera angle …2930
Handling voltage circuit of engine controller …2932
Handling battery disconnect switch …2933
Testing diodes …2934
Pm clinic …2935
Pm Clinic service …2935
40 Troubleshooting …2944
Table of contents …2945
Related information on troubleshooting …2951
Troubleshooting points …2951
Sequence of events in troubleshooting …2953
Checks before troubleshooting …2955
Inspection procedure before troubleshooting …2957
Preparation for troubleshooting of electrical system …2974
Classification and procedures for troubleshooting …2979
Symptom and troubleshooting numbers …2982
Information in troubleshooting table …2985
Troubleshooting method for open circuit in wiring harness of pressure sensor system …2987
Connector list and layout …2989
Connector contact identification …2998
T-branch box and T-branch adapter table …3036
Fuse location table …3041
Failure codes table …3043
Troubleshooting by failure code (Display of code) …3049
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit …3049
Failure code [879AKB] A/C Recirc Air Temp Sens Short …3050
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit …3051
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit …3052
Failure code [879CKA] Ventilating Sensor Open Circuit …3053
Failure code [879CKB] Ventilating Sensor Short Circuit …3054
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit …3055
Failure code [879EMC] Ventilation Damper Malfunction …3056
Failure code [879FMC] Air Mix Damper Malfunction …3057
Failure code [879GKX] Refrigerant Press Input Sig Out of Range …3058
Failure code [989L00] Engine Controller Lock Caution 1 …3059
Failure code [989M00] Engine Controller Lock Caution 2 …3060
Failure code [989N00] Engine Controller Lock Caution 3 …3061
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 …3062
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 …3063
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 …3064
Failure code [AB00KE] Charge Voltage Low …3065
Failure code [B@BAZG] Eng Oil Press Low …3067
Failure code [B@BCNS] Eng Water Overheat …3068
Failure code [CA115] Eng Ne and Bkup Speed Sens Error …3069
Failure code [CA122] Charge Air Pressure Sensor High Error …3070
Failure code [CA123] Charge Air Pressure Sensor Low Error …3072
Failure code [CA131] Throttle Sensor High Error …3074
Failure code [CA132] Throttle Sensor Low Error …3076
Failure code [CA144] Coolant Temperature Sensor High Error …3078
Failure code [CA145] Coolant Temperature Sensor Low Error …3080
Failure code [CA153] Charge Air Temperature Sensor High Error …3082
Failure code [CA154] Charge Air Temperature Sensor Low Error …3084
Failure code [CA187] Sensor 2 Supply Voltage Low Error …3086
Failure code [CA221] Ambient Pressure Sensor High Error …3088
Failure code [CA222] Ambient Pressure Sensor Low Error …3090
Failure code [CA227] Sensor 2 Supply Voltage High Error …3092
Failure code [CA234] Engine Overspeed …3093
Failure code [CA238] NE Speed Sensor Supply Voltage Error …3094
Failure code [CA239] NE Speed Sensor Supply Voltage High Error …3095
Failure code [CA271] PCV1 Short Circuit Error …3096
Failure code [CA272] PCV1 Open Circuit Error …3097
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit …3098
Failure code [CA324] Injector #3 (L#3) Open or Short Circuit …3100
Failure code [CA331] Injector #2 (L#2) Open or Short Circuit …3102
Failure code [CA332] Injector #4 (L#4) Open or Short Circuit …3104
Failure code [CA343] Engine Controller Internal Failure …3106
Failure code [CA351] Injectors Drive Circuit Error …3107
Failure code [CA352] Sensor1 Supply Voltage Low Error …3108
Failure code [CA356] MAF Sensor High Error …3110
Failure code [CA357] MAF Sensor Low Error …3112
Failure code [CA386] Sensor1 Supply Voltage High Error …3114
Failure code [CA435] Engine Oil Pressure SW Error …3115
Failure code [CA441] Battery Voltage Low Error …3116
Failure code [CA442] Battery Voltage High Error …3118
Failure code [CA449] Common Rail Pressure High Error 2 …3119
Failure code [CA451] Common Rail Pressure Sensor High Error …3120
Failure code [CA452] Common Rail Pressure Sensor Low Error …3122
Failure code [CA466] KVGT Motor Driver Position Error …3124
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error …3126
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error …3128
Failure code [CA553] Common Rail Pressure High Error 1 …3130
Failure code [CA555] Crankcase Pressure High Error 1 …3131
Failure code [CA556] Crankcase Pressure High Error 2 …3132
Failure code [CA559] Common Rail Pressure Low Error 1 …3133
Failure code [CA689] Engine NE Speed Sensor Error …3136
Failure code [CA691] Intake Air Temperature Sensor High Error …3138
Failure code [CA692] Intake Air Temperature Sensor Low Error …3140
Failure code [CA697] Engine Con Internal Temp Sens High Error …3142
Failure code [CA698] Engine Con Internal Temp Sens Low Error …3143
Failure code [CA731] Engine Backup Speed Sensor Phase Error …3144
Failure code [CA778] Engine Backup Speed Sensor Error …3146
Failure code [CA1117] Engine Controller Partial Data Lost Error …3150
Failure code [CA1695] Sensor 5 Supply Voltage High Error …3151
Failure code [CA1696] Sensor 5 Supply Voltage Low Error …3152
Failure code [CA1843] Crankcase Pressure Sensor High Error …3153
Failure code [CA1844] Crankcase Pressure Sensor Low Error …3155
Failure code [CA1896] EGR Valve Stuck Error …3157
Failure code [CA1942] Crankcase Pressure Sensor In Range Error …3158
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error …3159
Failure code [CA2185] Throttle Sensor Supply Voltage High Error …3160
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error …3162
Failure code [CA2249] Common Rail Pressure Low Error 2 …3164
Failure code [CA2272] EGR Valve Position Sensor Low Error …3165
Failure code [CA2311] IMV Solenoid Error …3167
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error …3168
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error …3170
Failure code [CA2357] EGR Valve Servo Error …3172
Failure code [CA2765] Injector Trim Data Mismatch …3173
Failure code [CA3419] MAF Sensor Supply Voltage High Error …3174
Failure code [CA3421] MAF Sensor Supply Voltage Low Error …3176
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error …3178
Failure code [CA3918] KVGT Stuck Error …3180
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error …3181
Failure code [CA3921] KVGT Servo Error 2 …3182
Failure code [CA3922] KVGT Motor Driver Open Error …3183
Failure code [CA3923] KVGT Motor Driver Short Error …3185
Failure code [D110KB] Battery Relay Output Short Circuit …3187
Failure code [D19JKZ] Personal Code Relay Open or Short …3189
Failure code [D811MC] KOMTRAX Malfunction …3192
Failure code [D862KA] GPS Antenna Open Circuit …3193
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) …3194
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) …3196
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX) …3197
Failure code [DA20MC] Pump Controller Malfunction …3199
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error …3200
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error …3202
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) …3204
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) …3206
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) …3208
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con) …3209
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con) …3211
Failure code [DAF0MB] Monitor ROM Abnormality …3212
Failure code [DAF0MC] Monitor Malfunction …3213
Failure code [DAF8KB] Camera Power Supply Short Circuit …3214
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) …3215
Failure code [DAFGMC] GPS Module Malfunction …3216
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) …3217
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) …3219
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) …3220
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) …3221
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) …3222
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con) …3226
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con) …3230
Failure code [DDNRKA] WE Lever Lock SW Open Circuit …3234
Failure code [DDNRKY] WE Lever Lock SW Short Circuit …3236
Failure code [DDNS00] Lock Lever Auto Lock Release SW On …3238
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault …3240
Failure code [DHPAMA] Front Pump Press Sens Defective Function …3242
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function …3244
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function …3246
Failure code [DHS5MA] Travel PPC Sensor Abnormality …3248
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function …3250
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function …3252
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function …3254
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function …3256
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function …3258
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function …3260
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality …3262
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality …3264
Failure code [DKULKA] PPC Lock Relay Open Circuit …3266
Failure code [DKULKB] PPC Lock Relay Short Circuit …3268
Failure code [DKULKY] PPC Lock Relay Hot Short Circuit …3270
Failure code [DV20KB] Travel Alarm Short Circuit …3272
Failure code [DW43KA] Travel Speed Solenoid Open Circuit …3274
Failure code [DW43KB] Travel Speed Solenoid Short Circuit …3276
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit …3278
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit …3279
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit …3282
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit …3284
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit …3286
Failure code [DWJ0KA] Merge-divider Sol Open Circuit …3288
Failure code [DWJ0KB] Merge-divider Sol Short Circuit …3290
Failure code [DWJ0KY] Merge-divider Sol Short Circuit …3292
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit …3293
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit …3295
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit …3297
Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit …3299
Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit …3301
Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit …3303
Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit …3305
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit …3307
Failure code [DY20KA] Wiper Motor Open Circuit …3309
Failure code [DY20MA] Wiper Motor Defective Function …3311
Failure code [DY2CKB] Washer Motor Short Circuit …3313
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit …3315
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit …3317
Troubleshooting of electrical system (E-mode) …3319
E-1 Engine does not start (Engine does not crank) …3319
E-2 Manual preheating system does not work …3325
E-3 While preheating is working, preheating monitor does not light up …3328
E-4 When starting switch is turned to ON position, machine monitor displays nothing …3330
E-5 Engine coolant temperature monitor lights up in white while engine is running …3333
E-6 Hydraulic oil temperature monitor lights up in white while engine is running …3334
E-7 Charge level monitor lights up while engine is running …3335
E-8 Fuel level monitor lights up in red while engine is running …3336
E-9 Engine coolant temperature monitor lights up in red while engine is running …3337
E-10 Hydraulic oil temperature monitor lights up in red while engine is running …3338
E-11 Engine oil pressure monitor lights up in red while engine is running …3339
E-12 Fuel gauge display does not move from minimum or maximum …3340
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty) …3341
E-14 Engine coolant temperature gauge display does not move from minimum or maximum …3342
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) …3343
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum …3344
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) …3346
E-18 Some areas of machine monitor screen are not displayed …3347
E-19 Function switch does not work …3348
E-20 Automatic warm-up system does not operate (in cold season) …3349
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated …3350
E-22 Auto-deceleration function does not operate or is not canceled while lever is operated …3351
E-23 Working mode selection screen is not displayed while working mode selector switch is operated …3353
E-24 Setting of engine and hydraulic pump is not changed while working mode is changed …3354
E-25 Travel speed monitor does not change when travel speed switch is operated …3355
E-26 Travel speed does not change while travel speed selection is changed …3356
E-27 Alarm buzzer does not stop sounding …3357
E-28 Service meter is not displayed, while starting switch is in OFF position …3358
E-29 Service mode cannot be selected …3359
E-30 Any of work equipment, swing and travel does not work …3360
E-31 Any of work equipment, swing and travel cannot be locked …3362
E-32 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position …3364
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position …3366
E-34 Work equipment does not operate while lock lever automatic release switch is in release position …3368
E-35 Alarm does not sound during travel …3370
E-36 Alarm does not stop sounding while machine is stopped …3371
E-37 Horn does not sound …3372
E-38 Horn does not stop sounding …3374
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated …3375
E-40 Wiper does not operate while wiper switch is operated …3376
E-41 Window washer does not operate while window washer switch is operated …3378
E-42 Boom LOWER is not displayed correctly with monitoring function …3379
E-43 Arm OUT is not displayed correctly with monitoring function …3380
E-44 Arm IN is not displayed correctly with monitoring function …3381
E-45 Boom RAISE is not displayed correctly with monitoring function …3382
E-46 Bucket CURL is not displayed correctly with monitoring function …3383
E-47 Bucket DUMP is not displayed correctly with monitoring function …3384
E-48 Boom swing left is not displayed correctly with monitoring function …3385
E-49 Boom swing right is not displayed correctly with monitoring function …3386
E-50 Swing is not displayed correctly with monitoring function …3387
E-51 Travel is not displayed correctly with monitoring function …3388
E-52 Blade RAISE ON is not displayed correctly with monitoring function …3389
E-53 Blade LOWER ON is not displayed correctly with monitoring function …3391
E-54 KOMTRAX system does not operate normally …3393
Troubleshooting of hydraulic and mechanical system (H-mode) …3395
Information described in troubleshooting table (H-mode) …3395
System chart of hydraulic and mechanical systems …3396
Failure mode and cause table …3398
H-1 All of work equipments, swing and travel operations lack speed or power …3406
H-2 Engine speed drops significantly or engine stalls …3408
H-3 Any of work equipment, swing and travel does not work …3409
H-4 Unusual sound is heard from around hydraulic pump …3410
H-5 Fine control performance or response is poor …3411
H-6 Boom speed or power is low …3412
H-7 Arm speed or power is low …3415
H-8 Bucket speed or power is low …3417
H-9 Boom swing speed or power is low …3419
H-10 Blade speed or power is low …3421
H-11 Work equipment does not move in single operation …3423
H-12 Hydraulic drift of boom is large …3424
H-13 Hydraulic drift of arm is large …3425
H-14 Hydraulic drift of bucket is large …3426
H-15 Hydraulic drift of blade is large …3427
H-16 Time lag of work equipment is large …3428
H-17 In combined operation of work equipment , equipment having heavier load moves slower …3430
H-18 In combined operation of swing and boom RAISE, boom rising speed is low …3431
H-19 In combined operation of work equipment or swing and travel, travel speed drops largely …3432
H-20 Machine does not travel straight …3434
H-21 Travel speed is slow …3436
H-22 Machine is hard to steer or travel power is low …3438
H-23 Travel speed does not change, or travel speed is too slow or fast …3441
H-24 One of tracks does not run …3442
H-25 Upper structure does not swing to the right or left …3444
H-26 Upper structure swing only to the right or left …3445
H-27 Swing acceleration or swing speed is low in both directions (right and left) …3446
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction …3447
H-29 Upper structure overruns excessively when it stops swinging (both right and left) …3448
H-30 Upper structure overruns excessively when it stops swinging (either right or left) …3449
H-31 Shock is large when upper structure stops swinging …3450
H-32 Large unusual noise is heard when upper structure stops swinging …3451
H-33 Swing drift on a slope is large while swing parking brake is applied …3452
H-34 Swing drift on a slope is large while swing parking brake is released …3453
H-35 Oil flow in attachment circuit cannot be controlled …3454
Troubleshooting of engine (S-mode) …3455
Information mentioned in troubleshooting table (S mode) …3455
S-1 Engine does not crank when starting switch is turned to START position …3456
S-2 Engine cranks but no exhaust smoke comes out …3457
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) …3458
S-4 Engine startability is poor …3459
S-5 Engine does not pick up smoothly …3461
S-6 Engine stops during operation …3463
S-7 Engine runs rough or is unstable …3465
S-8 Engine lacks power …3466
S-9 Exhaust smoke is black …3468
S-10 Engine oil consumption is excessive …3470
S-11 Oil becomes contaminated quickly …3471
S-12 Fuel consumption is excessive …3472
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …3473
S-14 Oil pressure drops …3474
S-15 Fuel mixes into engine oil …3475
S-16 Water mixes into engine oil (milky) …3476
S-17 Coolant temperature rises too high (overheating) …3477
S-18 Unusual noise is heard …3478
S-19 Vibration is excessive …3479
S-20 Air cannot be bled from fuel circuit …3480
50 Disassembly and assembly …3482
Table of contents …3483
Related information on disassembly and assembly …3485
How to read this manual …3485
Coating materials list …3487
Special tools list …3491
Sketches of special tools …3496
Engine and cooling system …3498
Removal and installation of supply pump assembly …3498
Removal and installation of injector assembly …3501
Removal and installation of cylinder head assembly …3508
Removal and installation of radiator assembly …3520
Removal and installation of hydraulic oil cooler assembly …3524
Removal and installation of aftercooler assembly …3527
Removal and installation of engine and main pump assembly …3530
Removal and installation of engine front oil seal …3538
Removal and installation of engine rear oil seal …3539
Removal and installation of fuel cooler assembly …3541
Removal and installation of fuel tank assembly …3542
Removal and installation of engine hood assembly …3544
Removal and installation of KDOC muffler …3545
Removal and installation of KCCV ventilator …3548
Removal and installation of air cleaner assembly …3550
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly …3552
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly …3554
Removal and installation of fan belt …3555
Power train system …3556
Removal and installation of travel motor and final drive assembly …3556
Disassembly and assembly of travel motor and final drive assembly …3558
Removal and installation of swing motor and swing machinery assembly …3591
Disassembly and assembly of swing machinery assembly …3593
Removal and installation of swing circle assembly …3601
Undercarriage and frame …3602
Separation and connection of track …3602
Removal and installation of sprocket …3603
Removal and installation of idler and idler cushion assembly …3604
Disassembly and assembly of idler assembly …3605
Disassembly and assembly of idler cushion assembly …3608
Disassembly and assembly of track roller assembly …3611
Removal and installation of revolving frame assembly …3614
Removal and installation of counterweight assembly [For machines with additional counterweight] …3616
Hydraulic system …3618
Removal and installation of center swivel joint assembly …3618
Disassembly and assembly of center swivel joint assembly …3620
Removal and installation of hydraulic tank assembly …3621
Removal and installation of main pump assembly …3624
Removal and installation of control valve assembly …3628
Disassembly and assembly of control valve assembly …3632
Disassembly and assembly of work equipment PPC valve assembly …3635
Disassembly and assembly of travel PPC valve assembly …3637
Disassembly and assembly of work equipment cylinder assembly …3638
Work equipment …3642
Removal and installation of work equipment assembly …3642
Removal and installation of boom swing bracket …3645
Removal and installation of blade assembly …3646
Cab and its attachments …3648
Removal and installation of operator’s cab assembly …3648
Removal and installation of operator’s cab door …3652
Removal and installation of operator’s cab glass (adhered glass) …3655
Removal and installation of front window assembly …3666
Removal and installation of floor frame assembly …3667
Removal and installation of air conditioner unit assembly …3672
Removal and installation of air conditioner compressor assembly …3677
Removal and installation of air conditioner condenser assembly …3679
Removal and installation of operator’s seat …3681
Removal and installation of seat belt …3682
Removal and installation of front wiper assembly …3683
Electrical system …3689
Removal and installation of starting motor assembly …3689
Removal and installation of engine controller assembly …3690
Removal and installation of pump controller assembly …3691
Removal and installation of machine monitor assembly …3692
Removal and installation of mass air flow and temperature sensor …3694
Removal and installation of KOMTRAX terminal assembly …3695
60 Maintenance standard …3696
Table of contents …3697
Engine and cooling system …3698
Engine mount …3698
PTO …3699
Cooling system …3700
Power train system …3702
Swing circle …3702
Swing machinery …3704
Sprocket …3706
Undercarriage and frame …3707
Track frame …3707
Idler cushion …3708
Idler …3709
Track roller …3710
Carrier roller …3711
Track shoe …3712
Hydraulic system …3718
Hydraulic tank …3718
Main pump …3719
Control valve …3723
Swing motor …3732
Travel motor …3734
PPC valve …3735
Work equipment and swing PPC valve …3735
Travel PPC valve …3738
Blade PPC valve …3740
Boom swing PPC valve …3742
Solenoid valve …3744
Center swivel joint …3746
Cab and its attachments …3747
Cab mount and cab tipping stopper …3747
Work equipment …3748
Work equipment …3748
Boom cylinder …3759
Arm cylinder …3760
Bucket cylinder …3761
Boom swing cylinder …3762
Blade cylinder …3763
80 Appendix …3764
Table of contents …3765
Air conditioner components …3766
Precautions for refrigerant …3766
Air conditioner component …3767
Configuration and function of refrigeration cycle …3770
Outline of refrigeration cycle …3771
Air conditioner unit …3773
Dual pressure switch …3778
Air conditioner controller …3779
Compressor …3780
Condenser …3781
Sunlight sensor …3783
Outer temperature sensor (outside air temperature sensor) …3784
Procedure for testing and troubleshooting …3785
Circuit diagram and arrangement of connector pins …3787
System diagram …3789
Input and output signals of the air conditioner controller …3790
Air conditioner unit …3792
Parts and connectors layout …3794
Testing air leakage (duct) …3800
Testing with self-diagnosis function …3802
Testing vent (mode) changeover …3805
Testing FRESH/RECIRC air changeover …3806
Testing sunlight sensor …3807
Testing (dual) pressure switch for refrigerant …3808
Testing relays …3810
Troubleshooting chart 1 …3811
Troubleshooting chart 2 …3812
Information in troubleshooting table …3815
Failure code list related to air conditioner …3816
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit …3817
Failure code [879AKB] A/C Recirc Air Temp Sens Short …3818
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit …3819
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit …3821
Failure code [879CKA] Ventilating Sensor Open Circuit …3823
Failure code [879CKB] Ventilating Sensor Short Circuit …3824
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit …3825
Failure code [879EMC] Ventilation Damper Malfunction …3827
Failure code [879FMC] Air Mix Damper Malfunction …3828
Failure code [879GKX] Refrigerant Press Input Sig Out of Range …3829
A-1 Troubleshooting for power supply system (Air conditioner does not operate) …3830
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) …3832
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) …3835
A-4 Troubleshooting for FRESH/RECIRC air changeover …3837
Troubleshooting with gauge pressure …3839
Connection of service tool …3842
Precautions for disconnecting and connecting refrigerant piping …3844
Handling of compressor oil …3846
90 Diagrams and drawings …3848
Table of contents …3849
Hydraulic circuit diagram …3850
Symbols in hydraulic circuit diagram …3850
Hydraulic circuit diagram …3854
Electric circuit diagram …3855
Symbols in electric circuit diagram …3855
Electrical circuit diagram …3858
Electrical circuit diagram of air conditioner unit …3863
INDEX…3864
TEN00287-06 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual…3874
COVER…3874
FOREWORD…3875
BEFORE READING THIS MANUAL…3876
SAFETY INFORMATION…3877
INTRODUCTION…3878
USE OF MACHINE…3878
DIRECTIONS OF MACHINE…3878
VISIBILITY FROM OPERATOR’S SEAT…3878
PRODUCT INFORMATION…3879
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3879
EPA REGULATIONS, ENGINE NUMBER PLATE…3879
SERVICE METER LOCATION…3880
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3880
CONTENTS…3881
SAFETY…3885
SAFETY…3886
SAFETY LABELS…3889
LOCATION OF SAFETY LABELS…3890
SAFETY LABELS…3891
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…3898
PRECAUTIONS BEFORE STARTING OPERATION…3898
PREPARATIONS FOR SAFE OPERATION…3898
FIRE PREVENTION…3900
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3901
DO NOT GET CAUGHT IN WORK EQUIPMENT…3903
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3903
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…3904
UNAUTHORIZED MODIFICATION…3904
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3904
PRECAUTIONS RELATED TO CAB GLASS…3904
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3905
PRECAUTIONS FOR OPERATION…3906
PRECAUTIONS FOR JOBSITE…3906
STARTING ENGINE…3908
OPERATION…3910
TRANSPORTATION…3918
TOWING…3919
LIFTING OBJECTS WITH BUCKET…3920
PRECAUTIONS FOR MAINTENANCE…3921
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3921
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3925
OPERATION…3931
MACHINE VIEW ILLUSTRATIONS…3932
OVERALL MACHINE VIEW…3932
CONTROLS AND GAUGES…3933
DETAILED CONTROLS AND GAUGES…3935
MONITORING SYSTEM…3935
SWITCHES…3994
CONTROL LEVERS AND PEDALS…3999
SUN ROOF…4003
WINDSHIELD…4004
SLIDING DOOR…4010
EMERGENCY ESCAPE HAMMER…4011
COVER WITH LOCK…4012
ENGINE HOOD…4013
MUD COVER…4015
BATTERY INSPECTION COVER…4016
AIR CONDITIONER CONTROLS…4017
RADIO…4030
FUSE…4035
FUSIBLE LINK…4036
AUXILIARY ELECTRIC POWER…4037
CONTROLLERS…4038
OPERATION MANUAL STORAGE…4039
CUP HOLDER…4039
TOOL BOX…4039
GREASE PUMP HOLDER…4039
ASHTRAY…4040
FIRE EXTINGUISHER…4040
MACHINE OPERATIONS AND CONTROLS…4041
BEFORE STARTING ENGINE…4041
STARTING ENGINE…4060
AFTER STARTING ENGINE…4065
STOPPING THE ENGINE…4075
MACHINE OPERATION…4076
STEERING THE MACHINE…4080
SWINGING…4082
WORK EQUIPMENT CONTROLS AND OPERATIONS…4083
WORKING MODE…4085
PROHIBITED OPERATIONS…4087
GENERAL OPERATION INFORMATION…4090
TRAVELING ON SLOPES…4092
ESCAPE FROM MUD…4094
RECOMMENDED APPLICATIONS…4095
BUCKET REPLACEMENT AND INVERSION…4097
PARKING MACHINE…4100
MACHINE INSPECTION AFTER DAILY WORK…4102
LOCKING…4102
ROAD LINERS AND RUBBER SHOES…4103
MACHINE READY FOR ATTACHMENT…4108
TRANSPORTATION…4118
TRANSPORTATION PROCEDURE…4118
LOADING AND UNLOADING WITH TRAILER…4119
LIFTING MACHINE…4125
COLD WEATHER OPERATION…4127
COLD WEATHER OPERATION INFORMATION…4127
AFTER DAILY WORK COMPLETION…4129
AFTER COLD WEATHER SEASON…4129
LONG TERM STORAGE…4130
BEFORE STORAGE…4130
DURING STORAGE…4130
AFTER STORAGE…4130
STARTING MACHINE AFTER LONG-TERM STORAGE…4131
TROUBLES AND ACTIONS…4132
RUNNING OUT OF FUEL…4132
PHENOMENA THAT ARE NOT FAILURES…4133
TOWING THE MACHINE…4134
SEVERE JOB CONDITION…4134
DISCHARGED BATTERY…4135
OTHER TROUBLE…4140
MAINTENANCE…4145
MAINTENANCE INFORMATION…4146
OUTLINE OF SERVICE…4148
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4148
ELECTRIC SYSTEM MAINTENANCE…4151
WEAR PARTS…4152
WEAR PARTS LIST…4152
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4154
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…4155
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4156
TIGHTENING TORQUE SPECIFICATIONS…4157
TIGHTENING TORQUE LIST…4157
SAFETY CRITICAL PARTS…4158
SAFETY CRITICAL PARTS LIST…4158
MAINTENANCE SCHEDULE…4160
MAINTENANCE SCHEDULE CHART…4160
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…4162
MAINTENANCE PROCEDURE…4163
WHEN REQUIRED…4163
CHECK BEFORE STARTING…4199
EVERY 100 HOURS MAINTENANCE…4200
EVERY 250 HOURS MAINTENANCE…4202
EVERY 500 HOURS MAINTENANCE…4209
EVERY 1000 HOURS MAINTENANCE…4220
EVERY 2000 HOURS MAINTENANCE…4230
EVERY 4000 HOURS MAINTENANCE…4234
EVERY 5000 HOURS MAINTENANCE…4235
SPECIFICATIONS…4239
SPECIFICATIONS…4240
ATTACHMENTS, OPTIONS …4243
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…4244
SAFETY FIRST…4244
ATTACHMENT INSTALLATION…4245
BUCKET WITH HOOK…4246
HOOK CONDITION…4246
PROHIBITED OPERATIONS…4246
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…4247
CONTROL PATTERN CHANGE PROCEDURE…4247
MACHINE CONTROL PATTERNS…4248
HYDRAULIC QUICK COUPLER PIPING…4249
LOCATIONS…4249
OPERATION…4250
POWER ANGLE BLADE…4252
BLADE CONTROL LEVER…4252
WHEN REQUIRED…4253
EVERY 500 HOURS SERVICE…4253
WEAR PARTS LIST…4254
SPECIFICATIONS…4254
ATTACHMENT GUIDE…4255
ATTACHMENT COMBINATIONS…4255
TRACK SHOES SELECTION…4257
RECOMMENDED ATTACHMENT OPERATIONS…4258
HYDRAULIC BREAKER…4258
CRUSHER…4263
HANDLING MACHINES EQUIPPED WITH KOMTRAX…4266
BASIC PRECAUTIONS…4266
INDEX…4267
TEN00468-01 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual…4271
COVER…4271
FOREWORD…4272
BEFORE READING THIS MANUAL…4273
SAFETY INFORMATION…4274
INTRODUCTION…4275
USE OF MACHINE…4275
DIRECTIONS OF MACHINE…4275
VISIBILITY FROM OPERATOR’S SEAT…4275
PROTECTIVE STRUCTURE…4275
PRODUCT INFORMATION…4276
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…4276
EPA REGULATIONS, ENGINE NUMBER PLATE…4276
SERVICE METER LOCATION…4277
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…4277
CONTENTS…4278
SAFETY…4282
SAFETY…4283
SAFETY LABELS…4286
LOCATION OF SAFETY LABELS…4287
SAFETY LABELS…4288
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4295
PRECAUTIONS BEFORE STARTING OPERATION…4295
PREPARATIONS FOR SAFE OPERATION…4295
FIRE PREVENTION…4297
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4298
DO NOT GET CAUGHT IN WORK EQUIPMENT…4300
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4300
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…4301
UNAUTHORIZED MODIFICATION…4301
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4301
PRECAUTIONS RELATED TO CAB GLASS…4301
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4302
PRECAUTIONS FOR OPERATION…4303
PRECAUTIONS FOR JOBSITE…4303
STARTING ENGINE…4305
OPERATION…4307
TRANSPORTATION…4315
TOWING…4316
LIFTING OBJECTS WITH BUCKET…4317
PRECAUTIONS FOR MAINTENANCE…4318
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4318
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4322
OPERATION…4328
MACHINE VIEW ILLUSTRATIONS…4329
OVERALL MACHINE VIEW…4329
CONTROLS AND GAUGES…4330
DETAILED CONTROLS AND GAUGES…4332
MONITORING SYSTEM…4332
SWITCHES…4391
CONTROL LEVERS AND PEDALS…4396
SUN ROOF…4400
WINDSHIELD…4401
SLIDING DOOR…4407
EMERGENCY ESCAPE HAMMER…4408
COVER WITH LOCK…4409
ENGINE HOOD…4410
MUD COVER…4412
BATTERY INSPECTION COVER…4413
AIR CONDITIONER CONTROLS…4414
RADIO…4427
FUSE…4432
FUSIBLE LINK…4433
AUXILIARY ELECTRIC POWER…4434
CONTROLLERS…4435
OPERATION MANUAL STORAGE…4436
CUP HOLDER…4436
TOOL BOX…4436
GREASE PUMP HOLDER…4436
ASHTRAY…4437
FIRE EXTINGUISHER…4437
MACHINE OPERATIONS AND CONTROLS…4438
BEFORE STARTING ENGINE…4438
STARTING ENGINE…4457
AFTER STARTING ENGINE…4462
STOPPING THE ENGINE…4472
MACHINE OPERATION…4473
STEERING THE MACHINE…4477
SWINGING…4479
WORK EQUIPMENT CONTROLS AND OPERATIONS…4480
WORKING MODE…4482
PROHIBITED OPERATIONS…4484
GENERAL OPERATION INFORMATION…4487
TRAVELING ON SLOPES…4489
ESCAPE FROM MUD…4491
RECOMMENDED APPLICATIONS…4492
BUCKET REPLACEMENT AND INVERSION…4494
PARKING MACHINE…4497
MACHINE INSPECTION AFTER DAILY WORK…4499
LOCKING…4499
ROAD LINERS AND RUBBER SHOES…4500
MACHINE READY FOR ATTACHMENT…4505
TRANSPORTATION…4515
TRANSPORTATION PROCEDURE…4515
LOADING AND UNLOADING WITH TRAILER…4516
LIFTING MACHINE…4522
COLD WEATHER OPERATION…4524
COLD WEATHER OPERATION INFORMATION…4524
AFTER DAILY WORK COMPLETION…4526
AFTER COLD WEATHER SEASON…4526
LONG TERM STORAGE…4527
BEFORE STORAGE…4527
DURING STORAGE…4527
AFTER STORAGE…4528
STARTING MACHINE AFTER LONG-TERM STORAGE…4529
TROUBLES AND ACTIONS…4530
RUNNING OUT OF FUEL…4530
PHENOMENA THAT ARE NOT FAILURES…4531
TOWING THE MACHINE…4532
SEVERE JOB CONDITION…4532
DISCHARGED BATTERY…4533
OTHER TROUBLE…4538
MAINTENANCE…4544
MAINTENANCE INFORMATION…4545
OUTLINE OF SERVICE…4547
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4547
ELECTRIC SYSTEM MAINTENANCE…4550
WEAR PARTS…4551
WEAR PARTS LIST…4551
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4553
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…4554
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4555
TIGHTENING TORQUE SPECIFICATIONS…4556
TIGHTENING TORQUE LIST…4556
SAFETY CRITICAL PARTS…4557
SAFETY CRITICAL PARTS LIST…4557
MAINTENANCE SCHEDULE…4559
MAINTENANCE SCHEDULE CHART…4559
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…4561
MAINTENANCE PROCEDURE…4562
WHEN REQUIRED…4562
CHECK BEFORE STARTING…4598
EVERY 100 HOURS MAINTENANCE…4599
EVERY 250 HOURS MAINTENANCE…4601
EVERY 500 HOURS MAINTENANCE…4608
EVERY 1000 HOURS MAINTENANCE…4620
EVERY 2000 HOURS MAINTENANCE…4630
EVERY 4000 HOURS MAINTENANCE…4634
EVERY 5000 HOURS MAINTENANCE…4635
SPECIFICATIONS…4638
SPECIFICATIONS…4639
ATTACHMENTS, OPTIONS…4642
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…4643
SAFETY FIRST…4643
ATTACHMENT INSTALLATION…4644
BUCKET WITH HOOK…4645
HOOK CONDITION…4645
PROHIBITED OPERATIONS…4645
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) …4646
CONTROL PATTERN CHANGE PROCEDURE…4646
MACHINE CONTROL PATTERNS…4647
HYDRAULIC QUICK COUPLER PIPING…4648
LOCATIONS…4648
OPERATION…4649
POWER ANGLE BLADE…4651
BLADE CONTROL LEVER…4651
WHEN REQUIRED…4652
EVERY 500 HOURS SERVICE…4652
WEAR PARTS LIST…4653
SPECIFICATIONS…4653
ATTACHMENT GUIDE…4654
ATTACHMENT COMBINATIONS…4654
TRACK SHOES SELECTION…4656
RECOMMENDED ATTACHMENT OPERATIONS…4657
HYDRAULIC BREAKER…4657
CRUSHER…4662
FALLING LOAD PROTECTIVE DEVICE (FALLING LOAD PREVENTIVE VALVE)…4665
HANDLING MACHINES EQUIPPED WITH KOMTRAX…4666
BASIC PRECAUTIONS…4666
INDEX…4668
WEAM009700 – Hydraulic Excavator PC80MR-3 Operation & Maintenance Manual…4672
1.1 FOREWORD…4674
1.2 INFORMATION ON SAFETY…4675
1.3 INTRODUCTION…4677
1.3.1 INTENDED USE OF THE MACHINE…4677
1.3.2 IMPROPER OR UNAUTHORIZED USES…4677
1.3.2.1 MAIN CHARACTERISTICS…4677
1.3.3 RUNNING-IN…4678
1.3.4 POSITIONS AND DIRECTIONS OF THE MACHINE…4679
1.4 PRODUCT IDENTIFICATION…4680
1.4.1 MACHINE SERIAL NUMBER…4680
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)…4680
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE…4681
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…4681
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…4681
1.4.6 CAB SERIAL NUMBER…4681
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…4682
1.5 KOMTRAX SYSTEM…4683
1.5.1 GENERAL PRECAUTIONS…4683
TABLE OF CONTENTS…4684
2.1 SAFETY, NOISE AND VIBRATION PLATES…4693
2.1.1 POSITION OF THE SAFETY PLATES…4693
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS…4694
2.1.3 POSITION OF THE NOISE PLATES…4701
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…4701
2.2 GENERAL PRECAUTIONS…4702
2.2.1 SAFETY RULES…4702
2.2.2 HOW TO BEHAVE IN CASE OF ANOMALIES…4702
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…4702
2.2.4 FIRE EXTINGUISHERS AND FIRST AID KIT…4703
2.2.5 SAFETY DEVICES AND GUARDS…4703
2.2.6 CLEANING THE MACHINE…4703
2.2.7 INSIDE OF THE CAB…4704
2.2.8 LEAVING THE OPERATOR SEAT…4704
2.2.9 GETTING ON AND OFF THE MACHINE…4705
2.2.10 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT…4705
2.2.11 ARTICULATED PARTS…4705
2.2.12 PREVENTING BURNS…4706
2.2.13 PREVENTING FIRES DUE TO FUEL AND OIL…4706
2.2.14 HOW TO BEHAVE IN CASE OF FIRE…4707
2.2.15 DETERGENT FOR THE WINDOWS…4707
2.2.16 PROTECTION AGAINST FALLING OBJECTS, FLYING OBJECTS, FOREIGN BODIES…4707
2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT…4707
2.2.18 COMBINING THE WORK EQUIPMENT…4707
2.2.19 WORK LIGHT AND CAB LIGHTS…4708
2.2.20 CAB WINDOWS…4708
2.2.21 PRECAUTIONS CONCERNING THE CAB STRUCTURE…4708
2.2.22 UNAUTHORIZED MODIFICATIONS…4708
2.2.23 SAFETY AT THE WORKPLACE…4708
2.2.24 WORKING ON LOOSE GROUND…4708
2.2.25 PREVENTING ELECTROCUTION…4709
2.2.26 VISIBILITY…4710
2.2.27 ROOM VENTILATION…4710
2.2.28 CHECKING THE SIGNALS OF THE SIGNALMAN AND THE FIXED SIGNS…4710
2.2.29 HAND SIGNALS…4711
2.2.30 EMERGENCY EXIT…4716
2.2.31 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…4716
2.3 PRECAUTIONS FOR USE…4717
2.3.1 BEFORE STARTING THE ENGINE…4717
2.3.1.1 CHECKS AND ADJUSTMENTS TO BE CARRIED OUT BEFORE STARTING THE ENGINE…4717
2.3.1.2 PRECAUTIONS TO BE TAKEN DURING THE START PROCEDURE…4717
2.3.1.3 PRECAUTIONS TO BE TAKEN IN COLD AREAS…4718
2.3.2 PRECAUTIONS TO BE TAKEN WHEN WORKING…4719
2.3.2.1 CHECKS AFTER STARTING THE ENGINE…4719
2.3.2.2 PRECAUTIONS TO BE TAKEN WHEN CHANGING DIRECTION…4719
2.3.2.3 PRECAUTIONS TO BE TAKEN DURING TRAVEL…4720
2.3.2.4 MOVING ON SLOPES…4721
2.3.2.5 WORKING ON SLOPES…4722
2.3.2.6 UNAUTHORIZED OPERATIONS…4722
2.3.2.7 WORKING ON ICY OR SNOW-COVERED SURFACES…4724
2.3.2.8 PARKING THE MACHINE…4724
2.3.3 TRANSPORTING THE MACHINE…4725
2.3.3.1 LOADING AND UNLOADING THE MACHINE…4725
2.3.3.2 TRANSPORTING THE MACHINE…4725
2.3.4 BATTERY…4726
2.3.4.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…4726
2.3.4.2 STARTING WITH BOOSTER CABLES…4727
2.3.5 REMOVAL…4728
2.3.5.1 PRECAUTIONS FOR THE REMOVAL…4728
2.4 PRECAUTIONS FOR MAINTENANCE…4729
2.4.1 WARNING PLATES…4729
2.4.2 KEEP THE WORK PLACE CLEAN AND ORDERLY…4729
2.4.3 APPOINT A SUPERVISOR WHEN WORKING WITH OTHER PEOPLE…4729
2.4.4 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION…4730
2.4.5 MAINTENANCE OPERATIONS TO BE CARRIED OUT WITH THE ENGINE RUNNING REQUIRE THE PRESENCE OF TWO OPERATORS…4731
2.4.6 TOOLS…4731
2.4.7 HYDRAULIC ACCUMULATOR…4731
2.4.8 MAINTENANCE STAFF…4732
2.4.9 EQUIPMENT…4732
2.4.10 WORKING UNDER THE MACHINE…4732
2.4.11 NOISE…4732
2.4.12 PRECAUTIONS TO BE TAKEN WHEN USING THE HAMMER…4733
2.4.13 REPAIR WELDS…4733
2.4.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL…4733
2.4.15 CHECKING THE COOLANT LEVEL IN THE RADIATOR…4734
2.4.16 USING LAMPS…4734
2.4.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR…4735
2.4.18 PRECAUTIONS CONCERNING THE STARTER…4735
2.4.19 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION…4736
2.4.20 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT…4736
2.4.21 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…4737
2.4.22 HANDLING HIGH-PRESSURE HOSES…4737
2.4.23 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE…4737
2.4.24 COOLING FAN AND BELT…4738
2.4.25 WASTE MATERIALS…4738
2.4.26 SERVICING THE AIR CONDITIONER…4738
2.4.27 COMPRESSED AIR…4738
2.4.28 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…4738
2.4.29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS…4739
2.4.30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES…4739
3.1 DESCRIPTION AND USE OF THE MACHINE…4741
3.1.1 GENERAL VIEW OF THE MACHINE WITH MONOBOOM…4741
3.1.2 GENERAL VIEW OF THE MACHINE WITH TWO-PIECE BOOM…4742
3.1.3 CONTROLS AND INDICATORS…4743
3.2 INSTRUMENTS AND CONTROLS…4744
3.2.1 DASHBOARD…4744
3.2.1.1 WARNING LIGHTS…4745
3.2.1.2 EMERGENCY WARNING LIGHTS…4747
3.2.1.3 WARNING LIGHTS AND INDICATORS DISPLAY…4749
3.2.1.4 SWITCHES…4753
3.2.2 SWITCHES AND PUSH BUTTONS…4755
3.2.3 CONTROL LEVERS AND PEDALS…4762
3.2.4 CAB…4767
3.2.4.1 WINDSHIELD…4768
3.2.4.2 SLIDING DOOR…4772
3.2.4.3 SIDE WINDOW…4773
3.2.4.4 EMERGENCY EXIT HAMMER…4775
3.2.5 COVERS WITH LOCK…4776
3.2.6 ENGINE HOOD…4777
3.2.7 TANK COVER…4778
3.2.8 FUSES AND RELAY…4779
3.2.8.1 CONTROL UNIT FUSES AND RELAYS…4779
3.2.8.2 VENTILATION RELAYS…4782
3.2.8.3 AIR CONDITIONER FUSE AND RELAY…4783
3.2.8.4 ENGINE LINE FUSES AND RELAYS…4783
3.2.8.5 MAIN FUSE…4784
3.2.9 CONTROLLER…4784
3.2.10 VENTILATION AND HEATING…4785
3.2.10.1 HEATING AND DEFROSTING CONTROL PANEL…4785
3.2.11 AIR CONDITIONER (if installed)…4788
3.2.11.1 AIR CONDITIONER CONTROL PANEL…4789
3.2.12 TECHNICAL DOCUMENTATION COMPARTMENT…4792
3.2.13 TOOL BOX…4792
3.2.14 GREASING PUMP SUPPORT…4792
3.2.15 ASHTRAY…4793
3.2.16 FIRE EXTINGUISHERS…4793
3.2.17 FIRST AID KIT…4793
3.3 USE OF THE MACHINE…4794
3.3.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE…4794
3.3.1.1 VISUAL CHECKS…4794
3.3.2 DAILY CHECKS…4796
3.3.2.1 CHECKING THE COOLANT LEVEL AND TOPPING UP…4796
3.3.2.2 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP…4797
3.3.2.3 CHECKING THE FUEL LEVEL AND REFUELLING…4798
3.3.2.4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP…4799
3.3.2.5 AIR FILTER CLOGGING CHECK…4801
3.3.2.6 CHECKING THE WATER SEPARATOR…4801
3.3.2.7 CHECK THE WIRING SYSTEMS…4802
3.3.2.8 HORN OPERATION CHECK…4802
3.3.3 ADJUSTMENTS…4803
3.3.3.1 ADJUSTING THE SEAT…4803
3.3.3.2 REAR-VIEW MIRRORS…4804
3.3.4 SEAT BELT…4805
3.3.4.1 FASTENING AND UNFASTENING THE SEAT BELT…4805
3.3.4.2 ADJUSTING THE SEAT BELT…4806
3.3.4.3 RETRACTABLE SEAT BELT (if provided)…4807
3.3.5 OPERATIONAL CHECKS…4808
3.3.6 STARTING THE ENGINE…4810
3.3.6.1 STARTING THE ENGINE IN NORMAL OPERATING CONDITIONS…4810
3.3.6.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES…4812
3.3.7 AFTER STARTING THE ENGINE…4815
3.3.7.1 RUNNING-IN…4815
3.3.7.2 WARMING-UP PROCEDURE…4816
3.3.8 STOPPING THE ENGINE…4818
3.3.9 CHECKS TO BE CARRIED OUT AFTER STOPPING THE ENGINE…4818
3.3.10 OPERATING THE MACHINE…4819
3.3.10.1 HOW TO MOVE THE MACHINE…4819
3.3.10.2 MOVING THE MACHINE FORWARD…4820
3.3.10.3 REVERSE…4821
3.3.10.4 HOW TO STOP THE MACHINE…4822
3.3.11 STEERING THE MACHINE…4823
3.3.11.1 STEERING (CHANGING DIRECTION)…4823
3.3.12 SWINGING THE TURRET…4825
3.3.13 WORK EQUIPMENT CONTROLS AND FUNCTIONS…4826
3.3.14 WORK MODE…4828
3.3.15 UNAUTHORIZED OPERATIONS…4829
3.3.16 IGENERAL INFORMATION ON THE OPERATION OF THE MACHINE…4831
3.3.17 MOVING ON SLOPES…4833
3.3.18 GETTING THE MACHINE OUT OF MUD…4835
3.3.19 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR…4836
3.3.20 CHANGING THE BUCKET…4838
3.3.21 PARKING THE MACHINE…4839
3.3.22 CHECKS TO BE CARRIED OUT ON THE MACHINE AT THE END OF THE WORK DAY…4840
3.3.23 LOCKING THE MACHINE…4840
3.3.24 ROAD LINERS AND RUBBER TRACKS…4841
3.3.24.1 INFORMATION ON THE ROAD LINERS AND THE RUBBER TRACKS…4841
3.3.24.2 WARRANTY ON THE ROAD LINERS AND THE RUBBER TRACKS…4841
3.3.24.3 USING THE ROAD LINERS AND THE RUBBER TRACKS…4841
3.3.24.4 HOW TO PRESERVE THE ROAD LINERS AND THE RUBBER TRACKS OVER TIME…4842
3.4 TRANSPORTING THE MACHINE…4846
3.4.1 TRANSPORT PROCEDURE…4846
3.4.2 LOADING AND UNLOADING THE MACHINE…4846
3.4.2.1 LOADING THE MACHINE…4847
3.4.2.2 HOW TO SECURE THE MACHINE…4849
3.4.2.3 UNLOADING THE MACHINE…4850
3.4.3 HOW TO LIFT THE MACHINE…4852
3.5 USING THE MACHINE IN COLD CLIMATES…4854
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON…4854
3.5.1.1 FUEL AND LUBRICANTS…4854
3.5.1.2 COOLANT…4854
3.5.1.3 BATTERY…4855
3.5.2 AT THE END OF THE WORK DAY…4856
3.5.3 AT THE END OF THE COLD SEASON…4856
3.6 LONG PERIODS OF INACTIVITY…4857
3.6.1 BEFORE A PERIOD OF INACTIVITY…4857
3.6.2 DURING A PERIOD OF INACTIVITY…4857
3.6.3 AFTER A PERIOD OF INACTIVITY…4858
3.7 TROUBLESHOOTING…4859
3.7.1 IF FUEL RUNS OUT COMPLETELY…4859
3.7.2 OCCURRENCES THAT ARE NOT FAILURES…4859
3.7.3 REMOVING THE MACHINE…4859
3.7.4 DEMANDING OPERATING CONDITIONS…4860
3.7.5 IF THE BATTERY IS DOWN…4860
3.7.6 REMOVING AND INSTALLING THE BATTERY…4861
3.7.7 CHARGING THE BATTERY…4862
3.7.8 STARTING WITH BOOSTER CABLES…4863
3.7.8.1 CONNECTING AND DISCONNECTING THE BOOSTER CABLES…4863
3.7.8.2 CONNECTING THE BOOSTER CABLES…4864
3.7.8.3 STARTING THE ENGINE…4864
3.7.8.4 REMOVING THE BOOSTER CABLES…4864
3.7.9 LOWERING THE WORK EQUIPMENT WHEN THE ENGINE STOPS BECAUSE OF A FAILURE…4865
3.7.10 OTHER TROUBLES…4866
3.7.10.1 ELECTRICAL SYSTEM…4866
3.7.10.2 FRAME…4867
3.7.10.3 ENGINE…4868
3.7.10.4 ELECTRONIC CONTROL SYSTEM…4870
4.1 GUIDE TO MAINTENANCE…4873
4.2 MAINTENANCE NOTES…4875
4.2.1 OIL, FUEL AND COOLANT…4875
4.2.1.1 OIL…4875
4.2.1.2 FUEL…4876
4.2.1.3 COOLANT…4876
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)…4877
4.2.1.5 STORING OIL AND FUEL…4878
4.2.1.6 FILTERS…4878
4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM…4879
4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM…4879
4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION…4879
4.3 PARTS SUBJECT TO WEAR…4880
4.3.1 LIST OF THE PARTS SUBJECT TO WEAR…4880
4.4 FUEL, COOLANT AND LUBRICANTS…4881
4.4.1 COOLANT…4882
4.4.2 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES…4883
4.5 TIGHTENING TORQUES…4884
4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS…4884
4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS…4885
4.6 LUBRICATION…4886
4.6.1 LUBRICATION DIAGRAM…4886
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS…4887
4.7.1 SAFETY-RELATED PARTS…4888
4.8 MAINTENANCE PLAN…4889
4.8.1 MAINTENANCE PLAN…4889
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER…4892
4.9 MAINTENANCE PROCEDURES…4893
4.9.1 WHEN REQUIRED…4893
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE…4893
4.9.1.b CLEANING THE WATER SEPARATOR FILTER…4896
4.9.1.c CHECKING THE TIGHTENING OF THE TRACKS…4897
4.9.1.d CHECKING AND ADJUSTING THE TRACK TENSION…4898
4.9.1.e CHECKING THE ROAD LINERS OR THE RUBBER TRACKS…4900
4.9.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION…4902
4.9.1.g CHANGING THE ROAD LINERS…4903
4.9.1.h CHANGING THE RUBBER TRACKS…4904
4.9.1.i REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER TRACKS…4907
4.9.1.j ADJUSTING THE BUCKET CLEARANCE…4908
4.9.1.k CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING UP…4909
4.9.1.l CHECKING, CLEANING AND LUBRICATING THE GUIDE OF THE CAB SLIDING DOOR…4910
4.9.1.m WASHING THE FLOOR…4911
4.9.1.n BLEEDING THE HYDRAULIC SYSTEM…4913
4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE…4916
4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)…4916
4.9.4 MAINTENANCE EVERY 50 HOURS OF OPERATION…4916
4.9.4.a COOLANT LEVEL CHECK IN THE RADIATOR…4916
4.9.5 MAINTENANCE EVERY 100 HOURS OF OPERATION…4917
4.9.5.a LUBRICATION…4917
4.9.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION…4917
4.9.7 MAINTENANCE EVERY 250 HOURS OF OPERATION…4918
4.9.7.a LUBRICATION…4918
4.9.7.b CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR AND TOPPING UP…4920
4.9.7.c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS AND TOPPING UP…4920
4.9.7.d BATTERY ELECTROLYTE LEVEL CHECK…4921
4.9.7.e CHECKING AND ADJUSTING THE FAN BELT TENSION…4922
4.9.7.f CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION (if installed)…4923
4.9.7.g DRAINING THE FUEL TANK…4924
4.9.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)…4925
4.9.9 MAINTENANCE EVERY 500 HOURS OF OPERATION…4925
4.9.9.a CHANGING THE FUEL FILTER CARTRIDGE…4925
4.9.9.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE…4927
4.9.9.c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE…4929
4.9.9.d CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR CONDITIONER…4931
4.9.9.e RADIATOR, EXCHANGER AND AIR CONDITIONER CONDENSER (if fitted) CHECK AND EXTERIOR CLEANING…4933
4.9.9.f LUBRICATING THE SWING BALL- BEARING RING…4934
4.9.9.g CHECKING THE GREASE LEVEL IN THE BALL-BEARING RING PINION AND TOPPING UP…4934
4.9.9.h DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)…4935
4.9.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION…4936
4.9.10.a CHANGING THE OIL IN THE SWING REDUCTION GEAR…4936
4.9.10.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS…4937
4.9.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION…4938
4.9.11.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER (Only for machines in which synthetic biodegradable oil HEES is used)…4938
4.9.11.b CHANGING THE COOLANT…4940
4.9.11.c CHECKING THE ALTERNATOR AND THE STARTER…4942
4.9.11.d CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE…4942
4.9.11.e CHECKING THE A/C REFRIGERANT GAS QUANTITY ((only for machines with air conditioner)…4942
4.9.12 MAINTENANCE EVERY 4000 HOURS OF OPERATION…4943
4.9.12.a CHANGING THE A/C FILTER DRIER (only for machines with air conditioner)…4943
4.9.12.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (only for machines with air conditioner)…4943
4.9.12.c CHECKING THE WATER PUMP…4943
4.9.13 MAINTENANCE EVERY 5000 HOURS OF OPERATION…4944
4.9.13.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER…4944
5.1 TECHNICAL DATA…4947
5.2 LIFTING CAPACITIES…4949
5.2.1 LIFTING CAPACITIES WITH MONOBOOM…4949
6.1 AUTHORIZED OPTIONAL EQUIPMENT…4955
6.1.1 PRECAUTIONS REGARDING SAFETY…4955
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT…4956
6.1.3 AUTHORISED TOOLS CHARACTERISTICS…4957
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER…4958
6.2.1 DESCRIPTION AND CONTROL…4958
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED…4959
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER…4964
6.2.3.1 INSTALLATION…4964
6.2.3.2 REMOVING THE HAMMER…4965
6.2.4 MAINTENANCE…4965
6.3 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM (second hydraulic line)…4966
6.4 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM (Third hydraulic line)…4969
6.5 INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT…4971
Komatsu Hydraulic Excavator PC80MR Repair Service Manuals