Komatsu PC88MR-10 Hydraulic Excavator (7001 and up) Shop Manual - SEN06467-02

This complete service repair workshop manual PDF download for the Komatsu PC88MR-10 Hydraulic Excavator (SN: 7001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : PC88MR-10
Serial Number : 7001 and up


TABLE OF CONTENTS :

00. Index and foreword
01. Specification
10. Structure and function
20. Standard value table
30. Testing and adjusting
40. Troubleshooting
50. Disassembly and assembly
60. Maintenance standard
80. Appendix
90. Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN06467-02
Total Pages : 1404


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00 Index and foreword
Index
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

01 Specification
Table of contents
Specifications
Specification drawing
Working range drawings
Specifications
Weight table
Table of fuel, coolant, and lubricants

10 Structure and function
Table of contents
Engine and cooling system
Engine related parts
PTO
VFT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDOC muffler
Cooling system
Power train
Power train system
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Hydraulic system
Hydraulic component layout
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Swing motor
Travel motor
Work equipment and swing PPC valve
Travel PPC valve
Blade PPC valve
Boom swing PPC valve
Solenoid valve
Multi-control valve
Center swivel joint
Accumulator
Work equipment
Work equipment
Work equipment shim
Bucket play adjustment shim
Cab and its attachments
Cab mount and cab tipping stopper
ROPS cab
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
KOMTRAX terminal
Sensor

20 Standard value tables
Table of contents
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system

30 Testing and adjusting
Table of contents
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing and adjusting air conditioner compressor belt tension
Replacing fan belt
Writing compensation values at replacement of injector and engine controller
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Testing and adjusting track tension
Hydraulic system
Releasing remaining pressure from hydraulic circuit
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting swing and blade circuit oil pressure
Testing oil pressure of control circuit
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing outlet pressure of solenoid valve
Testing PPC valve outlet pressure
Adjusting play of work equipment and swing PPC valves
Isolating the parts causing hydraulic drift in work equipment
Testing and adjusting travel deviation
Testing oil leakage
Bleeding air from hydraulic circuit
Cab and its attachments
Testing, cleaning and lubricating slide door rail and roller
Adjusting mirrors
Testing and adjusting hood catcher
Electrical system
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service

40 Troubleshooting
Table of contents
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit
Failure code [879AKB] A/C Recirc Air Temp Sens Short
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Malfunction
Failure code [879FMC] Air Mix Damper Malfunction
Failure code [879GKX] Refrigerant Press Input Sig Out of Range
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2
Failure code [AB00KE] Charge Voltage Low
Failure code [[email protected]] Eng Oil Press Low
Failure code [[email protected]] Eng Water Overheat
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Charge Air Pressure Sensor High Error
Failure code [CA123] Charge Air Pressure Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temperature Sensor High Error
Failure code [CA145] Coolant Temperature Sensor Low Error
Failure code [CA153] Charge Air Temperature Sensor High Error
Failure code [CA154] Charge Air Temperature Sensor Low Error
Failure code [CA187] Sensor 2 Supply Voltage Low Error
Failure code [CA221] Ambient Pressure Sensor High Error
Failure code [CA222] Ambient Pressure Sensor Low Error
Failure code [CA227] Sensor 2 Supply Voltage High Error
Failure code [CA234] Engine Overspeed
Failure code [CA238] NE Speed Sensor Supply Voltage Error
Failure code [CA239] NE Speed Sensor Supply Voltage High Error
Failure code [CA271] PCV1 Short Circuit Error
Failure code [CA272] PCV1 Open Circuit Error
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit
Failure code [CA324] Injector #3 (L#3) Open or Short Circuit
Failure code [CA331] Injector #2 (L#2) Open or Short Circuit
Failure code [CA332] Injector #4 (L#4) Open or Short Circuit
Failure code [CA343] Engine Controller Internal Failure
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sensor1 Supply Voltage Low Error
Failure code [CA356] MAF Sensor High Error
Failure code [CA357] MAF Sensor Low Error
Failure code [CA386] Sensor1 Supply Voltage High Error
Failure code [CA435] Engine Oil Pressure SW Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Common Rail Pressure High Error 2
Failure code [CA451] Common Rail Pressure Sensor High Error
Failure code [CA452] Common Rail Pressure Sensor Low Error
Failure code [CA466] KVGT Motor Driver Position Error
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error
Failure code [CA553] Common Rail Pressure High Error 1
Failure code [CA555] Crankcase Pressure High Error 1
Failure code [CA556] Crankcase Pressure High Error 2
Failure code [CA559] Common Rail Pressure Low Error 1
Failure code [CA689] Engine NE Speed Sensor Error
Failure code [CA691] Intake Air Temperature Sensor High Error
Failure code [CA692] Intake Air Temperature Sensor Low Error
Failure code [CA697] Engine Con Internal Temp Sens High Error
Failure code [CA698] Engine Con Internal Temp Sens Low Error
Failure code [CA731] Engine Backup Speed Sensor Phase Error
Failure code [CA778] Engine Backup Speed Sensor Error
Failure code [CA1117] Engine Controller Partial Data Lost Error
Failure code [CA1695] Sensor 5 Supply Voltage High Error
Failure code [CA1696] Sensor 5 Supply Voltage Low Error
Failure code [CA1843] Crankcase Pressure Sensor High Error
Failure code [CA1844] Crankcase Pressure Sensor Low Error
Failure code [CA1896] EGR Valve Stuck Error
Failure code [CA1942] Crankcase Pressure Sensor In Range Error
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error
Failure code [CA2185] Throttle Sensor Supply Voltage High Error
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error
Failure code [CA2249] Common Rail Pressure Low Error 2
Failure code [CA2272] EGR Valve Position Sensor Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2765] Injector Trim Data Mismatch
Failure code [CA3419] MAF Sensor Supply Voltage High Error
Failure code [CA3421] MAF Sensor Supply Voltage Low Error
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error
Failure code [CA3918] KVGT Stuck Error
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error
Failure code [CA3921] KVGT Servo Error 2
Failure code [CA3922] KVGT Motor Driver Open Error
Failure code [CA3923] KVGT Motor Driver Short Error
Failure code [D110KB] Battery Relay Output Short Circuit
Failure code [D19JKZ] Personal Code Relay Open or Short
Failure code [D811MC] KOMTRAX Malfunction
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX)
Failure code [DA20MC] Pump Controller Malfunction
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con)
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con)
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Malfunction
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor)
Failure code [DAFGMC] GPS Module Malfunction
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor)
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C)
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU)
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con)
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con)
Failure code [DDNRKA] WE Lever Lock SW Open Circuit
Failure code [DDNRKY] WE Lever Lock SW Short Circuit
Failure code [DDNS00] Lock Lever Auto Lock Release SW On
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault
Failure code [DHPAMA] Front Pump Press Sens Defective Function
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function
Failure code [DHS5MA] Travel PPC Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality
Failure code [DKULKA] PPC Lock Relay Open Circuit
Failure code [DKULKB] PPC Lock Relay Short Circuit
Failure code [DKULKY] PPC Lock Relay Hot Short Circuit
Failure code [DV20KB] Travel Alarm Short Circuit
Failure code [DW43KA] Travel Speed Solenoid Open Circuit
Failure code [DW43KB] Travel Speed Solenoid Short Circuit
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit
Failure code [DWJ0KA] Merge-divider Sol Open Circuit
Failure code [DWJ0KB] Merge-divider Sol Short Circuit
Failure code [DWJ0KY] Merge-divider Sol Short Circuit
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit
Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit
Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit
Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit
Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit
Failure code [DY20KA] Wiper Motor Open Circuit
Failure code [DY20MA] Wiper Motor Defective Function
Failure code [DY2CKB] Washer Motor Short Circuit
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Manual preheating system does not work
E-3 While preheating is working, preheating monitor does not light up
E-4 When starting switch is turned to ON position, machine monitor displays nothing
E-5 Engine coolant temperature monitor lights up in white while engine is running
E-6 Hydraulic oil temperature monitor lights up in white while engine is running
E-7 Charge level monitor lights up while engine is running
E-8 Fuel level monitor lights up in red while engine is running
E-9 Engine coolant temperature monitor lights up in red while engine is running
E-10 Hydraulic oil temperature monitor lights up in red while engine is running
E-11 Engine oil pressure monitor lights up in red while engine is running
E-12 Fuel gauge display does not move from minimum or maximum
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty)
E-14 Engine coolant temperature gauge display does not move from minimum or maximum
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty)
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty)
E-18 Some areas of machine monitor screen are not displayed
E-19 Function switch does not work
E-20 Automatic warm-up system does not operate (in cold season)
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated
E-22 Auto-deceleration function does not operate or is not canceled while lever is operated
E-23 Working mode selection screen is not displayed while working mode selector switch is operated
E-24 Setting of engine and hydraulic pump is not changed while working mode is changed
E-25 Travel speed monitor does not change when travel speed switch is operated
E-26 Travel speed does not change while travel speed selection is changed
E-27 Alarm buzzer does not stop sounding
E-28 Service meter is not displayed, while starting switch is in OFF position
E-29 Service mode cannot be selected
E-30 Any of work equipment, swing and travel does not work
E-31 Any of work equipment, swing and travel cannot be locked
E-32 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position
E-34 Work equipment does not operate while lock lever automatic release switch is in release position
E-35 Alarm does not sound during travel
E-36 Alarm does not stop sounding while machine is stopped
E-37 Horn does not sound
E-38 Horn does not stop sounding
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated
E-40 Wiper does not operate while wiper switch is operated
E-41 Window washer does not operate while window washer switch is operated
E-42 Boom LOWER is not displayed correctly with monitoring function
E-43 Arm OUT is not displayed correctly with monitoring function
E-44 Arm IN is not displayed correctly with monitoring function
E-45 Boom RAISE is not displayed correctly with monitoring function
E-46 Bucket CURL is not displayed correctly with monitoring function
E-47 Bucket DUMP is not displayed correctly with monitoring function
E-48 Boom swing left is not displayed correctly with monitoring function
E-49 Boom swing right is not displayed correctly with monitoring function
E-50 Swing is not displayed correctly with monitoring function
E-51 Travel is not displayed correctly with monitoring function
E-52 Blade RAISE ON is not displayed correctly with monitoring function
E-53 Blade LOWER ON is not displayed correctly with monitoring function
E-54 KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
System chart of hydraulic and mechanical systems
Failure mode and cause table
H-1 All of work equipments, swing and travel operations lack speed or power
H-2 Engine speed drops significantly or engine stalls
H-3 Any of work equipment, swing and travel does not work
H-4 Unusual sound is heard from around hydraulic pump
H-5 Fine control performance or response is poor
H-6 Boom speed or power is low
H-7 Arm speed or power is low
H-8 Bucket speed or power is low
H-9 Boom swing speed or power is low
H-10 Blade speed or power is low
H-11 Work equipment does not move in single operation
H-12 Hydraulic drift of boom is large
H-13 Hydraulic drift of arm is large
H-14 Hydraulic drift of bucket is large
H-15 Hydraulic drift of blade is large
H-16 Time lag of work equipment is large
H-17 In combined operation of work equipment , equipment having heavier load moves slower
H-18 In combined operation of swing and boom RAISE, boom rising speed is low
H-19 In combined operation of work equipment or swing and travel, travel speed drops largely
H-20 Machine does not travel straight
H-21 Travel speed is slow
H-22 Machine is hard to steer or travel power is low
H-23 Travel speed does not change, or travel speed is too slow or fast
H-24 One of tracks does not run
H-25 Upper structure does not swing to the right or left
H-26 Upper structure swing only to the right or left
H-27 Swing acceleration or swing speed is low in both directions (right and left)
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction
H-29 Upper structure overruns excessively when it stops swinging (both right and left)
H-30 Upper structure overruns excessively when it stops swinging (either right or left)
H-31 Shock is large when upper structure stops swinging
H-32 Large unusual noise is heard when upper structure stops swinging
H-33 Swing drift on a slope is large while swing parking brake is applied
H-34 Swing drift on a slope is large while swing parking brake is released
H-35 Oil flow in attachment circuit cannot be controlled
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
S-1 Engine does not crank when starting switch is turned to START position
S-2 Engine cranks but no exhaust smoke comes out
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
S-4 Engine startability is poor
S-5 Engine does not pick up smoothly
S-6 Engine stops during operation
S-7 Engine runs rough or is unstable
S-8 Engine lacks power
S-9 Exhaust smoke is black
S-10 Engine oil consumption is excessive
S-11 Oil becomes contaminated quickly
S-12 Fuel consumption is excessive
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
S-14 Oil pressure drops
S-15 Fuel mixes into engine oil
S-16 Water mixes into engine oil (milky)
S-17 Coolant temperature rises too high (overheating)
S-18 Unusual noise is heard
S-19 Vibration is excessive
S-20 Air cannot be bled from fuel circuit

50 Disassembly and assembly
Table of contents
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine and main pump assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of KDOC muffler
Removal and installation of KCCV ventilator
Removal and installation of air cleaner assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of fan belt
Power train system
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Separation and connection of track
Removal and installation of sprocket
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler cushion assembly
Disassembly and assembly of track roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly [For machines with additional counterweight]
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of work equipment cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Removal and installation of boom swing bracket
Removal and installation of blade assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab door
Removal and installation of operator's cab glass (adhered glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of operator's seat
Removal and installation of seat belt
Removal and installation of front wiper assembly
Electrical system
Removal and installation of starting motor assembly
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly

60 Maintenance standard
Table of contents
Engine and cooling system
Engine mount
PTO
Cooling system
Power train system
Swing circle
Swing machinery
Sprocket
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Hydraulic tank
Main pump
Control valve
Swing motor
Travel motor
PPC valve
Work equipment and swing PPC valve
Travel PPC valve
Blade PPC valve
Boom swing PPC valve
Solenoid valve
Center swivel joint
Cab and its attachments
Cab mount and cab tipping stopper
Work equipment
Work equipment
Boom cylinder
Arm cylinder
Bucket cylinder
Boom swing cylinder
Blade cylinder

80 Appendix
Table of contents
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Condenser
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit
Failure code [879AKB] A/C Recirc Air Temp Sens Short
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Malfunction
Failure code [879FMC] Air Mix Damper Malfunction
Failure code [879GKX] Refrigerant Press Input Sig Out of Range
A-1 Troubleshooting for power supply system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting refrigerant piping
Handling of compressor oil

90 Diagrams and drawings
Table of contents
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Electrical circuit diagram
Electrical circuit diagram of air conditioner unit

INDEX
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